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Journal of Thermal Analysis and Calorimetry

https://doi.org/10.1007/s10973-020-09606-x

Thermal management of modern electric vehicle battery systems


(MEVBS)
Asif Afzal1 · A. D. Mohammed Samee1 · R. K. Abdul Razak1 · M. K. Ramis1

Received: 18 September 2019 / Accepted: 19 March 2020


© Akadémiai Kiadó, Budapest, Hungary 2020

Abstract
The operating temperature of Li-ion batteries used in modern electric vehicles should be maintained within an allowable
range to avoid thermal runaway and degradation. One of the most challenging issues faced by the automobile industry is
providing proper thermal management mechanisms to avert thermal runaways. In this work, the effect of operating param-
eters like volumetric heat generation (S̅q), conduction–convection parameter (ζcc), Reynolds number (Re), and Aspect ratio
(Ar) on the thermal behavior of a prismatic battery cell is investigated numerically considering a realistic conjugate condi-
tion at the battery cell and coolant interface. Air is selected as the coolant that carries the heat generated uniformly in the
modern battery cell during charging or discharging from its surface. For variations in S̅q from 0.1 to 1.0, ζcc from 0.06 to
0.1, Re from 250 to 2000, and Ar from 10 to 35, the temperature distribution, as well as maximum temperature variation in
the battery cell, is determined. Further, the occurrence of the critical threshold of temperature and the necessary change in
these operating parameters to avoid thermal runaway is proposed. Finally, the effect of flow Reynolds number and channel
spacing on average Pressure and average Nusselt number is also discussed in this study. From the exhaustive analysis on the
effect of considered parameters, it is observed that apart from heat generation parameter S̅q, other parameters like ζcc and Re
play a prominent role in reducing the maximum temperature of the battery cell. However, Ar has a negligible impact on the
thermal performance of battery cell irrespective of any value of other parameters considered in this study. It was interesting
to find that for Re> 1000, the impact on temperature profiles of the battery cell is minimal, while the other parameters were
either kept constant or varying, putting a limit to higher values of Re.

Keywords Battery systems · Thermal runaways · Temperature · Reynolds number · Heat generation · Critical threshold
List of symbols q‴ Volumetric heat generation W m−3
Ar Aspect ratio of a battery cell S̅q Dimensionless volumetric heat generation
C Constant of Ar Pr Prandtl number
L Length of battery cell m Re Reynolds number
K Thermal conductivity W m−1 K−1 T Temperature K
lo Length of extra outlet fluid domain m To Maximum allowable temperature of battery cell K
li Length of extra fluid domain m T̅ Non-dimensional temperature
h Convective heat transfer coefficient W m−2 K−1 u Velocity along the axial direction m s−1
Lo Dimensionless length of extra outlet fluid domain U Non-dimensional velocity along the axial direction
Li Dimensionless length of extra inlet fluid domain u∞ Free stream velocity ­ms−1
Nu Nusselt number v Velocity along the transverse direction m s−1
p Pressure ­Nm−2
P Non-dimensional pressure
* Asif Afzal V Non-dimensional velocity along the transverse
asif.afzal86@gmail.com direction
* M. K. Ramis w Half-width m
ramismk@pace.edu.in W Non-dimensional width
1 x Axial direction
Department of Mechanical Engineering, P. A. College
of Engineering (Affiliated to Visvesvaraya Technological X Non-dimensional axial direction
University Belagavi), Mangaluru 574153, India

13
Vol.:(0123456789)
A. Afzal et al.

y Transverse direction They obtained uniform temperature distribution and reduced


Y Non-dimensional transverse direction maximum temperature. Xie et al. [16] utilized a combined
thermal management system for a Li-ion battery pack to
Greek symbols
show experimentally as well as numerically the difference
α Thermal diffusivity of fluid ­m2 s
between the air cooling and PCM liquid cooling. The pro-
ν Kinematic viscosity of fluid ­m2 s
posed method in this study for better temperature control
ρ Density of fluid kg m−3
and to avoid the thermal runaway of batteries is found to be
ζcc Conduction–convection parameter
effective when used in coupled condition rather than using
Subscripts independently.
avg Average Yang et al. [17] investigated the thermal performance of
c Center a 2D battery pack generating different energy rates energy,
f Fluid domain cooled with an axial flow of air. The results predicted that
m Mean the radial interval and air flux within the battery pack pro-
s Solid domain (battery cell) foundly influence the temperature uniformity. Yang et al.
∞ Free stream [18] presented a numerical simulation for improving the
thermal performance of a cylindrical lithium-ion battery
cell pack cooled with forced flow of air. In this analysis, a
Introduction comparison was made between the inline and staggered cell
arrangement and suggested the best way of arranging the
Automobile and electronic device manufacturers have battery cell, which can minimize the temperature rise, maxi-
expended several million dollars to protect the ecosystem mize the power efficiency, and better temperature uniformity.
by developing electric vehicles that have become more envi- Chen et al. [19] compared four different methods, i.e., (1)
ronmental friendly [1]. The modern electric vehicles use direct air cooling, (2) direct (3) liquid cooling, (4) indirect
lithium-ion (Li-ion) battery cells due to their high energy liquid cooling, and (4) fin cooling of a battery pack hav-
storage and discharge capacity [2, 3]. Thermal management ing Li-ion cells. The best and optimal method is suggested
of Li-ion batteries generating heat needs special attention in this three-dimensional numerical simulation in terms of
for their better performance, high efficiency, long life, and controlling the maximum range of temperature within the
safer operation [4–6]. If the heat generated in the battery battery pack, temperature uniformity, and power efficiency.
cell is not removed suitably, the temperature rise triggers Ciccino et al. [20] tested a Li-ion battery pack analyti-
further heat-generating exothermic reactions. This results cally and numerically in which they found out how the tem-
in increased battery cell temperature, which causes a ther- perature distribution within the battery pack changes with
mal runaway situation [7, 8]. Sometimes the thermal runa- respect to energy discharged from the battery, which is gen-
way situation may not arrive, but battery capacity degrades erally used in a lightweight commercial electric vehicle. The
undoubtedly by continuously operating at high temperatures, obtained results show that the proposed solution is suitable
i.e., above 50 °C [9]. Therefore, the heat generated in the for temperature distribution evaluation. Basu et al. [21] sug-
battery cell should be adequately removed, adopting an gested a correlation for predicting the temperature of each
effective cooling mechanism [10–12]. cell in a three-dimensional packed battery module, which
The increasing demand for Li-ion batteries in electronic can eliminate the usage of temperature sensors to a greater
devices and electric vehicles has enticed many researchers extent. The study also concludes that the conductivity of a
to investigate the problems pertinent to overheating, which conduction element, which acts as a screen between liquid
generally occurs due to poor thermal management systems coolant and battery cell, plays a very prime role in efficient
[13]. Ample work is available in the literature, which exclu- heat transfer. Bai et al. [22] used a numerical approach
sively talks about the methods of controlling the menace to investigate the effective cooling scheme for a pouch of
thermal behavior within the battery system. Wang et al. [8] lithium-ion battery with two-dimensional non-uniform heat
performed experimental and numerical analysis on the ther- source. The results of the study show that better tempera-
mal runaway, thermal models, essential reactions, battery ture uniformity within the battery cell can be achieved with
hazards, etc., and they provided safety methods and safety the combined effect of PCM (phase change material)/liquid
devices for thermal runaway prevention. Samba et al. [14] cooling methods. The research also shows that the amount of
conducted a transient simulation study on Li-ion pouch bat- heat generated can be removed effectively with liquid cool-
tery. The thermal behavior of the battery pouch was analyzed ing from the battery cell. Qian et al. [23] numerically inves-
in natural and forced cooling. Yu et al. [15] did a thermal tigated a three-dimensional Li-ion battery pack attached with
analysis on a battery pack with two-directional airflow man- mini channels cold plates for providing cooling effects dur-
agement using experimental and simulation approaches. ing the charging and discharging process. The study shows

