Browse Topic: Battery thermal management

Items (229)

Predictive Battery Thermal Management System Control Strategy and Simulation in Electric Vehicle

2025-01-502704/03/2025

With the global issue of fossil fuel scarcity and the greenhouse effect, interest in electric vehicles (EVs) has surged recently. At that stage, because of the constraints of the energy density and battery performance degradation in low-temperature conditions, the mileage of EVs has been criticized. To guarantee battery performance, a battery thermal management system (BTMS) is applied to ensure battery operates in a suitable temperature range. Currently, in the industry, a settled temperature interval is set as criteria of positive thermal management activation, which is robust but leads to energy waste. BTMS has a kilowatt-level power usage under high- and low-temperature environments. Optimizing the BTMS control strategy becomes a potential solution to reduce energy consumption and overcome mileage issues. An appropriate system simulation model provides an effective tool to evaluate different BTMS control strategies. In this study, a predictive BTMS control strategy, which adjusts

Huang, Zhipei, Chen, Jiangbo, Tang, Hai

Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit

2025-01-501703/21/2025

Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed

Birgül, Çağrı Emre, Meydan, Ömer

Internet of Things Enabled Automatic Battery Cooling System Using the Peltier Effect

2025-01-500401/23/2025

Electric vehicles (EVs) have developed rapidly and are popular due to their zero emissions and efficiency. However, several factors limit electric car development, including battery performance, cost, lifetime, and safety. Battery management is crucial for achieving maximum performance under various conditions. The battery thermal management system (BTMS) plays an important role in controlling the battery’s thermal behavior. A BTMS manages the battery’s operating temperature by either dissipating heat when it is too hot or providing heat when it is too cold. Various methods of cooling batteries include air cooling systems, liquid cooling systems, refrigerant cooling systems, and phase change material cooling systems. This study focuses on an innovative BTMS utilizing a Peltier module, regulated via the Internet of Things (IoT) platform for real-time temperature monitoring and control. The objective of this research is to design and develop a temperature-controlled cooling system for EV

Gunasekar, N., Abishek, H., Bharath, N. S., Gokul, G.

Cost-effective techniques for SCEV to improve performance & life of battery and motor by using efficient thermal systems

2024-26-027501/16/2024

The automotive world is moving towards electric powertrain systems. The performance of an electric powertrain and its electric components majorly depends on the operating temperature of the components. In the small commercial vehicle segment overall vehicle cost is a very sensitive parameter while competing in the market. This paper presents advanced efficient cost-effective thermal techniques for small commercial electric vehicles (SCEV) to improve the performance & life of major electric components. It is observed that from the literature survey, this technology is a novel technology for small commercial electric vehicle applications. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the battery and traction cooling system during battery charging and vehicle driving scenario for different ambient conditions. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which help

Chormule, Suhas Rangrao, Warule, Prasad, Jadhav, Vaibhav, Nagpure, Rahul

A Real-World Range Testing and Analysis Methodology Development for Battery Electric Vehicles

2024-26-012401/16/2024

Range anxiety is one of the major factors to be dealt with for increasing penetration of EVs in current Automotive market. The major reasons for range anxiety for customers are sparse charging infrastructure availability, unreliable range prediction and uncertain real-world range values. The uncertainty in real world range is due to the variation between the testing condition during vehicle development and real-world customer usage condition. This paper illustrates a more accurate test methodology development to derive the real-world range in electric vehicles (LMV) with experimental validation and system level analysis. The test methodology developed will be replicating the real-world usage scenario and bridge the gap between testing and Indian customer usage condition. Test conditions are developed based on matrix consisting of different routes, drive modes, Regeneration levels, customer drive behavior, time of drive, locations, ambient conditions etc. Based on the real world

B, SAKTHIVEL, Shams, Tausif, Lalasure, Santosh, Karnure, Shabbir Lalaso, Rajakumar, K., Omprasad, Karthick

Immersion Cooled Portable Battery Pack Concept for Small EVs

2024-26-011101/16/2024

India is amid of a mobility revolution with the adaption of electric vehicles (EV). Such large-scale EV adoption comes with critical safety challenges related to thermal management of batteries. EVs catching fire during running & parked conditions has been widely noticed throughout the country. The cause of fire in most of the cases is poor thermal management and thermal mitigation strategies. Owing to this in Sep-2022, the Government of India amended the EV battery testing standards and implemented Amendment-3 of AIS-156 in a phased manner, with Phase-1 came into effect from Dec-2022 & Phase-2 from Mar-2023. This paper introduces a battery thermal technology that will address these automotive safety needs and government requirements by achieving better thermal management of EV batteries and reducing thermal failures. Present EV battery thermal management systems are either air (active & passive) or liquid-based cooling systems. Most liquid cooling technologies usually incorporate a

Jadhav, Jeevesh, Neve, Gaurav, Hiremath, Vinodkumar, Nagpure, Shrikant, Emran, Ashraf

Integrated Battery and Traction Cooling Based on Reversed Brayton Refrigeration Cycle for High Speed Performance Bikes.

