Abstract
From a control perspective, the energy management system and the thermal management system of an electrified vehicle are often developed separately, which may not yield the optimal solution. Moreover, an optimal system design requires concurrent plant (topology and size) and controller optimization, which should apply to both energy and thermal domains. This paper originally provides a comprehensive analysis of design and control optimization layers to reveal the interconnections between them and how they influence the optimality of an electrified vehicle design considering both energy and thermal domains. It was found that energy and cost savings can be achieved by integrating these optimization layers, and the energy and thermal domains with four coordination schemes, namely, sequential, iterative, nested and simultaneous. There is a trade-off between optimality, causality, complexity and computational time. Additionally, future research directions in terms of reducing energy consumption and system costs of electrified vehicles are identified herein, such as using integrated design and control methods, employing electrified actuators, exchanging heat between powertrain components and utilizing waste heat recovery systems.