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Improving fuel economy and to satisfy more stringent emission legislations the Vehicle electrification becomes more important one. Compared to the combustion engine an electric vehicle will use energy from the grid to recharge their HV battery and this is converted with much higher efficiency and less CO2 emission. This makes a significant role in the present transition from conventional to electric vehicles. The addition of new components, such as power electronics, electric machine and HV battery, increases the torque availability, energy but also the weight. In addition, although they have really high efficiency, they produce a significant amount of heat that has to be removed. Another thermal management issue in PHEV and BEV is cabin heating, since the engine heat is not available. To guarantee system efficiency and reliability, a completely new thermal management layout has to be designed.

The performance of the Transmission Oil Cooler (TOC) is influenced significantly by the TOC plumbing lines which transmit the oil from transmission system to the oil cooler and back. Designing the optimum TOC plumbing line with lesser pressure drop is the need of the hour considering the complex nature of the vehicle packaging. Reducing the pressure drop increases the oil flow rate through the transmission which results in optimum performance. Improved transmission efficiency in turn shall improve the engine efficiency and performance. The improvements obtained from increased transmission and engine efficiency shall result in an overall increase in vehicle fuel economy. Optimization solutions are required in the early product development cycle where the components are not readily available and/or are prohibitively expensive to do testing. In such scenarios, one-dimensional (1D) simulations shall be employed to compute the pressure drop for faster and economical solutions.