13
Thermal management of modern electric vehicle battery systems (MEVBS)

how factors like coolant mass flow rate, flow direction, chan- distribution, or maximum temperature variations in a bat-
nel width, and a number of channels influence the thermal tery cell, or flow arrangements for efficient cooling, or
characteristics of a battery pack. The results of this research battery aging and degradation. These studies were mainly
elucidate which design model is useful for better and poor experimental or were simulation-based which were carried
uniformity of temperature within the battery cells. Chalise out using some commercial software like Ansys Fluent. In
et al. [24] investigated a conjugate heat transfer problem reality, the heat generated by the battery cell is carried by
pertinent to the liquid cooling of the Li-ion battery pack the coolant flowing past it. Hence, the coupled heat trans-
with an analytical approach. Different fluid and flow veloc- fer condition at the interface of the cell and coolant affects
ity were considered to determine the efficient performance the thermal behavior of batteries. Except for Chalise et al.
of the battery pack. They used a systematic method to solve [24], it is very clear from the above literature provided that
the boundary layer equation and performed external flow none of the studies was considering a realistic conjugate
analysis by keeping the mirror cell plate far away such that coupled heat transfer mode. Chalise et al. [24] examined
its effect if not felt. An effective thermal management system the boundary layer equation and solved it analytically. Their
of a lithium-ion battery pack with liquid cooling, air cooling study was limited to external flow and for a limited flow
and PCM methods or integrated method which exclusively velocity without considering the parametric effect. With
talks about the temperature uniformity, temperature distribu- this motivation, a detailed numerical analysis is performed
tion, optimal performance, and battery power, is discussed considering the parametric impact on the realistic conjugate
in detail [25–33]. thermal behavior of prismatic battery cell cooled by air. The
Focusing on steady-state thermal analysis of Li-ion packs, parameters considered are volumetric heat generation (S̅q),
Richter et al. [32] studied the aging of batteries and vari- conduction–convection parameter (ζcc), Reynolds number
ation in their thermal conductivity for temperature range (Re), and Aspect ratio (Ar). Accordingly, an indigenous
18 °C to 55 °C. Temperature profiles were analyzed for finite-volume method (FVM)-based code was developed to
different discharging rates. At high temperatures, the cell perform the analysis. Conjugate condition at the cell and
life cycle reduced while the thermal conductivity remained fluid interface was considered in which the continuity of
unchanged. Panchal et al. [25] developed neural network temperature and heat flux occurs. Temperature distribution
model for temperature distribution analysis and validated along the transverse direction and maximum temperature
the results with experimental work. Average surface tem- variation with these parameters were also analyzed. Particu-
perature for many boundary conditions was studied. In their lar focus was made on critical temperature and change in
next study, Panchal et al. [34] used experimental method parameters required at which thermal runaway in battery
and Ansys Fluent for velocity and temperature distribution cells can be avoided.
analysis placing a minichannel plate on battery. At 1C and
2C discharge and temperature 5 °C to 25 °C, the simulation
was carried out. Novel approaches like addition of plenum Battery module
as a secondary inlet in cylindrical batteries to avoid the prob-
lem of coolant recirculation was done by Shahid and Chaab Li-ion batteries have proved to offer good energy storage
[35]; lumped electrical thermal model at steady state was (> 240 W h kg−1) and discharge capability (> 104 W). The
adopted by Benjamin et al. [36] to restrict the number of main source of heat generation in a battery is due to Ohmic
parameters on thermal management study of battery. Yang heating and entropy change. Ohmic heating is an irreversible
et al. [37] used liquid metal for efficient heat removal from process, whereas entropy changes caused by electrochemi-
battery in which the pumping power was also lower. Saw cal reactions are a reversible heat generation process [41].
et al. [38] conducted numerical and experimental study for Reversible heat generation dominates at a low rate, and irre-
battery thermal management using mist cooling, and com- versible heat generation dominates at a high rate. The C-rate
parison was made with dry air cooling. Mist outperformed gives the rate at which the current is discharged from the
air in providing uniform temperature distribution. Mayyas battery. Depending upon the different C-rates, the volumetric
et al. [39] developed power split hybrid power train in con- heat generation in a battery cell varies from 6.855 × 10e3
nection with current and voltage of battery. Temporal and (standard US06) to 2 × 10e6 W m−3 (uphill condition) [1].
spatial temperature profiles were studied using this model. The heat generation in battery affects the safety of the device
Wang et al. [40] also modeled the battery as a network of and the performance of the battery. During the operation
thermal fluid estimating the surface and core temperature. of charging and discharging in batteries, temperature rises,
Accurate resolution of temperature distribution and captured which has to be properly removed and monitored [2]. Elec-
the cells interaction. trical energy being converted to chemical energy or the
Most of the research work carried out related to bat- reverse of this produces heat. With huge advancements in
tery thermal behavior is either focused on temperature the Li-ion battery system, the new generation cells provide

