From "supporting role" to "hub": The role upgrade of cooling fans in thermal management of new energy vehicles

In traditional fuel vehicles, the cooling fan is merely a single-function auxiliary component for dissipating heat from the engine's water tank. However, as automotive power systems evolve into "three-electricity" systems, the cooling fan has transitioned from being a dispensable supporting role to becoming an indispensable core execution unit in the overall vehicle thermal management system.

Multiple heat sources collaborate, challenging unprecedented complexity

The thermal management of new energy vehicles is far more complex than that of fuel vehicles. Batteries generate a large amount of heat during charging and discharging, and excessive temperature can accelerate cell degradation and even pose safety hazards. Motors and inverters also face the risk of overheating under high-load conditions. The power modules of fast-charging stations also require continuous heat dissipation. The cooling fan needs to serve multiple heat sources simultaneously, including the battery cooling plate, electric drive system, on-board charger, DC-DC converter, and air conditioning condenser.

Three major technological revolutions drive the leap of roles

Brushless motors have become the mainstream standard. Traditional brushed fans, with their low efficiency, high noise, and short lifespan, can no longer meet the stringent requirements of new energy vehicles. Brushless DC motors, with their advantages of high efficiency, low noise, long lifespan, and strong controllability, have become the standard configuration for the new generation of cooling fans. The application of high-efficiency brushless motors, combined with optimized aerodynamic fan blade design, significantly reduces the fan's own power consumption, which has a positive impact on increasing the vehicle's endurance mileage.

High-voltage platforms drive energy efficiency leaps. With the widespread adoption of 400V and 800V high-voltage platforms, cooling fans are evolving from traditional low-voltage systems to high-voltage drives. 800V high-voltage electronic fans, operating at the same power, draw lower current, allowing the use of thinner wiring harnesses to reduce cost and weight. They also reduce line losses, enhancing system energy efficiency. Currently, technical specifications for 200V to 800V high-voltage drive electronic fans have been officially released, signaling that this trend is moving towards standardization.

Intelligent control reshapes the "brain" of fans. Nowadays, cooling fans are no longer simply powered on to rotate and powered off to stop. Through PWM pulse width modulation, LIN or CAN bus communication, they can achieve stepless speed regulation and precise temperature control. The thermal management domain controller can coordinate and control multiple components such as fans and water pumps according to vehicle operating conditions, temperature signals, and energy status, achieving precise temperature regulation for batteries, electronic controls, and passenger cabins. Research shows that the cooling system using energy consumption optimization control strategy reduces energy consumption by 49.5% under a single CLTC-P cycle operating condition compared to traditional threshold control strategy. The fan system is evolving from an execution unit to an intelligent thermal management node.

The ultimate pursuit of silence and lightweight: Noise is one of the most sensitive pain points for electric vehicle users - the howling sound of the cooling fan during high-load driving or fast charging is particularly harsh at night. Cutting-edge technology is breaking the dilemma.