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Thermal analysis of a novel cycle for battery pre-warm-up and cool down for real driving cycles during different seasons

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Abstract

The temperature range of 25–35 °C provides the most suitable conditions for the best performance of batteries. This study introduced an advanced new thermal management system for batteries designed based on thermoelectric elements and radiators. The battery system is modeled during a real driving cycle. The simulation results showed that the temperature pattern of the battery surface followed a fluctuation pattern before reaching a steady-state condition in cold seasons. A similar model for hot months followed the velocity profile of the vehicle. Besides, the temperature profile was linear with a positive slope in hot seasons for the battery charge time. The surface temperature of the cold plate of the thermoelectric elements in cold seasons reduced with velocity from the cold to hot season while following the velocity profile of the vehicle in hot seasons, with a positive slope and linear trend. Concerning the surface temperature of the hot plate of the thermoelectric elements, the profile was linear and incremental. Furthermore, the increasing trend experienced some fluctuations that declined from the cold to hot season, while there were no fluctuations for the temperatures above 25 °C. In the cold seasons of the year, as the temperature increases from 6.9 to 15.5 °C, the oscillating state decreases for 500 s, and when it increases again to 21.5 °C, the time interval decreases for 100 s. Also, for thermal management in the hot season, kfan is reduced from 0.81 to 0.21 W K−1 to achieve balance and optimal operation of thermoelectric elements. The same fluctuation trend applies to all the results obtained from the energy stored in the battery diagram. It can be concluded that the newly introduced thermal management system can maintain the battery temperature at an appropriate temperature range. The results followed similar patterns for various thermal conditions wherein different parameters of the thermal management system were examined. The new cycle introduced using the fuzzy logic algorithm and the PID controller could manifest proper efficiency for real applications.

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Abbreviations

AAC:

Active air cooling

BEV:

Battery electric vehicle

BTMS:

Battery thermal management system

CFD:

Computational fluid dynamics

COP:

Coefficient of performance

CSGP:

Composite silica gel plate

EV:

Electric vehicle

FMHPA:

Flat micro-heat pipe array

FTP:

Federal test procedure

HEV:

Hybrid electric vehicle

HFE:

Hydrofluoroether

HPPICB:

Heat pipe-phase change material internal cooling battery

HSP:

Heat spreading plate

LC:

Liquid-cooled

LIB:

Lithium-ion battery

LN:

Liquid nitrogen

MHPA:

Micro-heat pipe array

NMHPA:

No U-shaped micro-heat pipe array

NTU:

Number of transfer units

PAC:

Passive air cooling

PCM:

Phase change material

PID:

Proportional integral derivative

PTC:

Positive temperature coefficient

SEI:

Solid electrolyte interphase

SOC:

State of charge

SPM:

Single-particle model

TMS:

Thermal management system

TR:

Thermal runaway

UDDS:

Urban dynamometer driving schedule

A :

Surface area (m2)

C D :

Aerodynamic drag factor (−)

C max :

Maximum heat capacity of the two fluids in the heat exchanger (W K−1)

C min :

Minimum heat capacity of the two fluids in the heat exchanger (W K−1)

C p :

Specific heat capacity (kJ kg−1 K−1)

C*:

Heat capacity ratio of the two fluids in the heat exchanger (−)

f :

Friction coefficient (−)

F :

Faraday’s constant (C mol−1)

g :

Gravitational constant (m s−2)

h :

Convective heat transfer coefficient (W m−2 K−1)

I :

Electrical current (A)

k :

Heat transfer coefficient (W K−1)

k eff :

Effective reaction rate constant (m2.5 mol−0.5 s−1)

m :

Mass of the vehicle (kg)

\(\dot{m}\) :

Mass flow rate (kg s−1)

NTU:

Number of transfer units (−)

P :

Total power of the vehicle's battery (W)

q :

Heat that is exchanged in the heat exchanger (W)

Q :

Exchanged heat (kJ)

q max :

Maximum heat that can be exchanged in the heat exchanger (W)

R :

Universal gas constant (kJ mole−1 K−1)

R p :

Electrical resistance of Peltier elements (Ω)

u :

Velocity of the vehicle (m s−1)

U :

Total heat transfer coefficient (W m−2 K−1)

U i :

Open-circuit voltage (V)

t :

Time (s)

T :

Temperature (K)

t + :

Transference number (−)

V :

Volume (m3)

x :

Direction of the computational domain (m)

\({\Phi }\) :

Electrical potential (V)

\(\alpha\) :

Seebeck coefficient (V K−1)

\(\rho\) :

Density (kg m−3)

\(\varepsilon\) :

Heat exchanger efficiency (−)

\({\text{cos}}\left( \alpha \right)\) :

Slope of the ground for the vehicle movement (−)

\(\delta\) :

Mechanical efficiency of the vehicle (−)

\(\sigma\) :

Electrical conductivity of the solid phase (S m−1)

\(\kappa\) :

Electrical conductivity of the electrolyte phase (S m−1)

acc:

Ambient and radiator convection

acf:

Ambient cool face

bat:

Battery

cf:

Cool face

cond:

Conductive

conv:

Convective

conva:

Ambient convection

convr:

Radiator convection

e:

Electrolyte

eff:

Effective

hf:

Hot face

i:

Anode or Cathode

j:

Joule

pcf:

Peltier cool face

phf:

Peltier hot face

rad:

Radiator

ref:

Reference state

rf:

Radiator face

rhf:

Radiator hot face

s:

Solid

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Authors and Affiliations

  1. School of Mechanical Engineering, College of Engineering, University of Tehran, P.O. Box, Tehran, 11155-4563, Iran

    Hamed Khalili, Pouria Ahmadi, Mehdi Ashjaee & Ehsan Houshfar

  2. College of Engineering, University of Tehran, North Kargar St., Room 818, Mech. Eng. Dept. (New Building), Campus 2, Tehran, Iran

    Ehsan Houshfar

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  1. Hamed Khalili
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HK contributed to the methodology, formal analysis, validation, writing—original draft; PA was involved in the conceptualization, methodology, writing—review and editing, supervision, validation, visualization; MA helped in the methodology, supervision, resources; EH was involved in the conceptualization, methodology, writing—review and editing, supervision, project administration, validation.

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Khalili, H., Ahmadi, P., Ashjaee, M. et al. Thermal analysis of a novel cycle for battery pre-warm-up and cool down for real driving cycles during different seasons. J Therm Anal Calorim 148, 8175–8193 (2023). https://doi.org/10.1007/s10973-022-11601-3

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