Optimization investigation on the liquid cooling heat dissipation structure for the lithium-ion battery package in electric vehicles

Abstract

The requirements of cooling and weight reduction for lithium-ion battery packages in electric vehicles are increasingly important. In this paper, a liquid cooling heat dissipation structure is designed and optimized. First of all, the effects of tube diameter, spacing, thickness and layout of the cooling plate on the heat dissipation of the battery package are investigated by using computational fluid dynamics. Afterwards, based on the optimal results of the single factor analysis, an orthogonal table with four factors and three levels are constructed to perform a single-objective optimization, where the minimization of the maximum temperature is the optimization object. Meanwhile, an experiment is carried out to verify the accuracy of the simulation model. In order to further reduce the mass of the cooling plate, a multi-objective optimization is performed, where the minimization of the maximum temperature and the mass are the optimization objects. The maximum temperature is increased by 10.9% in the multi-objective optimization when compared with that in the single objective optimization. However, the mass of the cooling plate in the multi-objective optimization can drop by 82.4%.

Keywords

Lithium-ion battery liquid cooling cooling plate orthogonal experiment optimization

Get full access to this article

View all access options for this article.

References

Budde-Meiwes

Drillkens

Lunz

et al . A review of current automotive battery technology and future prospects. P I Mech Eng D-J Aut 2013; 227: 761–776.

Sato

. Thermal behavior analysis of lithium-ion batteries for electric and hybrid vehicles. J Power Sources 2001; 99(1): 70–77.

Wang

Ping

Zhao

et al . Thermal runaway caused fire and explosion of lithium ion battery. J Power Sources 2012; 208: 210–224.

Kizilel

Lateef

Sabbah

et al . Passive control of temperature excursion and uniformity in high-energy Li-ion battery packs at high current and ambient temperature. J Power Sources 2008; 183(1): 370–375.

Pesaran

Burch

Keyser

. An approach for designing thermal management systems for electric and hybrid vehicle battery packs. In: Proceedings of the 4th vehicle thermal management systems, London, UK, 24–27 May 1999, pp. 24–27. Springfield: NTIS.

Huo

Rao

Liu

et al . Investigation of power battery thermal management by using mini-channel cold plate. Energ Convers Manage 2015; 89: 387–395.

Jeon

Baek

. Thermal modeling of cylindrical lithium ion battery during discharge cycle. Energ Convers Manage 2011; 52: 2973–2981.

Tao

Wagner

. A thermal management system for the battery pack of a hybrid electric vehicle: modeling and control. P I Mech Eng D-J Aut 2016; 230: 190–201.

Wang

Tseng

Zhao

et al . Thermal investigation of lithium-ion battery module with different cell arrangement structures and forced air-cooling strategies. Appl Energy 2014; 134: 229–238.

10.

Rao

Wang

. A review of power battery thermal energy management. Renew Sustainable Energy Rev 2011; 15(9): 4554–4571.

11.

M-S

Liu

Wang

Y-Y

et al . Heat dissipation design for lithium-ion batteries. J Power Sources 2002; 109(1): 160–166.

12.

Sabbah

Kizilel

Selman

et al . Active (air-cooled) vs. passive (phase change material) thermal management of high power lithium-ion packs: Limitation of temperature rise and uniformity of temperature distribution. J Power Sources 2008; 182(2): 630–638.

13.

Pesaran

. Battery thermal management in EV and HEVs: Issues and solutions. Battery Man 2001; 43: 34–49.

14.

Hansen

Wilhelm

Karditsas

et al . Full system nickel-metal hydride battery packs for hybrid electric vehicle applications. In: Battery conference on applications and advances, Long Beach, USA, 15–18 January 2002, pp.253–260. New York: IEEE.

15.

Hung

Wang

et al . Heat dissipation behavior of the nickel/metal hydride battery. J Electrochem Soc 2000; 147(3): 930–935.

16.

Kim

Pesaran

. Battery thermal management system design modeling, In: 22nd International Battery, Hybrid and Fuel Cell Electric Vehicle Conference and Exhibition, Yokohama, Japan, 23–28 October 2006, pp. 1–16. Springfield: NTIS.

