Solving EV Fluid Conveyance Issues With Custom Manifolds

By Jim Tuma, Marketing Services Manager, Fluid System Connectors Division, Parker Hannifin

The increasing adoption of electric vehicles has created new, complex challenges for heavy truck and off-highway equipment OEMs to overcome. However, with the U.S. Environmental Protection Agency’s Low-NOx mandate set to take effect in 2027 and similar regulations on the horizon globally, many OEMs are researching how to best incorporate battery electric power into their vehicles without diminishing performance or reliability.

While battery technology has rapidly advanced in recent years, we are still far from completely shifting from internal combustion engines to battery electric power. This is particularly true in the case of heavy trucks used for the most demanding applications.

For example, electric power is ideal for last-mile delivery trucks that return to a depot every night, as the full fleet’s batteries can conveniently be recharged when the vehicles are not scheduled for use. By comparison, heavy-duty trucks demand more power and need longer periods in between opportunities to recharge. Given this, manufacturers resourcefully use battery energy to enable some of the truck’s key ancillary systems, leaving the internal combustion engine to power the drivetrain.

Since battery systems require more robust thermal management, OEMs are continuously researching their designs to identify iterative improvement opportunities. No industry standard defines how a thermal management system should be structured and installed. Proper routing of the coolant conveyance lines is critical, but as with most automotive design challenges, space is at a premium.

Custom manifolds have emerged as an attractive choice for manufacturers to make running lines easier, reduce the number of ports, and simplify fluid conveyance systems. Whether used for air, fuel, or even coolant, manifolds can be designed with fewer required fittings and a minimal physical footprint. This customization reduces leak points and offers cost savings to manufacturers by simplifying installation. These manifolds are grouped into one of two categories, based on which are best suited for different types of applications based on their design and functionality.

Multi-Port Manifolds

A multi-port manifold allows for a reduction in the number of ports. Among other applications, they are typically seen on air tanks where compressed air is distributed through a single connection and routed throughout the tank. This setup reduces the number of potential leak points, cuts costs associated with additional ports, and helps OEMs move configurability further along within the assembly process.

Firewall Manifolds

Firewall manifolds are designed for placement between the truck engine and the cab. They contain built-in fittings so that tubing can be routed in and out of the firewall. This replaces the need for individually installed bulkhead fittings. This custom manifold also allows manufacturers to reduce installation time and complexity, including fewer cutouts. This, in turn, improves safety performance. For procurement teams, a custom firewall manifold also reduces the bill of materials for needed components.

After determining the manifold type, the next consideration is shape. Manifolds can be designed to a specific configuration that best fits a customer’s unique application. The limiting factor for shape is body material. Brass manifolds are machined and therefore limited, but composite manifolds are injection molded which allows for a significantly wider range.

The manifold’s connection types and number of ends can be customized for optimal system performance. Traditionally, custom manifolds utilize push-to-connect ends over threaded connections to minimize the chance of a leak. However, engineers are routinely accommodating requests for a threaded connection or other end configuration to support a customer’s particular use case or application.

While vehicle designs and powertrain systems will continue to change as EV technology evolves, manufacturers are seeing custom manifolds as one solution to help advance electrification in pursuit of a more sustainable future.