13
A. Afzal et al.

sufficient heat generation at uniform rates [1]. If the heat uniform in accordance with the cell zone [1]. The fluid
generation process during the battery operation leads to flow velocity ranges from 0.01 m s−1 to as high as 12 m s−1
exceeding the critical threshold of temperature rise, then the [43, 44]. The fluid operating temperature ranges from
thermal runaway situation arises [42]. Therefore, this study − 30 °C to 200 °C, and the cell dimensions vary between
investigates the thermal behavior and critical threshold tem- 0.1 and 30 mm in thickness, 50 mm to 550 mm in length,
perature of battery cells generating uniform volumetric heat. and 20 mm to 200 mm in width as available in the litera-
The present-day electric vehicles (EVs), hybrid elec- ture [1, 7, 14, 25, 32, 45]. Based on some of these facts,
tric vehicles (HEVs), and plug-in hybrid electric vehicles the range of the parameter is decided, and the laminar
(PHEVs) vary primarily in their necessary specifications flow regime is considered. Steady-state thermal analysis
like the number of cells, charge/discharge capacity, exterior is significantly reported in the literature in which the heat
dimensions, material, mass, etc. Generally, a battery cell generated during constant charging and discharging con-
module consists of a stack of prismatic battery cells and tinuously for a longer period of time is constant [24, 25,
coolant flowing between them to carry away the heat gener- 27, 32, 46]. To reduce the computational time cost, only
ated by the cells during charging and discharging, as shown half of the physical domain is considered (Fig. 2b) for
in Fig. 1a, b. The coolant (air in this case) enters the lower analysis with very few assumptions. It is assumed that
manifold and flows in the space between the cells, extracts the temperature of the air flowing from the cell stack in
the heat from the surface of the cell, and leaves from the the outlet flow domain, i.e., in the upper manifold is same
upper manifold. The coolant can be recirculated by lower- as the temperature of the air at the symmetric boundary
ing its temperature by passing it through a heat exchanger. of the fluid domain considered; hence, 𝜕Tf ∕𝜕ys = 0 . The
Pump/fan is used for the continuous circulation of air. Each heat lost from the trailing edge of the cell is negligible as
battery cell arranged in-line is considered as a prismatic the top of the prismatic cell consists of cathode and anode
cell of rectangular cross section dissipating heat flux to the current collector [15].
surrounding. The physical problem of thermal management in bat-
tery cells under consideration shown in Fig. 1 is reduced
to a two-dimensional computational domain, as shown in
Mathematical formulation Fig. 2. Axis of symmetry is considered for the solid and fluid
domain to perform the computational analysis. The temper-
The physical model shown as a schematic view in Fig. 1 is ature distribution in the cell is solved by the steady-state
further made plain by considering a symmetric model of conduction equation with heat generation q‴ W m−3. The
the battery cell, as shown in Fig. 2a. The physical domain temperature distribution in the fluid domain is solved using
considered here is a set of battery cells with air as coolant the steady-state energy equation considering the continuity
flowing past it. The heat generation is considered to be of heat flux and the same temperature at the interface of the

Baery cells /
Baery power
surrounding coolant

surrounding coolant
Heat flux to the

Heat flux to the

Coolant passage
Heat generaon in the
flowing

flowing
baery

Fan/pump

Coolant passage

Baery cells Coolant flowing

(a) Compact battery module with a stack of battery cells and coolant (b) Heat flux from the
passages battery cell surface

Fig. 1  Schematic view of the arrangement of battery cells with air circulation fan and heat generation in batteries

13
Thermal management of modern electric vehicle battery systems (MEVBS)

Fig. 2  The symmetric battery


(prismatic cell) and coolant flow
domain considered for computa-
Coolant flowing Extended outlet domain lo
tional analysis

Physical domain under


considera on
Baery cell

Baery cell

Baery cell

Baery cell
L

Ws Wf

X
Coolant flowing Extended intlet domain Y li

solid and fluid bodies. The energy conservation equation of represent energy and momentum equations in non-dimen-
the battery cell at a steady state is given by Eq. 1. sional form