17.

Baek

Nam

et al . A numerical study on uniform cooling of large-scale PEMFCs with different coolant flow field designs. Appl Therm Eng 2011; 31(8): 1427–1434.

18.

Chen

Gao

Loutfy

et al . Analysis of optimal heat transfer in a PEM fuel cell cooling plate. Fuel Cells 2003; 3(4): 181–188.

19.

Kurnia

Sasmito

Mujumdar

. Numerical investigation of laminar heat transfer performance of various cooling channel designs. Appl Therm Eng 2011; 31(6): 1293–1304.

20.

Nam

Lee

K-J

Sohn

et al . Multi-pass serpentine flow-fields to enhance under-rib convection in polymer electrolyte membrane fuel cells: Design and geometrical characterization. J Power Sources 2009; 188(1): 14–23.

21.

Zhao

Rao

. Thermal performance of mini-channel liquid cooled cylinder based battery thermal management for cylindrical lithium-ion power battery. Energ Convers Manage 2015; 103: 157–165.

22.

Ravishankar

Prakash

. Numerical studies on thermal performance of novel cooling plate designs in polymer electrolyte membrane fuel cell stacks. Appl Therm Eng 2014; 66(1): 239–251.

23.

Garrity

Klausner

Mei

. A flow boiling microchannel evaporator plate for fuel cell thermal management. Heat Transfer Eng 2007; 28(10): 877–884.

24.

Jarrett

Kim

. Design optimization of electric vehicle battery cooling plates for thermal performance. J Power Sources 2011; 196(23): 10359–10368.

25.

Sohn

Nam

et al . Numerical study to examine the performance of multi-pass serpentine flow-fields for cooling plates in polymer electrolyte membrane fuel cells. J Power Sources 2009; 194(2): 697–703.

26.

Zhang

. The Liquid Cooling System of the Ni-MH Battery Pack for Hybrid Electric Vehicles, Journal of Guangdong University of Technology 2008; 25: 28–31.

27.

Rao

Wang

et al . Experimental investigation on thermal management of electric vehicle battery with heat pipe. Energ Convers Manage 2013; 65: 92–97.

28.

Tang

Wang

et al . Adaptive heuristic search algorithm for discrete variables based multi-objective optimization. Struct Multidiscipl Optim 2013; 48(4): 821–836.

29.

Zabinsky

. Stochastic methods for practical global optimization. J Global Optim 1998; 13: 433–444.

30.

Reaume

Romeijn

Smith

. Implementing pure adaptive search for global optimization using Markov chain sampling. J Global Optim 2001; 20: 33–47.

31.

Simpson

Dandy

Murphy

. Genetic algorithms compared to other techniques for pipe optimization. J Water Res Pl-ASCE 1994; 120: 423–443.

32.

et al . Orthogonal experimental study on high frequency cascade thermoacoustic engine. Energ Convers Manage 2008; 49(5): 1211–1217.

33.

Lee

Shin

Yoon

et al . An orthogonal-array-based design-of-experiments method for designing a vehicle hood and bumper structure. P I Mech Eng D-J Aut 2008; 222: 161–171.

34.

Lee

S-J

Lee

H-A

S-I

et al . Design flow for the crash box in a vehicle to maximize energy absorption. P I Mech Eng D-J Aut 2013; 227: 179–200.

35.

Zhu

Chew

et al . Optimization method for building envelope design to minimize carbon emissions of building operational energy consumption using orthogonal experimental design (OED). Habitat Int 2013; 37: 148–154.

36.

Huang

Zhang

et al . Solid lipid nanoparticles of temozolomide: potential reduction of cardial and nephric toxicity. Int J Pharm 2008; 355: 314–320.

37.

Shimazaki

Miyazaki

Takezawa

et al . Excellent thermal conductivity of transparent cellulose nanofiber/epoxy resin nanocomposites. Biomacromolecules 2007; 8(9): 2976–2978.

38.

. Study on design methodology of graded thin-walled structures and its application in automotive body. PhD Thesis, Hunan University, P.R.China, 2015.