2022-28-041611/09/2022

Recent advancement and compact design requirements in the field of two wheeler Electric vehicle has resulted for the requirement of cooling system for high performance bikes. It has also been observed that heating requirement are dominant at higher speed, because of higher power consumption and thus cooling is required for high speed EV bikes. This paper represents an integrated motor and battery cooling system taking advantages of freely available air. Air collector will be installed in the direction of the vehicle motion to collect available ram air, the collected ram air will be divided into two parts, one part will be directed to motor and MCU for direct air cooling and the second part will be used for battery cooling. Second part will be made to pass through a drier to make air moisture free, the dry air is then made to pass through compressor where it is isentropically compressed to higher pressure. Then this compressed air will be intercooled to initial atmospheric temperature

Jha, Navneet Kumar

Numerical Modeling of Electro-Thermal Behavior of a Typical Lithium-Ion Cell and Pack Level Using NewmanP2D Approach

2022-28-040911/09/2022

Numerical simulation of lithium-ion batteries (LIB) has become extremely vital in the understanding of thermal behavior of LIBs in order to develop active and passive battery thermal management systems. The LIB is popular in consumer electronics. Beyond consumer electronics, the LIB is also growing in popularity for the automotive applications such as hybrid electric vehicles (HEVs) and battery electric vehicles (BEVs) due to its high energy density, high voltage, and low self-discharge rate. High amount of heat generally gets developed during charge and discharge of LIB based on the C-rate at which it is being discharged or charged. Hence, there should be a mechanism to understand the thermal behavior of these cells. Thus, in this paper a numerical procedure has been developed to model electrochemical-thermal behaviour of commercially available 21700 Li-ion cells. NewmanP2D approach is used to arrive at electrochemistry performance of Li-ion cell and pack. Well known commercial code

Gudi, Abhay, U, Reghunath, Bonala, Sastry

An Experimental Study on Effectiveness of Electronic Expansion Valve [EXV] in EV HVAC System

2022-28-042411/09/2022

HVAC system maintaining passenger comfort have evolved out as vital system as any other automotive systems. As the automotive industry is in its transition to EV technology, Battery Thermal Management is critical for the life, efficiency, performance, and safety of battery pack and thus the vehicle. Liquid Cooling is one of the more common battery cooling strategies that uses Chiller as a heat exchanger between coolant and refrigerant. The added thermal load imparted during battery cooling impacts the cabin temperature with a sensible effect. Present day TXV based chiller system creates a significant impact in the vent-level and in-cabin temperatures when the battery cooling request is ON. Gaining control over refrigerant mass flow to chiller quantitatively with thermal load can reduce the effect on cabin temperatures. This in turn cut down the load on compressor which will aid the range of EV. A comparative study is performed to evaluate the effect of battery cooling on cabin

Majumder, Sayan, Sampath, Karthikeyan, E A, Muhammed, K, Yashojeet

Systematic 1D Thermal Aimulation Approach for Battery Electric Vehicle (BEV) using Amesim.

2022-28-041011/09/2022

In this paper a complete vehicle thermal system of BEV battery electric vehicle is presented using 1D method. A battery electric vehicle (BEV), pure electric vehicle, only-electric vehicle, fully electric vehicle or all-electric vehicle is a type of electric vehicle (EV) that exclusively uses chemical energy stored in rechargeable battery packs, with no secondary source of propulsion All relevant components from battery, inverter, electric motor, gear box, vehicle, driver, refrigerant loop, cabin cooling, chiller, battery heater, DC-DC with auxiliary loads sensors and control system is considered in the simulation. The vehicle is built for HVAC refrigerant loop, battery coolant loop and electric power train loop (EPT) with driving cycle control and vehicle model. The thermal components are stacked from Grill, radiator, condenser, cooling fan and engine back resistances. The airflow to the radiator is computed for different vehicle speed. The condenser capacity is calculated from cabin

Solomon, Samson

Study of Various Battery Thermal Management Systems & its Benefits

2022-28-041411/09/2022

Electric Vehicle is the need of hour as the excessive usage of IC Engine driven Vehicles has depleted the ozone layer to a significant level. With new technology into the market, challenges come hand in hand because of Electric Vehicle. In comparison to IC Vehicle, areas of thermal management or the number of components for which thermal management needs to be done is higher and rather complex. As the thermal management system is the second highest energy consuming source after the powertrain of the electric vehicle, an efficient and reliable design becomes inevitable to ensure last mile driving range. Thermal Management of the Electric Vehicle has been identified as one of the critical parameters in defining the life, durability, range of the vehicle and the safety of its occupants. One of the major concerns in the development of lithium-ion battery packs for EVs is thermal management. The temperature of all cells must be strictly maintained within a few degrees C across the entire

Performance Analysis of Integrated Battery and Traction Motor Cooling Systems for Two-Wheeler Electric Vehicles Applications

2022-28-041311/09/2022

The automotive industry is a huge industry as millions of vehicles are running on the road & it's growing at a rapid rate. The emission from these vehicles are harmful in nature & are bigger concerns for the human being as its increasing day by day at an alarming rate. The emissions are causing various global problems such as global warming, green house effects, air pollutions etc. due to the use of fossil fuels in abundance. This drives to think for alternative solutions, which are eco-friendly & having less or no emissions. The electric vehicles (EVs) are the most reliable solution as it is having high performance & efficiency without emissions. EVs are most suitable option to reduce global warming & greenhouse effects etc. The evolution of EVs has fueled the two-wheeler EVs industry to flourish at a fast pace. Li-ion battery & traction motor is the most important components in two-wheeler EVs. Li-ion batteries are compact, light-weight, fast-chargeable, having low self-discharge