ks ∇2 T + q��� = 0 (1) X = 0; 0 ≤ Ys ≤ 1,T̄ s = 0

Ys = 0; 0 ≤ X ≤ 1,
𝜕 T̄ s
To solve the energy conservation of the fluid domain =0
Ys = 1; 0 ≤ X ≤ 1, T̄ s = T̄ f
using a SIMPLE algorithm, the continuity and momentum 𝜕X
(9)
equations in 2-D considered are given below in Eqs. 2–4,
X = 1; 0 ≤ Ys ≤ 1,
respectively. 𝜕 T̄ s
=0
𝜕Ys
∇u = 0 (2)
The extended inlet and outlet domains of the coolant as
1
(u∇u) = − ∇p + 𝜇∇2 u (3) shown in Fig. 2 are represented by length lo and li, respec-
𝜌 tively. The purpose of considering these extra domain
regions is to capture the formation of vortices when the fluid
u∇T = 𝛼∇2 T (4) interacts with bottom portion of the battery cell. The ther-
mal and flow outflow field are located in the extended outlet
Using the reference fluid flow properties like u∞ , T∞ domain at the downstream of the cell trailing edge. This is
and geometric variables like L, ws , wf , the above equations considered to enforce physically meaningful supplementary
are non-dimensionalized. The non-dimensional form of conditions.
energy, continuity and momentum equations are given below
− Li ≤ X ≤ 0 and L ≤ X ≤ Lo
(Eqs. 5–8) Yf = 1;
𝜕 T̄ f
= 0,
𝜕U
= 0, V=0
𝜕Yf 𝜕Yf

Yf = 1;0 ≤ X ≤ L,
𝜕 T̄ s
2 T̄
𝜕2 𝜕Tf 1 𝜕Ts
2
+ C 2s + CS̄ q = 0 (5) 𝜕Yf
=
𝜁cc 𝜕Ys
, U = 0, V=0
𝜕X 𝜕 Ys
Yf = 1 + W f ; − Li ≤ X ≤ (L + Lo ),
𝜕 T̄ f 𝜕U
= 0, V = 0, =0
𝜕Yf 𝜕Yf
∇U = 0 (6) X = −Li ;1 ≤ Yf ≤ (1 + W f ), T̄ s = 0, U = 1, V=0

X = L + Lo ;1 ≤ Yf ≤ (1 + W f ),
𝜕 T̄ s 𝜕U
1 2 = 0, = 0, V=0
U∇U = −∇P + ∇U (7) 𝜕X 𝜕Yf
Re (10)
The non-dimensional terms considered for the above non-
1 dimensional equations and boundary conditions 5–10 are
U∇Tf = ∇2 Tf (8)
Re Pr as follows:
Equations 9 and 10 are the boundary conditions applied The non-dimensional term appearing in Eq. 5 is given by
for battery cell and coolant domain, respectively, so as to

13
A. Afzal et al.

L q��� w2s on available literature considering the dimensional values


C = 4Ar2 , Ar = , S̄ q = , mentioned in Table 1. Even though the non-dimensional range
2ws ks (To − T∞ )
obtained is very wide as mentioned in Table 1, but selected
T − T∞ x y
T= , X = , and Ys = s range for these non-dimensional parameters is decided such
T 0 − T∞ L ws
as S̅q varying from 0.1 to 1.0, Re from 250 to 2000, ζcc from
The non-dimensional terms in continuity and momentum 0.06 to 0.1, Ar from 10 to 30, and W̅f from 0.06 to 0.14.
Eqs. 6–8 are defined as

u v p u∞ L 𝜈
U=
u∞
, V=
u∞
, P=
𝜌u2∞
, Re =
𝜈
, Pr =
𝛼 Numerical solution

The non-dimensional terms appearing in boundary condi- The dimensionless form of continuity Eq. 6 and momentum
tions (Equation 10) are defined as Eq. 7 are to be coupled; hence, they must be solved simul-
taneously. The conduction Eq. 5 and energy Eq. 8 are com-
li lo yf wf kf [ ws ]
Li = , Lo = , Yf = 1 + , Wf = , 𝜁cc = bined as the conjugate condition (continuity of heat flux and
L L L L ks L temperature) at the interface of solid and fluid body should
(11) be satisfied and hence are also solved together after obtain-
According to the Newton’s law of cooling, the heat flux ing the velocity and pressure components till the error is
at the interface is given by, below ­10e−6. The main issue in solving the continuity and
momentum equation is the presence of pressure term P. To
𝜕T ||
−k = h(Ty=ws − Tf,m ) counter this problem staggered grid method in the finite vol-
𝜕Y ||y=ws
ume method (FVM)-based SIMPLE algorithm procedure was
where T̅f, m is the mean temperature of the fluid domain and adopted to solve these equations. The second-order accurate
T̅s is the cell surface temperature. Using appropriate dimen- central differencing scheme was employed to discretize the
sionless parameters, the local ­Nux is obtained, which is inte- equations. The U* and V* velocity components arrived in
grated over the cell surface length to get ­Nuavg. the pressure correction procedure are solved by the line-by-
line Gauss–Seidel iteration method and Thomas algorithm
1 𝜕T || considering the boundary conditions mentioned earlier and
Nux = − | guessed pressure P*. The pressure correction P′ equation
(T Y=W − T f,m ) 𝜕Y ||Y=Ws
s
(12) obtained employing the continuity equation is solved by the
𝜕T || successive over-relaxation (SOR) method using the calcu-
1

∫0 (T
1
Nuavg = − | dX
− T f,m ) 𝜕Y ||Y=Ws lated U* and V* velocity from the previous computations.
The corrected pressure P′ calculated to satisfy the continuity
Y=W s

It is important to note that in this work, the thermal per- equation is further used to correct the guessed U*, V*, and
formance characteristics of the conjugate problem associated P*. At this stage, the temperature T̄ S from the 2-D conduction
with battery cell cooled by air (Pr = 0.7) are carried for five equation with source term S̄ q and the energy equation for T̄ f
non-dimensional parameters obtained from above mathemati- are solved simultaneously using the obtained corrected U, V,
cal modeling. Those five parameters are: volumetric heat gen- and P values from the previous computations. Line-by-line
eration (S̅q), conduction–convection parameter (ζcc), Reynolds Gauss–Seidel iteration method and the Thomas algorithm
number (Re), Aspect ratio (Ar), and spacing between the bat- are used for solving the T̄ of the solid and fluid domain. The
tery cells (W̅f). The range of these parameters is decided based U, V ,and P values are used as a guessed value for the next

