Marelli Debuts Intelligent Energy Management for EVs

Saitama City, Japan- Marelli Holdings Co., Ltd., a mobility technology supplier, has introduced its new Intelligent Energy Management solution for hybrid and electric vehicles at the 2025 CTI Europe Symposium in Berlin. Designed as a modular platform, the system is powered by proprietary software that integrates seamlessly with vehicle and zonal control units as well as key thermal components.

The solution enables coordinated optimization across the three primary energy domains of a vehicle thermal, propulsion and electronics. By managing these systems holistically, the technology enhances battery range, improves fast-charging efficiency, increases component longevity and preserves high standards of cabin comfort and system reliability. The innovation also aligns with the growing needs of hybrid powertrains and Software-Defined Vehicle (SDV) architectures.

A central part of the development process included the use of advanced digital-twin methodologies and innovative software strategies. These tools reduce development time and cost, while offering automakers a highly collaborative and flexible model for integration and validation.

Within the thermal domain, Marelli’s system regulates vehicle heating and cooling through intelligent, decoupled software algorithms. These algorithms manage complex thermal circuits, ensuring precise temperature control for improved overall efficiency and extended battery life. The optimized thermal strategies also cut energy losses and support the reuse of excess thermal energy, lowering operating costs and improving sustainability.

For hybrid and electric propulsion systems, the technology continuously monitors and fine-tunes power flow. This ensures optimal energy distribution, maximizes battery performance and extends driving range. By improving energy recovery and balancing power delivery, the system enhances the durability and resilience of next-generation electric vehicles.

In the electronics domain, the solution enhances intelligence and connectivity across all vehicle systems. It supports robust data exchange over communication protocols ranging from CAN to Ethernet, enabling direct control of sensors and actuators. This improves system responsiveness, operational smoothness and adaptability to evolving vehicle environments.

The digital-twin application at the core of the system models every key subsystem—from electronics and electromechanics to thermodynamics and hydraulics. These fully virtualized vehicle models allow automakers to test, iterate and refine designs more efficiently, accelerating time-to-market while reducing risk.

Leveraging Marelli’s software expertise, the Intelligent Energy Management system supports agile customization and rapid deployment for diverse OEM requirements. By simplifying architecture and reducing component count, Marelli delivers a cost-competitive, efficient and scalable solution while significantly lowering development and testing expenses.

Mr. Giovanni Mastrangelo, Head of R&D for Marelli's Propulsion business said, "Intelligent energy management is the central challenge facing today’s electric and hybrid vehicle development. At Marelli, we address this by delivering solutions that not only optimize energy flow across thermal, electric and propulsion domains, but also minimize losses and recover excess thermal energy. Through our digital twin and decoupled software approach, we empower our customers to reduce development timelines, gain flexibility, and accelerate adoption of cutting-edge technologies, driving the future of sustainable and efficient mobility."

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