Suman, Saurabh, Kushwah, Yogendra Singh

Feasibility Analysis of Submerged Battery Cooling System for Electric Vehicles

2022-28-041111/09/2022

Due to the depletion of fossil fuels and excessive air pollution, the world is moving towards electric vehicles. Usage of electric vehicles avoids the global warming and safeguard the earth. Batteries are the primary source of electricity for electric vehicles which generates lot of heat during its operation. Now a days, firing accidents of electric vehicles on roads are frequent. One of the most significant systems to avoid this fire accident is thermal management system. Effective thermal management of high-power density battery is essential for battery’s performance, life, and safety. Components that are used for the thermal management are to be as efficient as possible to achieve effective cooling of batteries. Direct Liquid Cooling has received lot of interest in recent years. A non-conductive dielectric fluid is used to submerge the battery cells. As the fluid is dielectric, the direct contact with the cell surfaces will not be tend to short circuit the battery. This direct

Deepan Kumar, Sadhasivam, M, Boopathi, Praveenkumar, Nagarajan, Sabariraj, R

Investigation on Thermophysical Characterization of Nano Composite Phase Change Materials for Battery Cooling in EV

2022-28-042011/09/2022

Li-ion batteries are preferred for Electric Vehicles (EV) due to its high energy density, high power, long life cycles and low self-discharge rate. The performance of Li-ion batteries and life span are limited by its operating temperature, the safest operating temperature of the Li-ion batteries are below 500C, The operating temperature exceeded during fast charging and discharging which causes internal heating of battery it is essential to increase the dissipation of heat generated by the battery rapidly. Nano Enhanced Phase change Material (PCM) is proposed as Battery Thermal Management System. by nature the pure paraffin has low thermal conductivity and sub-cooling characteristics . In order to increase the thermal conductivity of PCM, thermal conductive substance such as nanoparticles are added to PCM, SiO2 nanoparticles were dispersed into paraffin wax tosynthesisSiO2 –PCM nanocomposites. The chemical, physical and thermal properties of CPCMs were determined by various material

Deepan Kumar, Sadhasivam, Dhayaneethi, Sivaji, Gopal, Mathiselvan, VISHNU, ANANDAN

1-D Thermal Simulation and Experimental Validation of Li-Ion Battery Pack Cooling System

2022-28-042911/09/2022

In today’s world EV plays an important role in reducing fuel consumption, pollution and global climate change. In EVs, Li-ion batteries are most preferred ones and their optimum operating temperature should be 15 °C to 30 °C, for that Battery Cooling System (BCS) is needed during charging and discharging for better performance in tropical regions. A flexible design methodology is required to evaluate and enhance the performance of BCS before the prototyping. This study mainly focused on 1-D thermal analysis and experimental validation of BCS. The simulation results and tests data shows good agreement within ±10% variation.

Jangir, Kuldeep Kumar, Srivastava, Umang

Theoretical Analysis of the Thermal Resistance Network for Battery Thermal Management

2022-01-508710/12/2022

Battery thermal management for electric vehicles have gained significance over recent years, especially for the present lithium-ion batteries. However, high operating temperature and uneven temperature distribution inside the battery cell can significantly reduce capacity and lifetime. The temperature difference between the battery cells needs to be minimized to avoid premature aging of specific cells exposed to a higher temperature. The most common way to dissipate heat from the battery cells is to use air or liquid cooling. Air cooling is less complex than liquid cooling, but the extremely high ambient temperature dramatically limits the usage of air cooling. This paper developed a thermal connector that could be repeatedly assembled and disassembled between the battery cell. The thermal connector can effectively dissipate the heat into the refrigeration cycle while providing constant thermal resistance among the battery cells, which can be as lower as 0.115°C/W. Heat transfer

Lian, Yubo, Liu, Jianjian, Liao, Yinsheng, Xu, Haolun

Performance Analysis of Phase Change Material Based Battery Thermal Management System

2022-01-022803/29/2022

Interest on electric vehicles (EVs) has significantly increased from last decade, as whole world is concerned on reduction of emission of greenhouse gas by reducing the use of fossil fuel in transportation. The primary issue for electric vehicles is to develop an energy storage system i.e battery that can enable high mileage, rapid charging, and high-performance driving. Hence, battery management is required to get maximum, safe, and consistent performance of an electric vehicles when running in a variety of conditions. To get the most out of a battery, it's important to keep an eye on its operating conditions, especially temperature, which has been shown to have a direct impact on battery performance and life. So, battery thermal management system (BTMS) is crucial in control of the thermal behaviour of battery. In this study, we built and simulated one of the popular BTMS system using MATLAB/Simulink which uses phase change material (PCM) for colling and known as PCM colling system

Parameswaran, Siva

Modeling Climate Control Loads and the Impact on Vehicle Range for Last-Mile Electric Delivery Trucks in Cold Climates

2022-01-022503/29/2022

In cold climates, the cells in the battery of an electric vehicle are subject to environment-related performance degradation leading to a decrease in effective range. Cold ambient temperatures contribute to two primary sources of increased auxiliary power requirements – battery and cabin thermal management systems. Active battery temperature regulation is often implemented in battery electric vehicles (BEVs) to mitigate the detrimental effects of extreme temperatures on battery state of health and effective nominal capacity. At the same time, demands on heating, ventilation, and air conditioning (HVAC) systems increase in extreme environments to maintain driver comfort by regulating the cabin temperature. This paper presents a study to analyze and model increased auxiliary power demand from HVAC systems in cold climates. The developed model can be used to aid localized BEV range prediction. Practical driving data was periodically collected from an instrumented medium-duty internal

Eagon, Matthew, Trujillo, Jeromy, Northrop, William

3D FEA Thermal Modeling with Experimentally Measured Temperature Gradient Function from Large Format Ultra-Fast Charging Battery Module used in EVs

