#CFD in BTMS

[nnctales]

How Can Computational Fluid Dynamics (CFD) Be Used For Designing Better EV Battery And Thermal Management Systems (BTMS)

Introduction Electric vehicle batteries are transforming how we move, live, and work. Architects and engineers have a crucial role in shaping the future of EVs and their integration with buildings and infrastructure. By understanding electric vehicle batteries’ challenges and opportunities, they can create innovative and sustainable solutions that benefit both people and the planet. However, EVs…

[engineering-courses]

💡 What You’ll Learn: Setting up a BTMS simulation in Ansys Fluent. Understanding volumetric heat sources and material properties. Using the density-based solver with turbulence models. Analyzing results and running parametric studies.

🔍 Key Highlights: Geometry and meshing overview. Creating named selections and applying boundary conditions. Viewing results using CFD-Post. Running parametric analysis for optimization.

🚀 Take your first step into simulating Battery Thermal Management Systems with confidence. Perfect for students, engineers, and EV enthusiasts! Don't forget to like, subscribe, and hit the bell icon for updates on more simulation tutorials.

💡Check out the previous episodes of this series here: https://www.youtube.com/playlist?list=PL9-f9hWLZS61I2GoQAXCVwwYLclPNZZwA

If you’re interested in speaking with our experts and scheduling a personalized career plan, call us at +91-9342691281 or register here: https://bit.ly/3Zm5B8Z

[444namesplus]

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mft mfu mfv mfz mgb mgc mgd mgf mgg mgh mgi mgj mgk mgl mgm mgn mgp mgr mgs mgt mgu mgv mhb mhc mhd mhf mhg mhh mhi mhj mhk mhl mhm mhn mhp mhr mhs mht mhu mhv mhz mib mic mid mif mig mih mii mij mik mil mim min mip mir mis mit miu miv miz mjb mjc mjd mjf mjg mjh mji mjj mjk mjl mjm mjn mjp mjr mjs mjt mju mjv mjz mkb mkc mkd mkf mkg mkh mki mkj mkk mkl mkm mkn mkp mkr mks mkt mku mkv mkz mlb mlc mld mlf mlg mlh mli mlj mlk mll mlm mln mlp mlr mls mlt mlu mlv mlz mmb mmc mmd mmf mmg mmh mmi mmj mmk mml mmm mmn mmp mmr mms mmt mmu mmv mmz mnb mnc mnd mnf mng mnh mni mnj mnk mnl mnm mnn mnp mnr mns mnt mnu mnv mnz mpb mpc mpd mpf mpg mph mpi mpj mpk mpl mpm mpn mpp mpr mps mpt mpu mpv mpz mrc mrd mrf mrg mrh mri mrj mrk mrl mrm mrn mrp mrr

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svs svt svu svv svz szb szc szd szf szg szh szi szj szk szl szm szn szp szr szs szt szu szv szz tbb tbc tbd tbf tbg tbh tbi tbj tbk tbl tbm tbn tbp tbr tbs tbt tbu tbv tbz tcb tcc tcf tcg tch tci tcj tck tcl tcm tcn tcp tcr tcs tct tcu tcv tcz tdb tdc tdd tdf tdg tdh tdi tdj tdk tdl tdm tdn tdp tdr tds tdt tdu tdv tdz tfb tfc tfd tff tfg tfh tfi tfj tfk tfl tfm tfn tfp tfr tfs tft tfu tfv tfz tgb tgc tgd tgf tgg tgh tgi tgj tgk tgl tgm tgn tgp tgr tgs tgt tgu tgv tgz thb thc thd thf thg thh thi thj thk thl thm thn thp thr ths tht thu thv thz tib tic tid tif tig tih tij tik til tim tin tip tir tis tit tiu tiv tiz tjc tjd tjf tjg tjh tji tjj tjk tjl tjm tjn tjp tjr tjs tjt tju tjv tjz tkb tkc tkd tkf tkg tkh tki tkj tkk tkl tkm tkn tkp tkr tks tkt tku tkv tkz tlb tlc tld tlf tlg tlh tli tlj tlk tll tlm tln tlp tlr tls tlt tlu tlv tlz tmb tmc tmd tmf tmg tmh tmi tmj tmk tml tmm tmn tmp tmr tms tmt tmu tmv tmz tnb tnc tnd tnf tng tnh tni tnj tnk tnl tnm tnn tnr tns tnt tnu tnv tnz tpb tpc tpd tpf tpg tph tpi tpj tpk tpl tpm tpn tpp tps tpt tpu tpv tpz trb trc trd trf trg trh tri trj trk trl trm trn trp trr trs trt tru trv trz tsb tsc tsd tsf tsg tsh tsj tsk tsl tsm tsn tsp tsr tss tst tsu tsv tsz ttb ttc ttd ttf ttg tth tti ttj ttk ttl ttm ttn ttp ttr tts ttt ttu ttv ttz tub tuc tud tuf tug tuh tui tuj tuk tul tum tun tup tur tus tut tuu tuv tvb tvc tvd tvf tvg tvh tvi tvj tvk tvl tvm tvn tvr tvs tvt tvu tvv tvz tzc tzd tzf tzg tzh tzi tzj tzk tzl tzm tzn tzp tzr tzs tzt tzu tzv tzz ubb ubc ubd ubf ubg ubh ubi ubj ubk ubl ubm ubn ubp ubr ubs ubt ubu ubv ubz ucb ucc ucd ucf ucg uch uci ucj uck ucl ucm ucn ucp ucr ucs uct ucu ucv ucz udb udc udd udf udg udh udi udj udk udl udm udn udp udr uds udt udu udv udz ufb ufc ufd uff ufg ufh ufi ufk ufl ufm ufn ufp ufr ufs uft ufu ufv ufz