Table 1  Parameters used for numerical analysis and their non-dimensional range obtained
Parameter Dimensional range from literature References Non-dimensional
range obtained

Volumetric heat generation 406 W m−3 to 2 × 106 W m−3 (uphill condition) [1, 47, 48] S̅q = 0.001 to 1.5
Thermal conductivity of battery cell 3.4 W m−1 K−1 to 240 W m−1 K−1 [32, 49, 50] ζcc = 0.042 to
38.55
Fluid velocities 0.001 to 10 ms−1 [24, 53] Re = 15 to 133500
Dimensions of battery cell Length: 10 mm to 521.1 mm, Width: 52.9 mm to 167 mm [48–50] Ar = 3 to 30

13
Thermal management of modern electric vehicle battery systems (MEVBS)

iteration with some under relaxation and so on until the error considered to be external flow with Re = 2500, S̅q = 0.5 and
in the continuity equation and T̄ is < 10e−6. 0.75, Ar = 15, and ζcc = 0.35.

FVM code validation


Results and discussions
The FVM code developed exclusively to solve conjugate
problems for different conditions is numerically experi- In batteries, if the maximum temperature in the battery cell
mented for grid independence to capture the sharp tem- exceeds the critical threshold temperature value, then it leads
perature gradients at the interface. A grid size of 42 × 82, to severe damage of the battery module [42, 55]. This maxi-
62 × 122, 82 × 162 for the fluid domain, and grid size of mum temperature again depends on the working parameters
82 × 82, 82 × 122, and 122 × 122 for the cell domain were and has to be analyzed carefully. According to the definition
applied to obtain the numerical data for analysis. The of dimensionless temperature T̅ of solid from Eq. 11, if T
obtained T̄ values were found to overlap at these three differ- = To where To is the maximum allowable temperature of the
ent grid sizes; however, the figure is not added for the sake battery cell, then T̅ of solid becomes equal to unity, which
of brevity. In view of computational time taken by the code should not be crossed. Hence considering some of the above
and accuracy of the solution, the grid size of 62 × 122 for the listed facts the present work is intended to analyze in detail
fluid domain and 82 × 122 for the cell domain were finalized. the effect of these parameters on the thermal management of
The numerical results presented in this paper are obtained prismatic battery cells and the effect of same on the varia-
using indigenous code which can take care of various bound- tion of maximum temperature. The cell dimensions, thermal
ary conditions, by choice of appropriate input variables. conductivity, and flow velocity also varies largely depending
Therefore, the code is validated initially with the great on the working processes. In this study, the flow of air as
benchmark lid-driven cavity problem of Ghia et al. [52] for coolant is considered to be laminar, being circulated by the
the U and V velocity profiles. Figure 3a shows that the U fan continuously. In all the cases, the fluid width (spacing
and V velocity at the centerline of the cavity at Reynolds between the cells) W ̄ f is kept constant at 0.1 unless otherwise
number (Re) = 100 and are in complete agreement with stated. Also, the effect of W ̄ f on pressure distribution and
those of Ghia et al. [52]. Figure 3b shows the velocity con- pressure drop is studied at the end of this section. Effect on
tour at Re = 1000, having the primary vortex and the center average Nusselt number (Nuavg) for different Re and ζcc is
and secondary vortices at the bottom corners. Secondly, the also investigated.
temperature distribution was validated with the work avail-
able in literature close to the present work. Jahangeer et al. Effect of different parameters on transverse
[53] and Ramis and Jilani [54] analyzed the thermal behav- temperature distribution in battery cell
ior of nuclear fuel element considering the external flow of
fluid over the uniformly and non-uniformly heat-generating The dimensionless temperature T̅s for dynamic parameters
plates. The existing FVM code is also found to match with like S̅q, Re, ζcc, and Ar during the working process of Li-ion
their results in both the cases of heat generation at the axial battery prismatic cell is discussed as follows, one by one.
center of the fuel element (Fig. 4). Note that the flow was Figure 5 shows the change in T̅s away from the center of

Fig. 3  Validation of the present 1 1


FVM code with Ghia et al. [52]
at a Re = 100 and b Re = 1000 0.8 U velocity (Ghia et al. [1982])
0.8
FVM code
0.6
V velocity (Ghia et al. [1982])
0.6
0.4 FVM code
Y

0.2 0.4

0
0 0.2 0.4 0.6 0.8 1 0.2
– 0.2
0
– 0.4 0 0.2 0.4 0.6 0.8 1
X
(a) U and V velocity variation at the centerline of (b) velocity contour showing vortex at the
cavity center and bottom corners

13
A. Afzal et al.

0.9 the cell surface is considerable at higher S̅q and almost neg-
0.8 ligible at lower S̅q. Hence, it is noteworthy that for lower S̅q,
0.7
for a standalone cell, lumped thermal model can be assumed
for analysis, as made by Huang et al. [31] and few others
0.6
[48, 51, 56].
0.5 Another essential fact to be noted from Fig. 5 is that,
0.4 Jahangeer et al. [2007]
as we increase S̅q, the maximum temperature at the axial
T ̅s

0.3 Ramis & Jilani [2008] center reaches unity and, on the further increase, crosses this
Ramis & Jilani [2008]
FVM code limit. This condition is known as crossing the critical thresh-
0.2
FVM code old of temperature at which thermal runaway occurs as the
0.1 FVM code
maximum allowable limit To is crossed. At this higher tem-
0 peratures, oxygen gets released from the cathode and some-
0 0.2 0.4 0.6 0.8 1
Ys times may get reacted with electrolyte, which is flammable.
This leads to various damages like leakage of electrolyte,
Fig. 4  Validation of present work with the work of Jahangeer et al.
poor performance, explosions, power fade, self-discharge,
[53] and Ramis and Jilani [54] capacity fade, etc. [3, 7, 57]. Hence, it is very important
to keep the volumetric heat generation rate well below this
limit, which is possible by avoiding overcharging and over-
1.4 Sq̅ = 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 0.10 discharging, choosing proper cooling mechanism, hybrid
S̅q mode operation at full load conditions, etc. [13]. Inappro-
1.2
priate cooling mechanism, if the flow velocity, i.e., Re is
1 increased, it results in a reduced temperature, but this again
demands increased fan power for the fast circulation of air.
0.8
The effect of Re on temperature is provided ahead, which
T̅s

0.6 will offer a better understanding.