2022-01-084303/29/2022

In an electric vehicle (EV), due to a number of single cells connected either in series or parallel, generates a large amount of heat because of electrochemical reactions and physical changes, and that would result in the battery degradation (performance and capacity) and thermal runaway issues, and hence demands for an efficient battery thermal management system (BTMS). In this paper, an efficient BTMS is designed and developed for a large format Lithium-ion battery module using a liquid cooling technique. Experiments are conducted on 31Ah NMC/Graphite battery cell which is sandwiched by foams and heat sinks on both sides. A battery module is also developed with three batteries connected in parallel and four cold plates. A total twenty T-type thermocouples are used for this experimental work to measure thermal characteristics including the cell and foam surface temperature, heat flux distribution, and the heat generation from batteries under 2.5C and 3.5C constant power loss tests

Zhao, Ziyu, Panchal, Satyam, Kollmeyer, Phillip, Emadi, Ali, Gross, Oliver, Dronzkowski, David

Multiphysics approach for thermal design of liquid cooled EV battery pack

2022-01-023303/29/2022

Thermal management of battery packs is essential to keep the cell temperatures within safe operating limits at all times and, hence, ensure the healthy functioning of an EV. The life cycle of a cell is largely influenced by its operating temperature, maintaining the cell temperature in its optimum range improves its longevity by decreasing its capacity fade rate and in turn extending the life of an EV. Liquid cooling techniques have proven to be cost-effective compared to other techniques such as air cooling, PCM-based in terms of performance in the given volumetric constraints. The battery thermal management solution being presented employs a tabbed type liquid cooling technology that achieves low-temperature differentials for an in-house designed battery pack consisting of 320 LFP cells (Size: 32700) with a total voltage and capacity of 27V and 240Ah respectively. Thermal design of the battery pack considers maximum dissipation when continuously operating at 1C-rate conditions

Singh, Vaibhav Kumar, S N, Akshay

Dynamic modeling method of electric vehicle thermal management system based on improved moving boundary method

2022-01-020803/29/2022

The thermal management system, which is used to improve driving safety and thermal comfort, is one of the most important systems in electric vehicles. In recent years, researchers have coupled the heat pump system and the battery cooling system to effectively improve the heating COP (Coefficient of Performance), and therefore an accurate dynamic model of thermal management system plays a key role in studying system performance and optimal control strategies. In this paper, an electric vehicle thermal management system based on the four-way valve heat pump system is designed, and the moving boundary method is improved by considering the unsteady flow of the external fluid. And then a 14-order dynamic model of the thermal management system is established. Firstly, the control equations of the evaporator, condenser and chiller are derived according to the principle of conservation, and then a dynamic model of the thermal management system is established and implemented in Simulink

Gao, Mingyang, Li, Ruilong, Zhen, Ran, Shangguan, Wen-Bin

Battery Heat Load Estimation and modeling its Thermal management using Air Conditioning System of an Electric Vehicle

2021-28-023110/01/2021

The performance of lithium-ion batteries and its service life depends on its operating temperature. Operating the battery above 45 °C degrades the performance of the battery and reduces its service life. The high-temperature operation also leads to thermal runaway. So there is a need to monitor the operating temperature and voltage output of the battery using a battery thermal management system to ensure its safety. Battery Thermal Management System (BTMS) is a part of the battery management system. The effectiveness of the battery thermal management system depends on the battery pack design, battery chemistry, vehicle operating characteristics and ambient conditions. In this work, a refrigerant-based BTMS is modeled using MATLAB Simulink. Refrigerant R134a used in the air conditioning system of an Electric Vehicle is used as an evaporative cooling medium to cool the batteries. The battery pack is submerged in the pool of refrigerant for cooling and to control the battery temperature

Kaliaperumal, MuthuKrishnan

Thermal Management of Battery Cooling System

2021-26-016109/22/2021

Lithium-ion batteries has emerged as the most suitable option to lead the next wave of automotive revolution. Power density, high energy and packing efficiency are main factors for the currently available alternatives. Battery and cell types face issues which need to be worked upon. Battery thermal management is the main factor affecting the working of the battery due to dynamic operation and range of environments under which they operate.The design as well as the three-dimensional computational fluid dynamics (CFD) simulations were carried out for battery system with and without cooling management from single battery to module level and then to pack level. Initially battery system of 40 kWh/360V was designed with 192 Lithium ion pouch cells (48 modules),weight of 325 kg with overall dimensions of 1550x1190x270mm without any coolant system. The analysis resultant temperature distribution is above the optimal performance battery temperature range (35-55℃)with local heat spots

Rajadurai, Dr.Sivanandi, Benny, Bineesh, Bala, Harinivas

CFD Analysis of a Prismatic Liquid Cooled Battery Pack to Optimize the Cold Plate and Battery Temperature under Variable Operating and Coolant Conditions

2021-28-011609/15/2021

Heat generation from Lithium-ion batteries depends on its charge/discharge rates, SoC and temperature and hence varies considerably with vehicle driving conditions, DoD, ambient operating conditions and charging rate. To design and optimize the performance of a battery cooling system, it is desirable to study the impact of the system under variable heat load conditions. In the present study, a 3D CFD analysis has been performed to evaluate the performance of a prismatic liquid cooled Lithium Iron Phosphate battery pack under variable heat load conditions corresponding to different SoC and charge/discharge rates. An initial study is performed to validate the CFD model with experimental data and then the model is used to optimize the shape and size of the cold plate micro channels for improved heat transfer and reduced pressure drop. The varying heat load with SoC and charge/discharge rates is calculated from experimental data of LiFePO4 cells available from literature and is then

