Thermal Management System For Electric Vehicles

Parts You'll Need

This project is sourced from another site, not written by us — this list is our best match of their components against what we stock, not a verified bill of materials. Always check the original blog (linked above) for the actual parts list before buying.

This list includes a generic resistor set as a placeholder — it is not matched to the exact value or part number this circuit needs. The correct one is specified on the original source page linked above; check it before buying.

We don't carry yet: Battery (generic / unspecified)
Voltage Regulator IC (7805 / LM317 / 1117)
Potentiometer / Trimpot
Diodes (1N4007 / 1N4148 / Schottky / Zener)
Capacitors
Transistors (BC547 / 2N2222 / TIP / MOSFET)

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How It Works

The Thermal Management System for Electric Vehicles centers around the ESP32 development board, which continuously monitors the operational status of a 60V/40A/2.4kW electric vehicle battery. The system relies on a DS18B20 temperature sensor to track thermal fluctuations within the battery pack and an MQ135 smoke detector to identify potential outgassing or early signs of fire. Powering the logic circuit is a 12V Lithium-ion battery regulated down to 5V via an LM7805 voltage regulator, supported by 1N4009 rectifier diodes and 100nF ceramic disk capacitors to stabilize the voltage supply. The ESP32 processes sensor data and outputs real-time metrics to an I2C 16x2 LCD display, with screen contrast adjusted manually using a 10k potentiometer. If temperature thresholds or smoke concentration exceed safe operating limits, the ESP32 triggers a buzzer for audible feedback and activates a BC547A transistor to drive a high-power switching relay (GU-SH112D). This relay can physically interrupt power or trigger emergency mitigation systems. Additionally, system telemetry and alerts are transmitted wirelessly to an Android mobile phone running the Arduino Blue Control App, connected via the ESP32's onboard communication capabilities. An SPDT switch serves as the master power control for the diagnostic and management circuitry.

Why Build This

Design robust, embedded safety architectures capable of preventing thermal runaway and catastrophic battery failure in high-power electric vehicles.

Implement multi-sensor data fusion combining environmental gas detection and precise temperature logging using an ESP32 microcontroller.

Integrate local analog actuation (relays and buzzers) with wireless mobile monitoring via Bluetooth applications for comprehensive fleet or personal EV diagnostics.

Real-World Application

Electric vehicle battery safety systems, thermal runaway prevention, and early smoke/fire detection in personal electric bikes and cars.

Skills You'll Learn

Microcontroller interfacing

I2C bus communication

analog sensor signal conditioning

transistor-based relay switching

wireless mobile app integration

linear voltage regulation design

Safety Precautions

Exercise extreme caution when working with high-voltage EV lithium-ion batteries (60V/40A) to prevent electrical shock or fire hazards during testing and installation.

Technology Tags

ESP32

DS18B20 TEMPERATURE SENSOR

MQ135 SMOKE DETECTOR

I2C LCD DISPLAY

RELAY

BUZZER

ARDUINO BLUE CONTROL APP

Frequently Asked Questions

Why is an LM7805 voltage regulator needed if I already have a 12V battery?

The ESP32 microcontroller and associated logic sensors operate on 5V logic. The LM7805 steps down the 12V supply to a safe operating voltage, preventing permanent damage to the sensitive digital components.

Can I connect the 60V EV battery directly to the relay or microcontroller?

No. The ESP32 and low-voltage components cannot handle a 60V/40A bus directly. The high-power switching relay is used to isolate the low-voltage control circuit from the high-voltage power path, and extreme care must be taken when placing any monitoring leads near the main power lines.

How does the Android phone communicate with the ESP32?

The ESP32 communicates wirelessly with your Android phone running the Arduino Blue Control App, allowing you to view sensor metrics and system alerts remotely over a wireless connection.

Gallery

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