OSEM-EV · Project

Smart Thermal Management That Extends Electric Vehicle Range by Up to 50%

transportTestedTRL 6

Electric cars lose a huge chunk of their range just keeping passengers warm in winter or cool in summer — sometimes 30-50% of the battery drains on climate control alone. OSEM-EV figured out how to capture waste heat from the motor, battery, and electronics, store it in a compact tank, and recirculate it where it's needed — like a thermos that keeps your whole car comfortable. They also built a wireless charger that pre-heats or pre-cools the car while it's still plugged in, so you start every trip with maximum range. The result: a complete demonstrator vehicle that cuts comfort energy use in half and component cooling energy by a third.

By the numbers

50%

Reduction in energy used for passenger comfort vs. current full electric vehicles

30%

Reduction in energy used for component cooling in extreme conditions

1.5 MJ

Heat capacity of thermal energy storage unit

15L

Volume of thermal energy storage unit

Consortium partners across 6 countries

67%

Industry partner ratio in consortium

Physical demonstrator subsystems delivered

The business problem

What needed solving

Electric vehicles lose 30-50% of their range in extreme weather because heating and cooling the cabin and components drains the battery fast. This makes range unpredictable, frustrates customers, and slows EV adoption — especially for fleet operators who need reliable daily range. Simply adding bigger batteries adds cost and weight, which is not a viable solution.

The solution

What was built

The team built a complete demonstrator vehicle with 8 physical subsystems: a compact thermal storage unit (1.5 MJ in 15 liters), a thermally controlled battery system, a high-power wireless charger for pre-conditioning, a real-time motor control platform, innovative motor and inverter cooling, a heat-pump on a System-on-Chip, and an electro-thermal energy management platform. These work together as a thermal network that captures, stores, and reuses waste heat across the entire vehicle.

Audience

Who needs this

EV OEMs looking to improve range without increasing battery sizeTier-1 automotive suppliers developing thermal management componentsPower electronics companies designing EV inverters and motor controllersCommercial fleet operators needing predictable EV range in all weatherWireless charging infrastructure companies

Business applications

Who can put this to work

Electric Vehicle Manufacturing

enterprise

Target: EV OEMs and Tier-1 automotive suppliers developing electric powertrains

If you are an EV manufacturer struggling with range anxiety complaints from customers — this project developed a full electro-thermal management platform with a demonstrator vehicle that reduced energy used for passenger comfort by at least 50% and component cooling by at least 30% in extreme conditions. The system includes thermal storage (1.5 MJ in just 15 liters), a heat-pump subsystem on a System-on-Chip, and smart energy control algorithms that treat the whole vehicle as one thermal network.

Automotive Components & Electronics

mid-size

Target: Power electronics and semiconductor companies supplying the EV market

If you are a component supplier looking to differentiate with energy-efficient EV solutions — this project, led by Infineon Technologies, built a high-power wireless charging subsystem for thermal preconditioning, a real-time motor control platform (VEMCU), and innovative cooling concepts for both electric motors and inverters. These are hardware-demonstrated subsystems ready for integration into next-generation EV platforms.

Fleet Management & Electric Mobility Services

any

Target: Commercial fleet operators transitioning to electric vehicles

If you are a fleet operator worried about unpredictable EV range in varying weather conditions — this project addressed exactly that problem. The thermal management system limits the negative impact of both high and low ambient temperatures on range, making daily route planning more reliable. The 50% reduction in comfort energy consumption means your vehicles maintain usable range even in winter operations.

Frequently asked

Quick answers

What would it cost to integrate this thermal management system into our vehicles?

The project data does not include per-unit cost figures. However, the stated design goal was to improve mileage and predictable range 'without adding further cost and weight,' suggesting the consortium optimized for cost-neutral integration. The thermal storage unit fits in just 15 liters of volume. Contact the coordinator for licensing and integration cost details.

Can this scale to mass automotive production?

The consortium was 67% industry partners (8 out of 12), led by Infineon Technologies — a major semiconductor manufacturer. They built a full demonstrator vehicle and multiple hardware subsystems, indicating production-oriented design. The System-on-Chip heat pump controller and the wireless charger with developed manufacturing processes suggest scalability was considered from the start.

What is the IP situation — can we license or use these technologies?

The project ran under the EU's Horizon 2020 RIA funding scheme, which typically allows consortium partners to own the IP they generate. Infineon Technologies AG coordinated the project. Licensing arrangements would need to be negotiated directly with the relevant consortium partner that developed each specific subsystem.

How proven is the range improvement claim?

The project built 8 demonstrator subsystems including a complete OSEM-EV demonstrator vehicle. The targets were at least 50% reduction in comfort energy use and at least 30% reduction in component cooling energy under extreme conditions compared to current full electric vehicles. These were validated at subsystem and vehicle level through physical demonstrators.

Does this work with existing EV platforms or require a new architecture?

The project developed modular subsystems — thermal storage, battery thermal control, wireless charger, motor control platform, and heat pump — each demonstrated independently before vehicle integration. This modular approach suggests individual subsystems could be retrofitted or integrated into existing EV architectures, though the full benefit comes from the complete electro-thermal network.

What climate conditions was this tested for?

The project specifically targeted both high and low ambient temperature extremes. The objective states that the negative impact of extreme temperatures would be 'limited,' with the 50% comfort energy reduction and 30% cooling energy reduction measured against extreme conditions. Based on available project data, specific temperature ranges tested are not detailed in the public deliverable descriptions.

Consortium

Who built it

This is a strongly industry-driven consortium: 8 out of 12 partners are industry players (67%), led by Infineon Technologies AG, one of Europe's largest semiconductor companies. The consortium spans 6 countries (AT, CZ, DE, FR, IT, UK) with 3 universities and 1 research organization providing the scientific backbone. The demonstrator vehicle was built by AVL (Austria), a major automotive engineering firm. Only 1 SME is listed, indicating this project operated at a Tier-1 automotive supplier level. The heavy industry presence and the involvement of a global semiconductor leader as coordinator suggest that results are designed for real product integration, not just academic publication.

INFINEON TECHNOLOGIES AGCoordinator · DE
INTERACTIVE FULLY ELECTRICAL VEHICLES SRLparticipant · IT
THE UNIVERSITY OF SHEFFIELDparticipant · UK
VYSOKE UCENI TECHNICKE V BRNEparticipant · CZ
MERCEDES-BENZ GROUP AGparticipant · DE
AVL LIST GMBHparticipant · AT
HUTCHINSON SAparticipant · FR
SIEMENS AKTIENGESELLSCHAFTparticipant · DE
VALEO EQUIPEMENTS ELECTRIQUES MOTEUR SASparticipant · FR
SAFTparticipant · FR
TECHNISCHE UNIVERSITAET DRESDENparticipant · DE

How to reach the team

Infineon Technologies AG (Germany) — reach their automotive division or R&D partnerships team for licensing discussions

Order a report on this consortium See INFINEON TECHNOLOGIES AG profile →

Next steps

Talk to the team behind this work.

SciTransfer can connect you directly with the OSEM-EV team and help evaluate which subsystems fit your EV platform. Contact us for a detailed technology brief.

Order a report on this topic More in Transport & Mobility