0.4
The change in temperature T̅s for increasing conduction-
convection parameter ζcc from 0.06 to 0.1 is shown in Fig. 6
0.2 when the other parameters were kept constant at S̅q = 0.5,
0 Re = 750, and Ar = 10. Figure 6 shows clearly that ζcc has
0 0.2 0.4 0.6 0.8 1 a major impact on the reduction in temperature of the cell.
Ys
We can see that as the value of ζcc is slightly increased from
0.06 to 0.07, a sharp difference in temperature is observed.
Fig. 5  Variation of temperature away from the center of battery at Unlike in the case of the effect of S̅q shown in Fig. 5, the
X = 0.5 for different heat generations (S̅q)
difference in temperature is found to be uniform throughout
the cell thickness for all values of ζcc. However, as the value
the cell (for different Y locations) taken at the axial center of ζcc is increased, the difference in temperature reduces
(X = 0.5) position. The parameters are kept constant to Re monotonically. This shows that with an increase in ζcc, there
= 750, ζcc = 0.06, and Ar at 10, while the heat generation is an increase in thermal conductivity of the coolant flowing
parameter is varied from 0.1 to 1.0 with which temperature past the cell where the other terms S̅q, Ar, and Re are held
also increases significantly. However, the increase in temper- constant.
ature at the axial center is more prominent compared to the At this moment, an important aspect to be thought is that
temperature at the surface of the cell. This makes clear that if the value of ζcc is further increased, we may get a negligi-
the peak temperature occurs at the axial location of the cell, ble difference in temperature difference, putting a limit on
with a maximum value at the trailing edge. Similar tempera- the maximum value of ζcc. This is caused due to the fixed
ture profiles in the battery cell along the transverse direction thermal conductivity of the battery cell, and indeed there
for different C-rates are reported by Richter et al. [32] and will be a limit on the heat dissipation rate from the cell sur-
Dincer et al. [1]. Note that these studies were related to bat- face past which it cannot be enhanced. Indeed, it can also
tery cell aging and phase change material and not on the be deduced that decreasing ζcc will cause a thermal runaway
conjugate model, as in this case. The temperature difference situation. It should be noted that irrespective of the increase
ΔT̅s observed at the axial center is 1.22 relative to ΔT̅s = 0.75 in ζcc, if the heat generation is increased due to overcharg-
at the cell surface which due to the heat carried by the air at ing, then surely the peak temperature exceeds the allow-
the interface. It is also seen that the temperature difference able threshold value. It is notably observed that a specific
between the peak value at the center and minimum value at range has to be chosen for ζcc to avoid the thermal runaway

13
Thermal management of modern electric vehicle battery systems (MEVBS)

Fig. 6  For different ζcc and Ar, 0.7


Effect of
0.7
change in temperature away different Ar
0.65
from the center of the battery at 0.65
X = 0.5 0.6

0.55 0.6 Ar
0.5
0.55

T̅s

T̅s
0.45
ζcc = 0.06
0.4 0.5
= 0.07
0.35 = 0.08
= 0.09 0.45 Ar = 10, 15, 20, 25, 30
0.3 = 0.10 Effect of ζcc
0.25 0.4
0 0.2 0.4 0.6 0.8 1
Ys

0.95 rate caused due to higher convection effects at higher Re.


Re = 250
0.85 = 500 Similar to effect of ζcc, the trend followed is seen to be same
= 750 for different Re. At higher Re, the temperature difference is
0.75 = 1000
= 1250 very less as the heat dissipation from the cell surface is lim-
0.65
= 1500
= 1750
ited. The same effect is also seen in work of Mahamud and
= 2000 Park [58] and Tong et al. [26]. Therefore, further increase
T ̅s

0.55
in Re will simply demand in higher fan power for fast air
0.45 circulation. The peak temperature at the X = 0.5 is within
Re
0.35 the allowable limit of unity; however, further reduction in
flow velocity will lead to critical condition. From Fig. 7, an
0.25
0 0.2 0.4 0.6 0.8 1 important remark is that the behavior of temperature dis-
Ys tribution is with respect to when S̅q, ζcc, and Ar are con-
stant at 0.5, 0.06, and 10, respectively. Any increase in S̅q
Fig. 7  Effect of Re on temperature variation away from the center of or decrease in ζcc will cause a jump in peak temperature
battery at X = 0.5 causing thermal runaway situation as seen in Figs. 5 and 6.

