Abstract
Adhering to the thermal management requirements of prismatic battery modules, an improved lightweight parallel liquid cooling structure with slender tubes and a thin heat-conducting plate is proposed. The multiobjective optimization of the structure, operating parameters of the thermal management system, and thermal characteristics of a battery module are carried out. The effects of the equivalent diameter of the square tubes and the inner diameter of the circular tubes on the maximum temperature, maximum temperature difference of the batteries, and coolant pressure drop of liquid cooling battery thermal management system (BTMS) are investigated. The more significant factors, selected as the design variables, are the equivalent diameter of the square tubes, the inner diameter of the circular tube, and the coolant inlet velocity. Combining the computational fluid dynamics (CFD) method with multiobjective optimization, the different conditions of heat management parameters obtained by Latin hypercube sampling are numerically calculated, and the optimization of these parameters is carried out by the second-generation Elitist Nondominated Sorting Genetic Algorithm (NSGA-II). Compared with the thermal characteristics of the battery module before optimization, the maximum temperature of the module after optimization is reduced by 9.3%, the maximum temperature difference is reduced by 20.7%, and the coolant pressure drop from inlet to outlet is reduced by 49.1%.
Get full access to this article
View all available purchase options and get full access to this article.
Data Availability Statement
All data, models, and code generated or used during the study appear in the published article.
Acknowledgments
This work was financially supported by the Major Science and Technology Project of Anhui Province (No. 202003a05020014) and Hefei Natural Science Foundation (No. 2021045).
References
Ashkboos, P., A. Yousefi, and E. Houshfar. 2021. “Design improvement of thermal management for Li-ion battery energy storage systems.” Sustainable Energy Technol. Assess. 44 (Feb): 101094. https://doi.org/10.1016/j.seta.2021.101094.
Bernardi, D., E. Pawlikowski, and J. Newman. 1985. “A general energy balance for battery systems.” J. Electrochem. Soc. 132 (1): 5–12. https://doi.org/10.1149/1.2113792.
Chen, F., J. Wang, and X. Yang. 2022. “Topology optimization design and numerical analysis on cold plates for lithium-ion battery thermal management.” Int. J. Heat Mass Transf. 183 (Feb): 122087. https://doi.org/10.1016/j.ijheatmasstransfer.2021.122087.
Chen, K., J. Hou, M. Song, S. Wang, W. Wu, and Y. Zhang. 2021. “Design of battery thermal management system based on phase change material and heat pipe.” Appl. Therm. Eng. 188 (Feb): 116665. https://doi.org/10.1016/j.applthermaleng.2021.116665.
Cheng, J., S. Shuai, R. Zhao, and Z. Tang. 2022. “Numerical analysis of heat-pipe-based battery thermal management system for prismatic lithium-ion batteries.” J. Therm. Sci. Eng. Appl. 14 (8): 1–10. https://doi.org/10.1115/1.4053119.
Cheng, L., A. Garg, A. K. Jishnu, and L. Gao. 2020. “Surrogate based multi-objective design optimization of lithium-ion battery air-cooled system in electric vehicles.” J. Energy Storage 31 (May): 101645. https://doi.org/10.1016/j.est.2020.101645.
Deng, T., Y. Ran, Y. Yin, X. Chen, and P. Liu. 2019. “Multi-objective optimization design of double-layered reverting cooling plate for lithium-ion batteries.” Int. J. Heat Mass Transf. 143 (Nov): 118580. https://doi.org/10.1016/j.ijheatmasstransfer.2019.118580.
Ding, Y., M. Wei, and R. Liu. 2021. “Channel parameters for the temperature distribution of a battery thermal management system with liquid cooling.” Appl. Therm. Eng. 186 (Sep): 116494. https://doi.org/10.1016/j.applthermaleng.2020.116494.