ugb ugc ugd ugf ugg ugh ugi ugj ugk ugl ugm ugn ugp ugr ugs ugt ugu ugv ugz uhb uhc uhd uhf uhg uhh uhi uhj uhk uhl uhm uhn uhp uhr uht uhu uhv uhz uib uic uid uif uig uih uii uij uik uim uin uip uir uis uit uiu uiv uiz ujb ujc ujd ujf ujg ujh uji ujj ujk ujl ujm ujn ujp ujr ujs ujt uju ujv ujz ukb ukc ukd ukf ukg ukh uki ukj ukk ukl ukm ukn ukp ukr uks ukt uku ukv ukz ulb ulc uld ulf ulg ulh uli ulj ulk ull ulm uln ulp ulr uls ult ulu ulv ulz umb umc umd umf umg umh umi umj umk uml umm umn ump umr ums umt umu umv umz unb unc und unf ung unh uni unj unk unl unm unn unp unr uns unt unu unv unz upb upc upd upf upg uph upi upj upk upl upm upn upp upr ups upt upu upv upz urb urc urf urg urh uri urj urk url urm urn urp urr urs urt uru urv urz usb usc usd usf usg ush usi usj usk usl usm usn usp usr uss ust usu usv usz utb utc utd utf utg uth uti utj utk utl utm utn utp utr uts utt utu utv utz uub uuc uud uuf uug uuh uui uuj uuk uul uum uun uup uur uus uut uuu uuv uuz uvb uvc uvd uvf uvg uvh uvi uvj uvk uvl uvm