Manna, Suvankar, Nadge, Pankaj

Advanced BEV Battery Pack Thermal Simulation Model Development & Co-relation with Physical Testing

2021-28-013809/15/2021

Battery Thermal management is a major challenge for occupant safety in an electric vehicle. Predicting the battery electrical losses and thermal behaviour is another challenge for the battery management system. Different virtual models are developed for cell level and pack level thermal evaluation. All these models have a varying degree of accuracy and limitation. The latest developed model is more accurate and can predict the battery cell & pack level temperatures. The cell temperature in the battery pack not only depends upon the cell inside physics but also depends upon cell outside cooling physics. Cell outside physics is simulated by 3D CFD software during the design process. The pack level simulations are performed considering extreme conditions and fixed boundary steady-state conditions. Heat transfer coefficient data from thermal simulations are extracted and used in the BMS model, and 1D thermal model is developed. There are two challenges that exist in BMS model. The first is

dol, Yogesh Pradeep, Virmalwar, Ajay, Soni, Gaurav

Numerical study of Thermal management of lithium-ion battery pack using liquid cooling

2021-28-011809/15/2021

Thermal management of the battery deals with reducing the temperature of the battery pack as well as maintaining the equal temperature distribution among all cells in the battery pack. This paper deals with the thermal management of battery cells with liquid cooling to maintain equal temperature among all the cells in the battery pack. This study starts with thermal analysis of a single battery cell with numerical analysis and validates its results with experimental analysis. Further this we have done thermal management of battery pack with liquid cooling. By using the symmetry condition of the battery pack we have considered six cells in a row with an aluminum block kept between two cells. The two faces in the aluminum block contact with cells. Two faces of the aluminum block were kept in the shape of an arc which is the same as the arc of a cell in order to get more heat transfer area. These aluminum blocks are penetrated by five circular channels in order to flow coolant and hinged

Deshmukh, Vikrant Mahesh, Durgam, Shankar

Smart Control Logic of Battery Cooling System for Electric Vehicles (EVs)

2021-28-011709/15/2021

Transport sector comes under largest energy consuming category, after mining and other industries, a significant fuel economy improvement are required to reduce green house emission. Till now the most promising technologies in this attempt are electric vehicle. Electric vehicles use large batteries to store energy, most common battery used in electric vehicles are lithium ion and lithium polymer preferred due to their high energy density compared to weight.The flow of current causes heating in the battery cells, performance of Lithium-Ion battery cells is greatly impacted by their temperature. For optimum performance it should operate in desired temperature range ( 15°C-35°C).Battery cooling system is the system which maintain optimum temperature of battery by cooling/heating to increases the thermal efficiency of vehicle. Most common Battery Thermal Management methods used today are, Air Cooled , Indirect liquid Cooled and Direct Cooled. In choosing a cooling method for battery system

Yadav, Tejash, Upadhyay, Ashish, Arora, Rajeev

Design Optimization of Battery Thermal Management System for Electric Vehicles

2021-28-012309/15/2021

High vehicle emission resulting in increasing the air pollution day by day has challenged and forced the automotive industry to look for alternate and more environment friendly technologies. The transformation of the automotive industry in near future towards green energy solutions has also fueled the technological advancement in this industry. In order to fulfill this requirement, Electrical Vehicles (EVs) have emerged as the best solution available till now. It has become very popular because of the zero emission and higher wheel-drive efficiency. The vehicle has some limitations in terms of performance, cost, lifespan & battery safety. The EVs have lithium ion batteries incorporated to cater the drive power requirement. In order to maximize the vehicle performance, thermal management of the batteries becomes very critical. The battery thermal management system (BTMS) has crucial role in controlling the thermal behaviour of the batteries. Several cooling methods are used for battery

Suman, Saurabh, Goel, Arunkumar, Kushwah, Yogendra Singh

Curing the Porosity Problem in Additive Manufacturing

21AERP08_0208/01/2021

Additive manufacturing, also known as 3D printing, allows the fast and cost-effective production of complex high-quality components in a range of materials. The rise of this technology has been fast, and it is rapidly altering the manufacturing landscape. In 2019, the global additive manufacturing market size was valued at $11.58 billion and is predicted to grow at a CAGR (compound annual growth rate) exceeding 14% from 2020 to 2027 (GVR). Additionally, research from Deloitte shows that additive manufacturing is empowering industry 4.0.

018 - Simulation of Advanced Regenerative Braking Strategies in a Series Plug-in Hybrid Electric Vehicle

SAE-PP-0014101/23/2021

Regenerative braking is an important factor in improving hybrid electric vehicle efficiency. This paper proposes a new regenerative braking strategy that activates preemptively during a distracted driving scenario, before service brakes are utilized. The strategy uses onboard advanced driver assistance systems, such as forward facing radar, to detect when an object is approaching fast enough to enable regenerative braking in response. The proposed strategy is simulated on a full-vehicle model of a series plug-in hybrid electric vehicle. A driver model is developed to mimic the behavior of a distracted driver through delayed response time to the changing speed of a lead vehicle. Multiple trials are simulated using different combinations of existing regenerative braking strategies along with the proposed strategy. Results show that a preventative regenerative braking control strategy can recuperate significant amounts of energy while also improving vehicle safety. Coupling the proposed

Mutagaana, Festo

Solid-State Technology Enables Smaller, Safer Batteries

TBMG-3834601/01/2021

A number of cellphone fires in 2016 brought attention to lithium-ion batteries, a technology that helped advance modern portable electronics but has been plagued by safety concerns. As interest in electric vehicles increases, so does the need for improved rechargeable battery technology that can safely and reliably power cars, autonomous vehicles, robotics, and other next-generation devices.