Hata, H., S. Wawd, T. Yamada, K. Hirata, T. Yamada, and N. Ono. 2018. “Performance evaluation of a battery-cooling system using phase-change materials and heat pipes for electric vehicles under the short-circuited battery condition.” J. Therm. Sci. Technol. 13 (2): JTST0024. https://doi.org/10.1299/jtst.2018jtst0024.
Jiang, Z. Y., Z. G. Qu, J. F. Zhang, and Z. H. Rao. 2020. “Rapid prediction method for thermal runaway propagation in battery pack based on lumped thermal resistance network and electric circuit analogy.” Appl. Energy 268 (Jan): 115007. https://doi.org/10.1016/j.apenergy.2020.115007.
Jiaqiang, E., et al. 2018a. “Orthogonal experimental design of liquid-cooling structure on the cooling effect of a liquid-cooled battery thermal management system.” Appl. Therm. Eng. 132 (Mar): 508–520. https://doi.org/10.1016/j.applthermaleng.2017.12.115.
Jiaqiang, E., M. Yue, J. Chen, H. Zhu, Y. Deng, Y. Zhu, F. Zhang, M. Wen, B. Zhang, and S. Kang. 2018b. “Effects of the different air cooling strategies on cooling performance of a lithium-ion battery module with baffle.” Appl. Therm. Eng. 144 (Aug): 231–241. https://doi.org/10.1016/j.applthermaleng.2018.08.064.
Kiani, M., M. Ansari, A. A. Arshadi, E. Houshfar, and M. Ashjaee. 2020a. “Hybrid thermal management of lithium-ion batteries using nanofluid, metal foam, and phase change material: An integrated numerical–experimental approach.” J. Therm. Anal. Calorim. 141 (5): 1703–1715. https://doi.org/10.1007/s10973-020-09403-6.
Kiani, M., S. Omiddezyani, E. Houshfar, S. R. Miremadi, M. Ashjaee, and A. Mahdavi Nejad. 2020b. “Lithium-ion battery thermal management system with nanofluids and phase change material.” Appl. Therm. Eng. 180 (Feb): 115840. https://doi.org/10.1016/j.applthermaleng.2020.115840.
Kong, D., R. Peng, P. Ping, J. Du, G. Chen, and J. Wen. 2020. “A novel battery thermal management system coupling with PCM and optimized controllable liquid cooling for different ambient temperatures.” Energy Convers. Manage. 204 (Nov): 112280. https://doi.org/10.1016/j.enconman.2019.112280.
Lai, Y., W. Wu, K. Chen, S. Wang, and C. Xin. 2019. “A compact and lightweight liquid-cooled thermal management solution for cylindrical lithium-ion power battery pack.” Int. J. Heat Mass Transf. 144 (Dec): 118581. https://doi.org/10.1016/j.ijheatmasstransfer.2019.118581.
Liang, J., Y. Gan, Y. Li, M. Tan, and J. Wang. 2019. “Thermal and electrochemical performance of a serially connected battery module using a heat pipe-based thermal management system under different coolant temperatures.” Energy 189 (Dec): 116233. https://doi.org/10.1016/j.energy.2019.116233.
Liao, X., C. Ma, X. Peng, Y. Li, L. Duan, A. Garg, and L. Gao. 2021. “A framework of optimal design of thermal management system for lithium-ion battery pack using multi-objectives optimization.” J. Electrochem. Energy Convers. Storage 18 (2): 1–12. https://doi.org/10.1115/1.4048010.
Ling, Z., W. Lin, Z. Zhang, and X. Fang. 2020. “Computationally efficient thermal network model and its application in optimization of battery thermal management system with phase change materials and long-term performance assessment.” Appl. Energy 259 (Oct): 114120. https://doi.org/10.1016/j.apenergy.2019.114120.
Lu, M., X. Zhang, J. Ji, X. Xu, and Y. Zhang. 2020. “Research progress on power battery cooling technology for electric vehicles.” J. Energy Storage 27 (Dec): 101155. https://doi.org/10.1016/j.est.2019.101155.
