Reduction of overheating of HV components in Electric Vehicles

Overheating of high-voltage (HV) components remains a critical challenge in electric vehicle (EV) manufacturing and operation. This paper focuses on three key interventions to address coolantrelated issues at the manufacturing stage. First, an L3 control system integrates a wireless torque wrench with PLC for precise hose joint tightening to eliminate leakage. Second, a refractometerbased system ensures optimal coolant concentration through real-time measurement and automatic adjustment. Third, a digital twin of the coolant filling machine provides variant-specific, closedloop validation using PLC S7-1200 and OPC UA communication. These solutions are interconnected: leak-proof joints (L3) maintain system integrity, accurate concentration ensures thermal performance, and the digital twin guarantees precise filling. Results from implementation show complete elimination of leakage, consistent concentration control, and improved filling accuracy, significantly reducing the risk of HV component overheating.