uvn uvp uvs uvt uvu uvv uvz uzb uzc uzd uzf uzg uzh uzi uzj uzk uzl uzm uzn uzp uzr uzs uzt uzu uzv uzz vbb vbc vbd vbf vbg vbh vbi vbj vbk vbl vbm vbn vbp vbr vbs vbt vbu vbv vbz vcb vcc vcd vcf vcg vch vci vcj vck vcl vcm vcn vcp vcr vcs vct vcu vcv vcz vdb vdc vdd vdf vdg vdh vdi vdj vdk vdl vdm vdn vdp vdr vds vdt vdu vdv vdz vfb vfc vff vfg vfh vfi vfj vfk vfl vfm vfn vfp vfr vfs vft vfu vfv vfz vgb vgc vgd vgf vgg vgh vgi vgj vgk vgl vgm vgn vgp vgr vgs vgt vgu vgv vgz vhb vhc vhd vhf vhg vhh vhi vhj vhk vhl vhm vhn vhp vhr vhs vht vhu vhv vhz vib vic vid vif vig vih vii vij vik vil vim vin vip vir vis vit viu viv viz vjb vjc vjd vjf vjg vjh vji vjj vjk vjl vjm vjn vjp vjr vjs vjt vju vjv vjz vkb vkc vkd vkf vkg vkh vki vkj vkk vkl vkm vkn vkp vkr vks vkt vku vkv vkz vlb vlc vld vlf vlg vlh vli vlj vlk vll vlm vln vlp vlr vls vlt vlu vlv vlz vmb vmc vmd vmf vmg vmh vmi vmj vmk vml vmm vmn vmp vmr vms vmu vmv vmz vnb vnc vnd vnf vng vnh vni vnj vnk vnl vnm vnn vnp vnr vns vnt vnu vnv vnz vpb vpc vpd vpf vpg vph vpi vpj vpk vpl vpm vpn vpp vpr vps vpt vpu vpv vpz vrb vrc vrd vrf vrg vrh vri vrj vrk vrl vrm vrn vrp vrr vrs vrt vru vrv vrz vsb vsc vsd vsf vsg vsh vsi vsj vsk vsl vsm vsn vsp vsr vss vst vsu vsv vsz vtb vtc vtd vtf vtg vth vti vtj vtk vtl vtm vtn vtp vtr vts vtt vtu vtv vtz vub vuc vud vuf vug vuh vui vuj vuk vul vum vun vup vur vus vut vuu vuv vuz vvb vvc vvd vvf vvg vvh vvi vvj vvk vvl vvm vvn vvp vvr vvs vvt vvu vvv vvz vzb vzc vzd vzf vzg vzh vzi vzj vzk vzl vzm vzn vzp vzr vzs vzt vzu vzv vzz zbb zbc zbd zbf zbg zbh zbi zbj zbk zbl zbm zbn zbp zbr zbs zbt zbu zbv zbz zcb zcc zcd zcf zcg zch zci zcj zck zcl zcm zcn zcp zcr zcs zct zcu zcv zcz zdb zdc zdd zdf zdg zdh zdi zdj zdk zdl zdm zdn zdp zdr zds zdt zdv zdz zfb zfc zfd zff zfg zfh zfi zfj zfk zfl zfm zfn zfp zfr zfs zft zfu zfv zfz zgb zgc zgd zgf zgg zgh zgi zgj zgk zgl zgm zgn zgp zgr zgs zgt zgu zgv zgz zhb zhc zhd zhf zhg zhh zhi zhj zhk zhl zhm zhn zhp zhr zhs zht zhu zhv zhz zib zic zid zif zig zih zii zij zik zil zim zin zip zir zis zit ziu ziv ziz zjb zjc zjd zjf zjg zjh zji zjj zjk zjl zjm zjn zjp zjr zjs zjt zju zjv zjz zkb zkc zkd zkf zkg zkh zki zkj zkk zkl zkm zkn zkp zkr zks zkt zku zkv zkz zlb zlc zld zlf zlg zlh zli zlj zlk zll zlm zln zlp zlr zls zlt zlu zlv zlz zmb zmc zmd zmf zmg zmh zmi zmj zmk zml zmm zmn zmp zmr zms zmt zmu zmv zmz znb znc znd znf zng zni znj znk znl znm znn znp znr zns znt znu znv znz zpb zpc zpd zpf zpg zph zpi zpj zpk zpl zpm zpn zpp zpr zps zpt zpu zpv zpz zrb zrc zrd zrf zrg zrh zri zrj zrk zrl zrm zrn zrp zrr zrs zrt zru zrv zrz zsb zsc zsd zsf zsg zsh zsi zsj zsk zsl zsm zsn zsp zsr zss zst zsu zsv zsz ztb ztc ztd ztf ztg zth zti ztj ztk ztl ztm ztn ztp ztr zts ztt ztu ztv ztz zub zuc zud zuf zug zuh zui zuj

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[atsthermal]

Industry Developments in Thermal Management of Electric Vehicle Batteries

Electric vehicles (EV) fall into two main categories: vehicles where an electric motor replaces a combustion engine and vehicles that feature a combustion engine assisted by an electric motor. All EV contain large, complex, rechargeable batteries, sometimes called traction batteries, to provide all or a portion of the vehicle’s propelling power.