Mevawalla, A., Y. Shabeer, M. K. Tran, S. Panchal, M. Fowler, and R. Fraser. 2022. “Thermal modelling utilizing multiple experimentally measurable parameters.” Batteries 8 (10): 147. https://doi.org/10.3390/batteries8100147.
Mohammed, A. G., K. E. Elfeky, and Q. Wang. 2021. “Thermal management evaluation of Li-ion battery employing multiple phase change materials integrated thin heat sinks for hybrid electric vehicles.” J. Power Sources 516 (Feb): 230680. https://doi.org/10.1016/j.jpowsour.2021.230680.
Panchal, S., K. Gudlanarva, M. K. Tran, M. S. Herdem, K. Panchal, R. Fraser, and M. Fowler. 2022. “Numerical simulation of cooling plate using K-epsilon turbulence model to cool down large-sized graphite/LiFePO4 battery at high C-rates.” World Electr. Veh. J. 13 (8): 138. https://doi.org/10.3390/wevj13080138.
Shang, Z., H. Qi, X. Liu, C. Ouyang, and Y. Wang. 2019. “Structural optimization of lithium-ion battery for improving thermal performance based on a liquid cooling system.” Int. J. Heat Mass Transf. 130 (Mar): 33–41. https://doi.org/10.1016/j.ijheatmasstransfer.2018.10.074.
Shen, J., Y. Wang, G. Yu, and H. Li. 2020. “Thermal management of prismatic lithium-ion battery with minichannel cold plate.” J. Energy Eng. 146 (1): 1–11. https://doi.org/10.1061/(ASCE)EY.1943-7897.0000621.
Tang, Z., J. Li, Z. Liu, and J. Cheng. 2021a. “Thermal performance of a thermal management system with a thin plate and a slender tube for prismatic batteries.” Int. J. Energy Res. 45 (4): 5347–5358. https://doi.org/10.1002/er.6157.
Tang, Z., Z. Liu, J. Li, and J. Cheng. 2021b. “A lightweight liquid cooling thermal management structure for prismatic batteries.” J. Energy Storage 42 (Feb): 103078. https://doi.org/10.1016/j.est.2021.103078.
Tang, Z., Z. Liu, R. Zhao, and J. Cheng. 2022. “Investigation on the thermal management performance of a parallel liquid cooling structure for prismatic batteries.” J. Electrochem. Energy Conv. Stor. 19 (2): 1–12. https://doi.org/10.1115/1.4051727.
Tete, P. R., M. M. Gupta, and S. S. Joshi. 2021. “Developments in battery thermal management systems for electric vehicles: A technical review.” J. Energy Storage 35 (Sep): 102255. https://doi.org/10.1016/j.est.2021.102255.
Tousi, M., A. Sarchami, M. Kiani, M. Najafi, and E. Houshfar. 2021. “Numerical study of novel liquid-cooled thermal management system for cylindrical Li-ion battery packs under high discharge rate based on AgO nanofluid and copper sheath.” J. Energy Storage 41 (Jul): 102910. https://doi.org/10.1016/j.est.2021.102910.
Wang, C., G. Zhang, L. Meng, X. Li, W. Situ, Y. Lv, and M. Rao. 2017. “Liquid cooling based on thermal silica plate for battery thermal management system.” Int. J. Energy Res. 41 (15): 2468–2479. https://doi.org/10.1002/er.3801.
Wang, J., Y. Gan, J. Liang, M. Tan, and Y. Li. 2019. “Sensitivity analysis of factors influencing a heat pipe-based thermal management system for a battery module with cylindrical cells.” Appl. Therm. Eng. 151 (Jan): 475–485. https://doi.org/10.1016/j.applthermaleng.2019.02.036.
Wang, J., S. Lu, Y. Wang, Y. Ni, and S. Zhang. 2020. “Novel investigation strategy for mini-channel liquid-cooled battery thermal management system.” Int. J. Energy Res. 44 (3): 1971–1985. https://doi.org/10.1002/er.5049.
