Experimental Analysis and Optimization of Battery Thermal Management Systems

Abstract

Batteries have become vital to daily life, with demand increasing due to the widespread adoptionof electric vehicles. As battery usage expands, ensuring safe and efficient operation is crucial. A key challenge is the gradual degradation of cell capacity, which accelerates over repeated charge and discharge cycles. Factors such as charging rates, ambient conditions, and excessive heat generation significantly impact battery longevity. In high-power applications like EVs, rapid charging and discharging can elevate cell temperatures beyond recommended limits, leading to increased degradation and potential safety risks, making the battery pack unusable. This study investigates various cooling strategies to regulate lithium-ion cell temperatures and prevent excessive heat buildup. By charging cells at different C-rates and continuously monitoring surface temperatures in a battery pack, the effectiveness of passive and active cooling mechanisms in preventing thermal runaway and uniform cell temperature is evaluated. Additionally, the study explores water cooling and PCM-based thermal regulation, analyzing their impact on temperature stability. The results provide insights into battery thermal management optimization, enhancing both safety and longevity in EVs and other high-demand applications. Furthermore, using the experimentally collected data, a thermal model is developed to predict temperature behavior during the charge cycle of a single cell. This model serves as a foundation for future improvements in battery pack thermal modeling, allowing for more accurate simulations and optimized cooling system designs. The findings contribute to the advancement of Battery Thermal Management Systems, ensuring reliable and efficient performance in nextgeneration energy storage solutions.