Maximum and critical temperature analysis


situation when the other parameters are kept fixed. Hence for variations in Re, S̅q, ζcc and Ar
the value of ζcc gives an insight into the selection of proper
coolant at various heat generation loads. The measurement of critical temperature variations, along
The effect of aspect ratio Ar on the temperature profiles with a change in operating parameters, is of prime impor-
is shown in the inset of the same Fig. 6. It can be seen that tance to prevent the situation of thermal runaways in bat-
when the severely effecting parameters like S̅q = 0.5, ζcc teries. A large number of studies reported on battery cell
= 0.06, and Re = 750, as discussed in preceding results, performance generally perform the study of thermal runaway
are fixed the effect of Ar on the temperature difference is by investigating the maximum temperature rise in the cell
minor. The temperature variation for an increase in Ar is under different circumstances. In this study, the effect of
found to be the same throughout the cell width. Thus, it can operating parameters in some ranges is considered for the
be concluded that the temperature distribution in the cell examination of maximum temperature and critical threshold
is independent of Ar while the other parameters are fixed. (T̅s> 1) in a battery cell.
Figure 7 depicts the effect of Re on the variation of trans-
verse temperature profiles at X = 0.5, while S̅q, ζcc, and Ar Effect of Re for various S̅q, ζcc and Ar
are constant to 0.5, 0.06, and 10, respectively. It is clearly
noticeable that the temperature profiles in Figs. 6 and 7 are Figure 8 shows how the maximum temperature decreases
of the same nature, and also the temperature reduction is with an increase in Re irrespective of S̅q while ζcc and Ar
monotonous for an increase in Re from the center of the are fixed to 0.06 and 10, respectively. The reduction in maxi-
cell to its surface. Reduction in temperature is very sharp at mum temperature is very prominent when the Re 250 to
lower Re, whereas it is very less at higher Re. The decrease 750 and later the reduction remains monotonous. A huge
in temperature distribution is by increased heat dissipation alteration in maximum temperature along the increase in Re

13
A. Afzal et al.

2.5
Critical threshold be considered to be safe, and upon increase in Re will bring
larger values of S̅q within allowable limit. However, higher
S̅q = 0.1, 0.2, 0.3, 0.4, 0.5,
2
0.6, 0.7, 0.8, 0.9, 0.10 values of S̅q are always not preferable which calls for higher
Sq̅
Re leading to greater maintenance cost. The maximum tem-
1.5 perature location is found to be at the top of cell middle
portion and nearer to the negative electrode, and the mini-
T̅max

1
mum temperature location is always at the bottom of the cell
where the coolant comes in the first contact. The same nature
0.5
of temperature location is found by Bai et al. [22].
The reduction in maximum temperature with increasing
0
250 500 750 1000 1250 1500 1750 2000 ζcc (Fig. 9) is found to be of a similar trend as in Fig. 8.
Re Again, the effect of Re at lower values of 250 and 500 on
maximum temperature is found to be above and close to the
Fig. 8  Maximum temperature in battery cell varying with Re and S̅q critical value. For Re ≥ 750, the effect is to reduce maximum
temperature smoothly till Re = 2000. With the increase in
ζcc, a further decrease in maximum temperature is seen, and
from 250 to 2000 with an increase in S̅q can be observed. when ζcc ≥ 0.08 below critical temperature is obtained for
Initially, at Re = 250, a large portion of cell temperature all values of Re. The decline in maximum temperature with
remains above the critical threshold, whereas a large portion an increase in ζcc is attributed to the fact that there is a pos-
of cell temperature for Re = 2000 is within the allowable sible increase in thermal conductivity of the coolant flowing
limit. Due to the increase in fast heat removal from the sur- past the cell surface. Nevertheless, with an increase in ζcc,
face of cell-associated with higher Re, the cell temperature the reduction in maximum temperature, which is uniform
comes under a safe portion. for all Re, is noticed to be reducing. A decrease in ζcc at
Another point to be witnessed is that as Re increases the lower Re will undoubtedly lead to an increase in maximum
maximum temperature gradient reduces for entire range temperature, causing thermal runaway harshly. Thus ζcc for
of S̅q. For lower values of S̅q and lower Re, the maximum fixed S̅q = 0.5, Ar = 10, and the entire range of considered
temperature becomes flatter much earlier compared to the Re is found to reduce the maximum temperature except at
maximum temperature at higher values of S̅q and Re. Hence Re = 250. This puts a limit on ζcc at lower Re. For full load
in order to keep the battery module safer, higher Re would discharging or overcharging situations where S̅q> 0.5 and
be preferred but demands extra fan power for air circulation. Ar> 10, the effect of ζcc on maximum temperature has to be
The difference in maximum temperature ΔT̅max at Re analyzed. This will be discussed in the forthcoming section.
= 750 and Re = 250 is significantly higher than the ΔT̅max In Fig. 9, along the secondary axis, the effect of differ-
at Re = 750 and Re = 2000. A similar nature in a variation ent Ar is also plotted for Re ≥ 250. The magnified view of
of T̅max for an increase in airflow velocity is reported by maximum temperature for increasing Ar is shown on the
Rao et al. [27] and Tong et al. [26]. Therefore, Re≤ 750 right side of Fig. 9. Like in the case of temperature distribu-
is not preferable for a significant portion of S̅ q seems tion shown in Fig. 6, the effect on maximum temperature is
to be highly dangerous as the maximum temperature is similar in this case. However, due to the nature of Re, it will
immensely beyond the safe limit. Re ≥ 750 and S̅q≤ 0.6 can

Fig. 9  Effect of ζcc and Ar on 1.2 1.2


maximum temperature for vary- Critical threshold
ing airflow Re at S̅q = 0.5 and 1.1
1.1
Ar = 10 Effect of
1 different Ar
Effect of ζcc 1 Ar
0.9
T̅max

0.8 0.9
T̅max

0.7
0.8
0.6
0.7 Ar = 10, 15, 20, 25, 30
0.5
ζcc = 0.06, 0.07, 0.08, 0.09 0.10
0.4 0.6
250 500 750 1000 1250 1500 1750 2000
Re