Wu, W., S. Wang, W. Wu, K. Chen, S. Hong, and Y. Lai. 2019. “A critical review of battery thermal performance and liquid based battery thermal management.” Energy Convers. Manage. 182 (Jan): 262–281. https://doi.org/10.1016/j.enconman.2018.12.051.
Xi, Y., Y. Feng, Y. Xiao, and G. He. 2020. “Novel Z-shaped structure of lithium-ion battery packs and optimization for thermal management.” J. Energy Eng. 146 (1): 1–11. https://doi.org/10.1061/(ASCE)EY.1943-7897.0000635.
Xia, G., L. Cao, and G. Bi. 2017. “A review on battery thermal management in electric vehicle application.” J. Power Sources 367 (Nov): 90–105. https://doi.org/10.1016/j.jpowsour.2017.09.046.
Xie, Y., W. Li, X. Hu, M. K. Tran, S. Panchal, M. Fowler, and K. Liu. 2022a. “Co-estimation of SOC and three-dimensional SOT for lithium-ion batteries based on distributed spatial-temporal online correction.” IEEE Trans. Ind. Electron. 70 (6): 5937–5948. https://doi.org/10.1109/TIE.2022.3199905.
Xie, Y., Y. Liu, M. Fowler, M. K. Tran, S. Panchal, W. Li, and Y. Zhang. 2022b. “Enhanced optimization algorithm for the structural design of an air-cooled battery pack considering battery lifespan and consistency.” Int. J. Energy Res. 46 (15): 24021–24044. https://doi.org/10.1002/er.8700.
Yalçın, S., S. Panchal, and M. S. Herdem. 2022. “A CNN-ABC model for estimation and optimization of heat generation rate and voltage distributions of lithium-ion batteries for electric vehicles.” Int. J. Heat Mass Transf. 199 (Dec): 123486. https://doi.org/10.1016/j.ijheatmasstransfer.2022.123486.
Yang, W., F. Zhou, H. Zhou, and Y. Liu. 2020. “Thermal performance of axial air cooling system with bionic surface structure for cylindrical lithium-ion battery module.” Int. J. Heat Mass Transf. 161 (Nov): 120307. https://doi.org/10.1016/j.ijheatmasstransfer.2020.120307.
Yu, R., H. Han, C. Yang, and W. Luo. 2022. “Optimal design and decision making of an air cooling channel with hybrid ribs based on RSM and NSGA-II.” J. Therm. Anal. Calorim. 147 (10): 5839–5854. https://doi.org/10.1007/s10973-021-10807-1.
Zhu, H., L. Liu, T. Long, and L. Peng. 2012. “A novel algorithm of maximin Latin hypercube design using successive local enumeration.” Eng. Optim. 44 (5): 551–564. https://doi.org/10.1080/0305215X.2011.591790.
Zichen, W., and D. Changqing. 2021. “A comprehensive review on thermal management systems for power lithium-ion batteries.” Renewable Sustainable Energy Rev. 139 (Jan): 110685. https://doi.org/10.1016/j.rser.2020.110685.
Information & Authors
Information
Published In
Journal of Energy Engineering
Volume 149 • Issue 3 • June 2023
Copyright
© 2023 American Society of Civil Engineers.
History
Received: Sep 15, 2022
Accepted: Feb 7, 2023
Published online: Mar 30, 2023
Published in print: Jun 1, 2023
Discussion open until: Aug 30, 2023
ASCE Technical Topics:
- Batteries
- Computational fluid dynamics technique
- Energy infrastructure
- Energy storage
- Engineering fundamentals
- Engineering mechanics
- Fluid dynamics
- Fluid mechanics
- Hydrologic engineering
- Infrastructure
- Lifeline systems
- Mathematics
- Measurement (by type)
- Parameters (statistics)
- Statistics
- Structural engineering
- Structural members
- Structural systems
- Systems engineering
- Systems management
- Temperature effects
- Temperature measurement
- Thermal effects
- Thermal properties
- Thermodynamics
- Tubes (structure)
- Water and water resources
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.