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Large-scale zone-based approach to global modeling and optimization for a novel thermal management system of module-free lithium-ion battery

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Abstract

Urgent need for driving range of lightweight electric vehicles has given birth to module-free lithium-ion batteries with high efficiency and low costs. Conventional module-based design methodology is not suitable for module-free battery thermal management systems (MF-BTMS). In this study, zone-based modeling and optimization approach is proposed for MF-BTMSs, which consists of zone definition, zone connection and pack-level optimization. Using this approach, with temperature uniformity and energy efficiency taken into consideration, a novel air-cooling MF-BTMS with heat pipe group and phase change materials (HPG–PCM) is designed. It is applied to batteries with different scales to study the effects of in-ventilation fin spacings and air-velocity under ambient temperature. It is found that with zone-based model, the in-pack predicted temperature error does not exceed 3% on average. Comparing to the conventional one, this method improves in-pack temperature uniformity 50.79% on average, and the highest value is 93.28%. Meanwhile, the energy consumption for cooling systems can be saved by 61.71%, which will extend the cruise range. It is also proved that air-cooling HPG–PCM system can be effective for MF-BTMSs, as the heat dissipation performance is enhanced with the assistance of cooling fins, while in-pack temperature maldistribution is reduced by adjusting fin spacings.

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (Grant Nos. 51621004, 51575171) and special funds for the construction of innovative provinces in Hunan Province (2019GK4006).

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha, 410082, People’s Republic of China

    Jinhao Li, Fei Lei, Wenhao Zhu, Zhifeng Qiu & Hailong Wu

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  1. Jinhao Li
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  2. Fei Lei
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  3. Wenhao Zhu
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  4. Zhifeng Qiu
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Correspondence to Fei Lei.

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Replication of results

The 90 CFD samplings and the MATLAB code for the iteration process are presented as Supplementary Material.

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Li, J., Lei, F., Zhu, W. et al. Large-scale zone-based approach to global modeling and optimization for a novel thermal management system of module-free lithium-ion battery. Struct Multidisc Optim 64, 3621–3636 (2021). https://doi.org/10.1007/s00158-021-03042-7

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