Mahle amps up electrification R&D, battery-cooling capability

20TOFHP12_0712/01/2020

Best known for pistons and other reciprocating components inside internal combustion engines (ICE), Stuttgart-based Tier 1 Mahle claims it is keeping the R&D throttle wide open to cement its role in propulsion's electrified future. Laying out its near-term development vision via a virtual event in October, CEO Jörg Stratmann and engineering lead Martin Berger reiterated the continuing role ICE will play, augmented via hybrid and fuel-cell technologies in larger commercial applications. According to Stratmann, Mahle's technology group is maintaining its extensive R&D investments despite the COVID crisis, and that it is expanding its global footprint in key development areas including battery systems and hydrogen applications. These include a hydrogen infrastructure testing installation begun at its headquarters in Stuttgart, and an expanding battery R&D facility scheduled to open in December 2020 in Suzhou, China, which will focus on solutions specifically for the Chinese market.

Seredynski, Paul

Self-Heating Battery Enables Quick Recharging of Electric Vehicles

TBMG-3782210/01/2020

A self-heating battery was developed that can charge an electrical vehicle in 10 minutes for a 200- to 300-mile range while maintaining 2,500 charging cycles or the equivalent of half a million miles of travel.

Battery Management Systems for Rechargeable Lithium Batteries Used in Aerospace Standards

AIR6897 (Current)

08/20/2020

This AIR provides basic background information and guidance for design and development of BMS architectures to be used in RLBs for aerospace applications. This guidance applies to batteries that are considered “installed” equipment and are intended to be part of the original or supplemental type certification or military airframe qualification.

AE-7D Aircraft Energy Storage and Charging Committee

Increasing connectivity, leveraging intelligence

SAE-MA-0441006/03/2020

Like so many other companies, Parker Hannifin’s plans to share its latest solutions at ConExpo/Con-Agg and IFPE in March were dashed due to the coronavirus pandemic.

Shuttleworth, Jennifer

Increasing connectivity, leveraging intelligence

20TOFHP06_0306/01/2020

Parker Hannifin expert discusses IoT for mobile equipment and moving beyond standard telematics by integrating systems controllers and smart components. Like so many other companies, Parker Hannifin's plans to share its latest solutions at ConExpo/Con-Agg and IFPE in March were dashed due to the coronavirus pandemic. COVID-19 did not stop Truck & Off-Highway Engineering from talking with Parker's Clint Quanstrom, IoT General Manager, Motion Systems Group, via Microsoft Teams about technologies the company would have presented, future goals and industry trends. While demonstrating technologies is Quanstrom's preferred method of sharing the company's solutions, “Plan B” provided the opportunity to discuss one-on-one Parker's work relative to the Internet of Things (IoT) for motion systems. Booth visitors at ConExpo would have seen representative data that Parker can pull from machines. “We can provide tools like dashboards that offer customers an idea of how their systems are performing

Shuttleworth, Jennifer

Adhesives, Sealants, and Heat Transfer Materials in Battery Systems: A Primer on Materials, Applications, and End-Use Performance Requirements

J3178_202005 (Current)

05/05/2020

This SAE Information Report introduces key concepts and properties of adhesives, sealants, and HTMs and the roles they serve in present-day battery systems applications. The basic chemistry and properties of the three types of materials are summarized along with important health and environmental information. Relevant material dispense methodologies and equipment for material dispensing is reviewed. A series of representative battery applications examples employing adhesives, sealants, and HTMs is also provided with particular attention given to end-use performance.

Battery Systems Adhesives, Sealants and Heat Transfer Matl's

Adhesives, Sealants, and Heat Transfer Materials in Battery Systems: A Primer on Materials, Applications, and End-Use Performance Requirements

J3178_202005-TEST-REC (Historical)05/05/2020

This SAE Information Report introduces key concepts and properties of adhesives, sealants, and HTMs and the roles they serve in present-day battery systems applications. The basic chemistry and properties of the three types of materials are summarized along with important health and environmental information. Relevant material dispense methodologies and equipment for material dispensing is reviewed. A series of representative battery applications examples employing adhesives, sealants, and HTMs is also provided with particular attention given to end-use performance.

Battery Systems Adhesives, Sealants and Heat Transfer Matl's

Thermal Management and Performance Characteristic of Electric Vehicle

2020-28-002204/30/2020

Thermal Management System is one of key parallel branch for internal combustion engine (ICE) vehicle over 4 decades as it ensures performance of power train/engine or after treatment system or HVAC (Climate control). In automotive industry, Range Anxiety and safety of Electric Vehicle (EV) are the hot topic of discussion. This paper is dealing with some importance aspects of thermal management system and their link with the performance/Safety Parameter of Electric vehicle. Battery Cooling or Battery thermal management System (BTMS or BCS) and Traction cooling system (TCS) are coupled with near conventional HVAC circuit. BTMS plays important role to ensure performance of Li-ion Battery pack which is indirectly related with Range and safety of electric vehicle. Similar, other 2 Cooling circuit has major role to ensure vehicle performance and comfort. Here, Thermal management system become utmost important to overcome the challenge of range and safety concern of EV along with many other

Biswas, Sanjoy, Ghate, Asmita

Simulation Methodology for design and development of Li-ion Cell and Battery Pack