In EV batteries, current flow, both charge and discharge, generates heat inside the cells and in their interconnection systems. This heat is proportional to the square of the flowing current multiplied by the internal resistance of the cells and the interconnect systems. The higher the current flow the more the heating will be produced. [1]

Battery manufacturers and researchers routinely investigate how the rate of heat generation in cells varies over the course of charging and discharging. Heat can be generated from multiple sources including internal losses of joule heating and local electrode overpotentials, the entropy of the cell reaction, heat of mixing, and side reactions. [2]

Proper thermal management of EV batteries (lithium-ion is the most common) is essential to maintain adequate and consistent performance of the battery and the vehicle. Excessive temperature will negatively affect an EV’s battery and its performance. Features that can be impacted include its electrochemical system, charge acceptance, power output, safety and life cycle/replacement cost and the vehicle’s driving distance.

From a thermal point of view, there are three main aspects to consider when using lithium-ion batteries in an EV:

At temperatures below 0°C (32°F), batteries lose charge due to slower chemical reactions taking place in the battery cells. The result is a significant loss in power, acceleration and driving range, and higher potential for battery damage during charging.

At temperatures above 30°C (86°F) the battery performance degrades, posing a real issue if a vehicle’s air conditioner is needed for passengers. The result is an impact on power density and reduced acceleration response.

Temperatures above 40°C (104°F) can lead to serious and irreversible damage in the battery. At even higher temperatures, e.g. 70-100°C, thermal runaway can occur. This is triggered when the runaway temperature is reached. The result is a self-heating chain reaction in a battery cell that causes its destruction while propagating to adjacent cells.

The ideal temperature range for an EV’s lithium-ion battery is akin to that preferred by human beings. To keep it in this range, the battery temperature must be monitored and adjusted. A battery thermal management system (BTMS) is necessary to prevent temperature extremes, ensure proper battery performance, and achieve the expected life cycle. An effective BTMS keeps cell temperatures within their allowed operating range. [1]

As defined by engineers at the U.S. Department of Energy’s NREL (National Renewable Energy Laboratory), EV battery pack thermal management is needed for three basic reasons: [5]

To ensure the pack operates in the desired temperature range for optimum performance and working life. A typical temperature range is 15-35°C.

To reduce uneven temperature distribution in the cells. Temperature differences should be less than 3-4C°.

To eliminate potential hazards related to uncontrolled temperature, e.g. thermal runaway.

Various cooling agents and methods are in use today as part of the thermal management of EV batteries. Among these are air cooling, the use of flowing liquid coolants, or direct immersion.

Air Cooling

The lowest cost method for EV battery cooling is with air. A passive air-cooling system uses outside air and the movement of the vehicle to cool the battery. Active air-cooling systems enhance this natural air with fans and blowers. Air cooling eliminates the need for cooling loops and any concerns about liquids leaking into the electronics. The added weight from using liquids, pumps and tubing is also avoided.

The trade-off is that air cooling, even with high-powered blowers, does not transport the same level of heat as a liquid system can. This has led to problems for EV in hot climates, including more temperature variation in battery pack cells. Blower noise can also be an issue.

Still, air-cooling solutions have their roles and value. An example is the custom-built Volkswagen EV race car that finished first in the Pikes Peak International Hill Climb in Colorado Springs, Colo. To optimize performance, the car was designed to combine minimum weight, as much downforce as possible, and maximum power. Volkswagen used air-cooling systems to reduce weight. It used thermal software in virtual driving tests along the entire race to ensure the air-cooling system would perform sufficiently. [10]

Liquid Cooling

Piped liquid cooling systems provide better battery thermal management because they are better at conducting heat away from batteries than air-cooling systems. One downside is the limited supply of liquid in the system compared with the essentially limitless amount of air that can flow through a battery.

Tesla’s thermal management system (as well as GM’s) uses liquid glycol as a coolant. Both the GM and Tesla systems transfer heat via a refrigeration cycle. Glycol coolant is distributed throughout the battery pack to cool the cells. Considering that Tesla has 7,000 cells to cool, this is a challenge. [11]

The Tesla Model S battery cooling system consists of a patented serpentine cooling pipe that winds through the battery pack and carries a flow of water-glycol coolant; thermal contact with the cells is through their sides by thermal transfer material.

