Battery Cooling System

TY- Mechanical
Batch 1
Division: C
Batch Guide:cDr. Prof. Sachin Komble

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 Group Members
Roll PNR Name
No. Number

1 4 12110972 Atharva Kulkarni

2 11 12110020 Ajay kulsange

3 19 12220211 Lavkesh Salunke

4 20 12220179 Varad Lomte

5 24 12221101 Nishiraj Mane

6 26 12110779 Shubham Mane

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 Content

● Introduction
● Objective
● Literature Review
● Advantage
● Disadvantage
● Result
● Reference

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Introduction

A battery cooling system is a mechanism designed to maintain the optimal temperature of a

battery pack in an electric vehicle or energy storage system. The cooling system typically
circulates a coolant fluid around the battery cells to dissipate heat generated during charging and
discharging.

●PCM cooling uses a phase change material, which is a material that absorbs or releases heat as
it changes phase from a solid to a liquid or vice versa.
●When the temperature of the battery cells rises above a certain threshold, the PCM melts and
absorbs heat, preventing the temperature from rising further.
Objective

The objective of this study is to provide an effective passive cooling method for a battery
thermal management system using phase change material.

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 Literature Review

Title Objective Methodology Results Conclusion

Heat Dissipation Objective of paper is To To evaluate the We got the This paper first establishes
evaluate the effectiveness of composite difference of air the geometric model of the
Analysis on the
cooling, water
Liquid Cooling effectiveness of and metal propeller using power battery system.
cooling, heat
System Coupled different cooling FEA. & Thermal Analysis pipe cooling According to the actual
with a Flat Heat methods are simulated is performed on both Al & working characteristics of
and compared composite propeller to find the power battery system,
Pipe of a Lithium-
out the heat flux and the effects of different
Ion Battery
thermal error discharge rates, different
coolant flow rates, and
different coolant inlets

Table No: 1
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 Literature Review

Title Objective Methodology Results Conclusion

Structural Objective of paper is liquid cooling system for increasing inlet It is difficult to improve the
to enhance the heat lithium-ion battery with mass flow can overall performance of the
optimization of
effectively limit
lithium-ion dissipation capability changing contact surface is battery by only optimizing a
the maximum
battery for and prevent thermal designed. Contact surface is temperature, single factor. Three factors
improving runaway, thereby determined by the width of but cannot (mass flow rate, inlet
improving the safety, cooling plate. Mathematical improve temperature, the width of
thermal
reliability, and lifespan derivation and numerical temperature cooling plate) for the thermal
performance uniformity
of the battery. analysis are conducted to performance of battery are
based on a liquid evaluate cooling performance significantly. optimized by using the single
cooling system and the consumption of pump factor analysis and the
power. orthogonal test.

Table No: 2
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 Literature Review

Battery Thermal Management System

-Omkar Kapkar, Siddhi Kanade Pallavi Kamble, Tushar Kamble Prof. Sonali
Mahajan

● The cooling fins and batteries are 2 mm thick

each, summing up to a total unit cell
thickness of 6 mm. The overall volume of one
cell is (100*2*100) mm

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● The difference between the highest
and lowest temperature in the pack is
about 3 K.
● The temperature variation between
different batteries along the y-axis is
smaller than the temperature
variation within a single battery in the
x z-plane.

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A review on recent key technologies of lithium-ion battery thermal management: External cooling systems

Author : Marwa Mahmoud Hamed, A. El-Tayeb **, Ibrahim Moukhtar, A.Z. El Dein, Esam H. Abdelhameed

Problem statement:
Electric vehicles and hybrid power systems, need large-scale lithium battery packs in Li-ion batteries.
The performance of a battery cell depends strongly on its temperature, accordingly, for battery safety,
enhanced performance, service life, and cycle stability, the operating temperature of the battery cell must be
maintained within a specific range of temperature, i.e. between 15 ◦C and 35 ◦C.
Another issue with batteries is regarding the battery aging .Battery aging causes severe harmful effects
such as decreasing the battery lifespan and reducing the power efficiency and energy. Subsequently, it
raises the failure risk and the cost of applications that utilize
those batteries
Battery thermal management systems are implemented to maintain appropriate operating temperature and efficient perf.
of Li-ion battery which ensures safety during operation and a longer life. There are 3 types of external cooling systems

Conclusion :
Air cooling systems are simple, have a lower mass, and have no possibility of leakage, but it has small heat capacity, in
addition, Liquid cooling strategies are more effective than air cooling strategies as they have high heat transfer and
thermal conductivity but they are expensive , complex and can generate leakages.
Many researchers preferred to combine two or more techniques of cooling to take advantage of their features. Moreover
utilizing nanoparticles can increase the thermal conductivity and heat transfer coefficient .
Novel design optimization for passive cooling PCM assisted
battery thermal management system in electric vehicles
Rekabra Youssef, Md Sazzad Hosen, Jiacheng He, Mohammed AL-Saadi, Joeri Van Mierlo, Maitane Berecibar

This study provides a novel design optimization to improve the environmental aspect of the cooling system and
reduce its weight.

It represents the first attempt to use a combination of jute and PCM in order to maximize temperature efficiency
enhanced.