2020-28-000904/30/2020

The thermal management of Li-ion Cell/ battery pack while charging-discharging plays a significant role in the development of Electric Vehicles, as increase in rate of charge-discharge leads to higher heat generation which decrease the life of li-ion cell drastically, it also increases the possibility of hazard. The present paper reports the simulation methodology for optimizing the design of li-ion cell by performing the simulation to study the variation of potential difference, heat generation and temperature distribution across the cell on different charging- discharging cycles. These simulations lead for better cell design with lesser heat generation. The Computational Fluid Dynamics Analysis is performed for the better thermal management of the battery pack so that maximum heat dissipation could take place. It is expected that this simulation methodology gives an edge in the designing of li-ion cell and battery packs and optimising the performance of cell/ battery pack and ensure

Saxena, Akash, Rathore, Gopal Singh, Chauhan, Adesh Kumar, chawla, Shubham

Cabin and Battery Cooling Performance Trade-off in an Electric Vehicle

2020-28-000404/30/2020

Electric vehicle (EV) carries two main anxieties in users which are its range and battery life, hence these are important parameters to take care during electric vehicle development. EV range depends on many parameters like vehicle weight, parasitic loads like cabin Heating, Ventilation and Air Conditioning (HVAC), battery and traction cooling, accessories, etc. which consumes power from a High Voltage (HV) battery. Severe hot ambient in India asks for big size AC system, on the other hand, battery pack needs refrigerated cooling system to keep its temperature in control. Hence, the major parasitic consumers in an EV are HVAC and BCS systems. In order to enhance the overall efficiency, a trade-off between these two systems is crucial, as both the systems are served with common compressor and condenser in dual loop refrigerant circuit. This work comprises of experiments done on an EV with dual loop refrigerant circuit, which has common compressor and condenser unit, where the HVAC

Varma, Mohit, Jaybhay, Sambhaji, Kadam, Kiran, Venu, Santosh, Kulkarni, Shridhar, Kapoor, Sangeet

Experimental Investigation of Dual AC System used for Battery cooling plate

2020-28-002104/30/2020

As the global warming due to carbon footprint is very alarming, vehicle emissions are getting stringent day by day. In such situation vehicle hybridization or fully electric vehicles are of obvious choices. However in any of the cases the battery cooling is a big concern area. As the heat produced by the battery need to be dissipated within no time to prevent failure, it is of utmost need to develop and understand the battery cooling system. Present paper describes the experimental investigation of a battery cooling circuit. A complete bench comprising of both primary and secondary circuit is used for the testing. The primary circuit has a cooling unit with TXV, condenser and electric compressor run by high voltage. The secondary circuit consists of a chiller (integrated with TXV) unit responsible for battery cooling. The whole circuit typically resembles with one of dual air conditioning unit and uses one of known refrigerant used in vehicle AC system. However each circuit is

Singh, Kamlesh Kumar, Sen, Somnath, Singh, Kamlesh Kumar, Sen, Somnath

High Voltage Battery durability enhancement in electric mobility through 1D CAE

2020-28-001304/30/2020

The public transport in India is gradually shifting towards electric mobility. Long range in electric mobility can be served with High voltage battery (HVB), but HVB can sustain for its designed life if it’s maintained within a specific operating temperature range. Appropriate battery thermal management through battery cooling system (BCS) is critical for vehicle range and battery durability This work focus on two aspects BCS sizing and coolant flow optimization in Electric bus. BCS modelling was done in 1D CAE by using KULI software from M/s Magna Steyr. The objective is to develop a model of battery cooling system in virtual environment to replicate the physical testing. Electric bus contain numerous battery packs and a complex piping in its cooling system. BCS sizing simulation was performed to keep the battery packs in operating temperature range. Iterations were carried out to maintain uniform flow at the battery packs as well as to sustain target coolant flow requirement in order

Venu, Santosh Kumar, Venu, Santosh Kumar, Jaybhay, Sambhaji, Jaybhay, Sambhaji, Kadam, Kiran, Kadam, Kiran, Varma, Mohit, Kapoor, Sangeet, Kapoor, Sangeet

An Electric Motor Thermal Bus Cooling System for Vehicle Propulsion - Design and Test

2020-01-074504/14/2020

Automotive and truck manufacturers are introducing electric propulsion systems into their ground vehicles to reduce fossil fuel consumption and harmful tailpipe emissions. The mobility shift to electric motors requires a compact thermal management system that can accommodate heat dissipation demands with minimum energy consumption in a confined space. An innovative cooling system design, emphasizing passive cooling methods coupled with a small liquid system, using a thermal bus architecture has been explored. The laboratory experiment features an emulated electric motor interfaced to a thermal cradle and multiple heat rejection pathways to evaluate the transfer of generated heat to the ambient surroundings. The thermal response of passive (e.g., carbon fiber, high thermal conductivity material, thermosyphon) and active cooling systems are investigated for two operating scenarios. The test results demonstrate that up to 93% improvement can be achieved in cooling system energy

Shoai Naini, Shervin, Miller, Richard, Wagner, John, Rizzo, Denise, Sebeck, Katherine

Research on the Performance of Battery Thermal Management System Based on Optimized Arrangement of Flat Plate Heat Pipes

