Concurrent design optimization of powertrain component modules in a family of electric vehicles

Maurizio Clemente, Mauro Salazar and Theo Hofman

Applied Energy, 2025, vol. 379, issue C, No S0306261924022232

Abstract: We present a modeling and optimization framework to design powertrains for a family of electric vehicles, focusing on the concurrent sizing of their motors and batteries. Whilst tailoring these component modules to each individual vehicle type can minimize energy consumption, it can result in high production costs due to the variety of component modules to be realized for the family of vehicles, driving the Total Costs of Ownership (TCO) high. Against this backdrop, we explore modularity and standardization strategies whereby we jointly design unique motor and battery modules to be installed in all the vehicles in the family, using a different number of these modules when needed. Such an approach results in higher production volumes of the same component module, entailing significantly lower manufacturing costs due to Economy-of-Scale (EoS) effects, and hence a potentially lower TCO for the family of vehicles. To solve the resulting “one-size-fits-all” problem, we instantiate a nested framework consisting of an inner convex optimization routine which jointly optimizes the modules’ sizes and the powertrain operation of the entire family, for given driving cycles and modules’ multiplicities. Likewise, we devise an outer loop comparing each configuration to identify the minimum-TCO solution with global optimality guarantees. Finally, we showcase our framework on a case study for the Tesla vehicle family in a benchmark design problem, considering the Model S, Model 3, Model X, and Model Y. Our results show that, compared to an individually tailored design, the application of our concurrent design optimization framework achieves a significant reduction of the production costs for a minimal increase in operational costs, ultimately lowering the family TCO in the benchmark design problem by 3.5%. Moreover, our concurrent design optimization methodology can reduce the TCO by up to 17% for the market conditions considered in our sensitivity study.

Keywords: Electric vehicles; Design methodologies; Powertrain design; Convex optimization; Product family design; Concurrent design optimization (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1016/j.apenergy.2024.124840

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