General Motor’s Chevrolet Volt features a liquid cooling system to manage battery heat. Each rectangular battery cell is about the size of a children’s book. Sandwiched between the cells is an aluminum cooling plate. There are five individual coolant paths passing thru the plate in parallel, not in series as the Tesla system does. Each battery pouch (cell) is housed in a plastic frame. The frames with coolant plates are then stacked longitudinally to make the entire pack. [12]

Thermodynamic engineers at Porsche develop and optimize each vehicle’s entire cooling system. This includes the battery, of course, and one example is the liquid-filled cooling plate from the traction battery in the Boxster E. [13]

Based on the results of the analysis in the thermal model described above, the cooling plate was designed geometrically and optimized using computational fluid dynamics (CFD). The result is a highly efficient and lightweight heat exchanger, optimally tailored and adapted to the battery pack, with low pressure losses, high cooling performance and a very even distribution of temperature.

Liquid Immersion

Instead of snaking coolant through lines and chambers within a battery pack’s case, XING Mobility takes a different approach by immersing its cells in a non-conductive fluid with a high boiling point. The coolant is 3M Novec 7200 Engineered Fluid, a non-conductive fluid designed for heat transfer applications, fire suppression and supercomputer cooling.

XING’s batteries take the form of 42 lithium-ion-cell modules that can be put together to build larger battery solutions. The complete XING battery houses 4,200 individual 18,650 lithium-ion cells encased in liquid-cooled module packs. [14]

Simulation Technologies

Design of thermal management solutions requires extensive knowledge of cooling systems and the amount of heat generated by cells throughout the battery pack. Engineers must also weigh various tradeoffs and factors such as cost, packaging, manufacturability, efficiency, reliability of heat dissipation components, and battery pack as an integrated, modular system.

Batteries require a unique range of issues be taken into consideration. First, detailed models and sub-models are needed to simulate the chemical and physical phenomena inside battery cells. Then, these models need to be tied into a system-level model of a battery pack, which can comprise hundreds of cells and cooling circuits. Finally, the battery pack model needs to be integrated with the system model of the entire powertrain and vehicle.

Engineers must consider the physical placement of the battery pack within the EV, not only to minimize the effects of ambient temperatures and maximize heat dissipation but also to avoid excessive mechanical stresses, structural fatigue from road vibrations, and potential impact from road debris. The team also must consider crash scenarios in which passengers must be protected from toxic acids released from the battery pack.

References: 1. https://avidtp.com/what-is-the-best-cooling-system-for-electric-vehicle-battery-packs/ 2. Hu, X., Battery Thermal Management in Electric Vehicles. Ansys, Inc., 2011. 3. https://www.mpoweruk.com/chemistries.htm 4. Wang, Q., Jiang, B., Xue, Q., Sun, H., Li, B., Zou, H. and Yan, Y., Experimental Investigation on EV Battery Cooling and Heating by Heat Pipes, Applied Thermal Engineering, 2015. 5. Rugh, J., Pesaran, A. and Smith, K., Electric Vehicle Battery Thermal Issues and Thermal Management Techniques, NREL, SAE Alternative Refrigerant and System Efficiency Symposium, 2011. 6. https://www.hybridcars.com/chevy-bolt-evs-battery-is-as-big-as-a-teslas/ 7. https://cleantechnica.com/2018/07/08/tesla-model-3-chevy-bolt-battery-packs-examined/ 8. https://www.greencarreports.com/news/1064332_nissan-leafs-battery-pack-should-last-as-long-as-the-car 9. http://synergyfiles.com/2016/07/battery-thermal-management-system-review/ 10. https://www.theverge.com/2018/6/24/17078544/volkswagen-ev-race-car-pikes-peak-hill-climb-record https://media.vw.com/en-us/releases/1008 11. https://insideevs.com/tesla-or-gm-who-has-the-best-battery-thermal-management-bower/ 12. https://www.youtube.com/watch?time_continue=113&v=h4nM7rXpsJg 13. Thermal Management in Vehicles with Electric Drive System, Porsche Engineering Magazine, January 2011. 14. https://www.greencarreports.com/news/1114188_new-approach-to-electric-car-battery-cooling-immerse-cells-in-coolant

Advanced Thermal Solutions, Inc. (ATS) is hosting a series of monthly, online webinars covering different aspects of the thermal management of electronics. This month’s webinar will be held on Thursday, Oct. 25 from 2-3 p.m. ET and will cover the cooling of automotive batteries. Learn more and register at https://qats.com/Training/Webinars.

For more information about Advanced Thermal Solutions, Inc. (ATS) thermal management consulting and design services, visit https://www.qats.com/Consulting/Custom-Cooling-Solutions or contact ATS at 781.769.2800 or ats-hq@qats.com.