2020-01-016204/14/2020

The thermal management system is essential for the safe and long-term operation of the power battery. The temperature difference between the individual cells exceeds the acceleration of the battery performance, which leads to battery out of use and affects the performance of the vehicle. Compared with the low heat transfer coefficient of the air-cooling system, the complex structure of the liquid-cooling system and the large quality of phase change material system, the heat pipe has high thermal conductivity, strong isothermal performance and light weight, it’s an efficient cooling element that can be used for thermal management. In this study, the flat plate heat pipe(FPHP) is used to manage the temperature of the battery, through experiments, the optimized placement of the flat heat pipe is obtained. Based on this, the thermal performance of the thermal management system is studied, thus achieve the purpose of reducing the maximum temperature of the batteries and balancing the

Zheng, Xingmang, Tan, Gangfeng, Sun, Meng, Zhou, Fangyu, Liu, ZhiQiang

Powertrain Thermal System Development for Small BEV

2020-01-138304/14/2020

The dynamic performance of battery electric vehicles (BEV) is affected by battery output power, which depends on state of charge (SOC) and the temperature of battery cells. The temperature of the batteries varies in particular with the environment, in which the user stores the vehicle, and the battery output power. It is therefore necessary to employ thermal management systems that can control the battery temperature within the optimal range under severely hot and cold conditions in BEVs. A highly sophisticated thermal management system and its operation strategy were developed to fulfill the above requirements. The powertrain components to be thermo-controlled were located into two coolant circuits having different temperature range. The compact and efficient front-end heat exchangers were designed to optimally balance the cooling performance of powertrain, cabin comfort, vehicle aerodynamics and the vehicle design. The battery pack was optimally thermo-controlled by precisely

Ohnuma, Yoshikazu, Yamagishi, Yosuke, Minami, Katsuya

Engine and Aftertreatment Co-Optimization of Connected HEVs via Multi-Range Vehicle Speed Planning and Prediction

2020-01-059004/14/2020

Connected vehicles (CVs) have situational awareness that can be exploited for control and optimization of the powertrain system. While extensive studies have been carried out for energy efficiency improvement of CVs via eco-driving and planning, the implication of such technologies on the thermal responses of CVs (including those of the engine and aftertreatment systems) has not been fully investigated. One of the key challenges in leveraging connectivity for optimization-based thermal management of CVs is the relatively slow thermal dynamics, which necessitate the use of a long prediction horizon to achieve the best performance. Long-term prediction of the CV speed, unlike the short-range prediction based on vehicle-to-infrastructure (V2I) and vehicle-to-vehicle (V2V) communications-based information, is difficult and error-prone. The multiple timescales inherent to power and thermal systems call for a variable timescale optimization framework with access to short- and long-term

Hu, Qiuhao, Amini, Mohammad R., Feng, Yiheng, Yang, Zhen, Wang, Hao, Kolmanovsky, Ilya, Sun, Jing, Wiese, Ashley, Qiu, Zeng, Buckland, Julia

Electric Vehicle Cold Start Range Estimation through Battery-in-the-Loop Simulations within a Virtual Driving Environment

2020-01-045304/14/2020

Lithium-ion (Li-ion) batteries have become a research focus in the field of electric and hybrid electric vehicles, due to key advantages such as high specific energy, high energy density and low self-discharge rate in comparison with other battery technologies. Nevertheless, key issues involving safety, performance, cost, charging time and durability restrict the mass market adoption of electric vehicles. Cold-temperature operation of Li-ion batteries is currently a subject of major research efforts in industry and academia. The effects of low temperature reduce the available energy of the battery and increase its internal impedance. Moreover, Li-ion batteries experience serious degradation mechanisms at low temperatures, strongly affecting performance, which poses difficulties for cold-climate countries. In this work, a battery-in-the-loop experiment has been set up to estimate and analyze Li-ion battery cold start range at temperatures down to -40°C. This experimental setup is

Sarmiento-Carnevali, Maria, Fly, Ashley, Piecha, Pascal

Thermal Analysis of Parallel Connected Li-Ion Batteries for Hybrid Aircraft

2020-01-089104/14/2020

Due to rising emissions, electric aircraft may indeed become inevitable. With the increase in production of hybrid aircraft, due to such needs for reduced energy sources and increased storage systems, the importance of batteries will also increase in the near future. When selecting batteries, consideration must be given to their energy density, non-toxicity, weight and optimum operating temperature. The density of lithium in the liquid state is only half that of water and in the solid state it is the lightest metal. Furthermore, lithium has a tendency to give electrons and charge, thus making it an important choice for use in batteries and the focus of this study. In this study, a sum of 20 batteries in the form of 2 parallel, 10 series were investigated. The thermal performance of the batteries was studied under natural conditions. It was concluded that forced convection should be done instead of natural convection for C ratios 2 and 2.5, because natural convection proved inadequate.

Yetik, Ozge, Karakoç, Hikmet, Yilmaz, Nadir

Simulation and Parametric Analysis of Battery Thermal Management System Using Phase Change Material

2020-01-086604/14/2020

The thermophysical parameters and amount of composite phase change materials (PCMs) have decisive influence on the thermal control effects of thermal management systems (TMSs). At the same time, the various thermophysical parameters of the composite PCM are interrelated. For example, increasing the thermal conductivity is bound to mean a decrease in the latent heat of phase change, so a balance needs to be achieved between these parameters. In this paper, a prismatic LiFePO4 battery cell cooled by composite PCM is comprehensively analyzed by changing the phase change temperature, thermal conductivity and amount of composite PCM. The influence of the composite PCM parameters on the cooling and temperature homogenization effect of the TMS is analyzed. which can give useful guide to the preparation of composite PCMs and design of the heat transfer enhancement methods for TMSs.

Lin, Chunjing, Sun, Yuhan, Li, Zhao, Xu, Sichuan

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