Jute fibers as a planet-system, available, cheap, and weightless material is combined with the PCM battery
thermal management based.
The results with the periodic load profile shows that the
maximum temperature for the cooling strategies of no-
cooling, PCM cooling and PCM with jute reaches 39.22
°C, 38.22 °C and 35.09 °C ,respectively.

Further applying aggressive high constant discharge

current leads to maximum temperature of 47.27 °C,
41.06 °C, and 36.29 °C ,respectively.
18650 Cells
The 18650 battery has a voltage of 3.6v and has between 2600mAh and
3500mAh (mili-amp-hours). (Osborne, 2019) These batteries are used in
flashlights, laptops, electronics and even some electric cars because of their
reliability, long run-times, and ability to be recharged hundreds of times

A123 Pouch Cells

The A123 Pouch Cells has a voltage of 3.6v and has between 25Ah.
A123 Lithium Iron Phosphate (LFP) and Nickel Manganese Cobalt (NMC)
technologies offer high-powered cell performance compatible with virtually
any lithium-ion application to deliver more power and extend life.
Lithium Ion Battery

The lithium-ion battery is promising energy storage that provides proper stability, no memory effect, low self-
discharge rate, and high energy density. During its usage, batteries generate heat caused by energy loss due to the
transition of chemical energy to electricity and the electron transfer cycle
Phase Change Material

PCM is a material that undergoes a phase change and uses its chemical bonds
to absorb and release heat. The PCM at room temperature can be in solid form.
Once the temperature gets high, the PCM absorbs the excess heat until its
melting point. At this high temperature, the PCM changes to a liquid melting
phase, then retreat to solid when the temperature reverts to normal. Besides
integrating the system, PCM as a passive cooling system is also an efficient,
easy to maintain, long-term, low price,

The phase change material while conducting the project was Heneicosane it is
the organic compound with the formula CH3(CH2)19CH3. It is the straight
chain, saturated C21 hydrocarbon.
Pouch Cell
CAD and Meshing

Fig. Isometric view of battery CAD. Fig. Isometric view of Mesh geometry.
Calculations

Heat generated by A123 li-ion cell = 84000 J

Ambient temp.= 298 K

C-rate = 8

Mass of A123 cell= 0.556kg.

CP= 1241

Heat transfer coefficient=30.

Volume of A123 cell=0.000161

Calculations
Result

Fig. Isometric view of battery with temp. Fig. Isometric view of PCM material
difference.
Advantage

1. Enhanced Safety: By maintaining the battery temperature within a safe range, the risk of thermal runaway is greatly
reduced, which enhances the safety of the system.
2. Improved Performance: A well-designed battery cooling system can help to improve the overall performance of the
battery pack by ensuring that it operates at optimal temperature.
3. Extended Lifespan: Heat is one of the main factors that can degrade the performance and lifespan of a battery. A
battery cooling system can help to extend the lifespan of the battery by reducing the impact of heat on its
performance.
Disadvantage

1. Increased Cost: A battery cooling system can add to the overall cost of the system, as it requires additional
components such as a coolant pump, heat exchanger, and temperature sensors.
2. Additional Complexity: The addition of a cooling system adds complexity to the system, which can increase the
risk of failure or malfunction.
3. Reduced Efficiency: The cooling system itself consumes energy, which can reduce the overall efficiency of the
system. However, this can be minimized through the use of efficient components and control algorithms.
Conclusion

Cells when discharged at C-rate of 8 for 30 secs reach 121.74℃ without cooling. The cell won't sustain this kind
of temperature for longer periods. Hence battery cooling is necessary. Phase Change Cooling is very efficient and
the cell when cooled by PCM reaches 35℃.
References

1. J. Yang, X. Sun, and K. Liu, "Design and Optimization of Battery Thermal Management System for Electric Vehicles," IEEE
Transactions on Power Electronics, vol. 34, no. 2, pp. 1899-1909, Feb. 2019. doi: 10.1109/TPEL.2018.2835680
2. H. Kim, J. Kim, and S. H. Kim, "Optimal cooling strategy of lithium-ion battery pack for electric vehicles," IEEE Transactions
on Vehicular Technology, vol. 67, no. 1, pp. 156-163, Jan. 2018. doi: 10.1109/TVT.2017.2731810
3. S. C. Lee, C. H. Lee, and K. H. Kim, "Active cooling system design for a large format lithium-ion battery pack," IEEE
Transactions on Industrial Electronics, vol. 61, no. 1, pp. 417-425, Jan. 2014. doi: 10.1109/TIE.2013.2256354
4. J. M. Anderson, G. S. Shaffer, and M. A. Treadaway, "Thermal management of battery systems in hybrid electric vehicles
using phase change materials," IEEE Transactions on Components and Packaging Technologies, vol. 33, no. 3, pp. 646-655,
Sep. 2010. doi: 10.1109/TCAPT.2010.2046187
5. W. Wang, K. K. Tse, and Y. C. Chan, "An intelligent battery thermal management system for electric vehicles," IEEE
Transactions on Industrial Informatics, vol. 11, no. 6, pp. 1463-1473, Dec. 2015. doi: 10.1109/TII.2015.2482580

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THANK YOU

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