13
Thermal management of modern electric vehicle battery systems (MEVBS)

undoubtedly reduce the maximum temperature as in all cases 1.7


Ar
described in the preceding results. 1.5

1.3
Effect of S̅q for various ζcc and Ar at fixed Re = 750 1.1 Ar = 10
= 15
0.9

T̅max
The effect of heat generation parameter S̅q on maximum = 20
= 25
0.7
temperature along with increasing ζcc for each S̅q is shown in = 30
Fig. 10. It is very clear from Fig. 10 and the previous inter- 0.5
Critical threshold
pretations that there is an increase in maximum tempera- 0.3
ture with each S̅q and decreases with ζcc. Linearly increasing 0.1
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
maximum temperature with S̅q is impacted by ζcc at different
Sq̅
rates. As ζcc is reduced from 0.06 to 0.10, the reduction in
maximum temperature also reduces. Like in effect of ζcc
Fig. 11  Negligible effect of Ar on maximum temperature with
(Figs. 6 and 9), it is understood that the decrease in maxi- increasing S̅q
mum temperature reduces and further becomes minimal,
putting a restriction on higher values of ζcc. One remark-
able point to be noticed is that by increasing ζcc from 0.06 Effect of ζcc for different Ar at fixed S̅q = 0.5 and Re = 750
to 0.10, the maximum temperature at S̅q = 0.6 to 0.8 comes
under the safe limit. However, a slight decrease in ζcc from For a change in ζ cc, the maximum temperature varia-
0.06 will abruptly increase the maximum temperature well tion for different Ar is depicted in Fig. 12. A very slight
beyond the critical threshold. increase in maximum temperature is noted initially at Ar
If a comparison is made between Figs. 8 and 10, it can = 10 to 15. There onwards, with the increase in Ar negli-
be inferred that when ζcc = 0.06 and S̅q = 0.8 to 1.0 for the gible effect on maximum temperature irrespective of any
entire range of Re, the maximum temperature crosses the value of ζcc, is seen. The fact behind this involves under-
critical limit which introduces severe thermal abuse circum- standing the nature of total heat generation in the battery
stances and other several harms. To avoid this severe prob- cell. Ar, according to the definition mentioned in Eq. 11,
lem if ζcc is increased with a slight increase in Re, it will is the ratio of cell dimension along the X-axis (L) to the
cause the maximum temperature to reduce below the critical Y-axis (w). Hence, irrespective of the increase in H or
limit. Till S̅q = 0.5, no change in ζcc is also allowable but decrease in w, the total heat generation per unit volume
turns out to be substantial after S̅q> 0.5, and there onwards remains constant, which causes the same temperature dis-
increase in both Re and ζcc will show there major impression tribution in the cell. Even though it is noticeable that for
on reducing the maximum temperature. On the other hand, all values of Ar, the effect of ζcc remains the same; ζcc
for any value of S̅q> 0.5 or S̅q< 0.5, no effect of Ar is seen should not be reduced below 0.06, which leads to a sharp
on reducing the maximum temperature as shown in Fig. 11. increase in maximum temperature irrespective of Ar and
Hence it is deduced from this description that except Ar, the other parameter remaining constant.
other parameters have a very crucial role in controlling and
avoiding the thermal runaway state.

1.7

1.5 0.85
Critical threshold
1.3
0.8 Ar
1.1
T̅max

0.9 0.75
ζcc = 0.06
T̅max

0.7 = 0.07
Ar = 10
= 0.08 0.7 = 15
0.5 = 0.09
= 20
= 0.10 = 25
0.3 0.65 = 30
0.1
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 0.6
S̅q 0.06 0.07 0.08 0.09 0.1
ζcc

Fig. 10  Reduction in maximum temperature for different ζcc with


increasing S̅q Fig. 12  Maximum temperature with increasing ζcc and Ar

13
A. Afzal et al.

39 4 W̅f = 0.06 45
Re = 0.08 ζcc

Average pressure drop (∆Pavg)


3.5
34 Re = 250 = 0.10
= 0.12 40
= 500 3
29 = 0.14
Average pressure (Pavg )

= 750 ζcc = 0.06


= 1000 2.5 = 0.07 35

Nuavg
24 = 1250 = 0.08
= 1500 2 = 0.09
Effect of ζcc
19 = 1750 = 0.10 30
1.5 on Nuavg
= 2000
14 1
25
0.5
9
W̅f
0 20
4 250 500 750 1000 1250 1500 1750 2000
0 0.2 0.4 0.6 0.8 1
Re
X

Fig. 14  Increase in average Nu and reduction in pressure drop with


Fig. 13  Pavg variation along the channel for different Re increase in flow Re

Effect of Re on pressure variations and average step of 0.01 a significant decrease in Pavg is obtained for
Nusselt number (Nuavg) all Re monotonously. Later, for larger W̅f the decrease in
Pavg is seen to be reducing and becomes less significant.
The average pressure variations (Pavg) along the channel From this, it can be deduced that there is an upper limit-
length is shown in Fig. 13, varying Re from 250 to 2000. ing value of W̅f beyond which the pressure drop becomes
For very low Re, the hydrodynamic boundary layer grows negligible and any increase in W̅f will result in large size
slowly, and the boundary thickness penetrates deeper along of the battery module. Another most important feature to
the channel width. This creates full development of flow will be understood is that for higher Re and even at smaller W̅f
be very close to the leading edge of the channel plates, i.e., the pressure drop looks very near to each other. Hence for
cell surfaces. This causes a substantial drop in pressure from Re> 1250, the W̅f does not have much role in reducing the
the leading edge to the trailing edge. When the Re is slowly pressure drop. From the same Fig. 14 along the secondary
increased, the full development of flow will move away from axis, the improvement in average Nusselt number (Nuavg)
the leading edge as the thickness of the boundary layer stays is plotted for increasing Re and ζcc. Nuavg was computed
closer to the surface, causing less drop in pressure. As seen from the below Eq. 12.
from Fig. 13, the pressure gradient at all locations is linear The Nuavg shown in Fig. 14 improved significantly for all
for all Re. But, the pressure gradient is quite noticeable at Re increasing Re as the convective heat transfer coefficient
= 250 and becomes much flatter as Re is increased. None- improves with it. The effect on ­Nuavg for increasing ζcc is
theless, the change in Pavg is highest between Re = 250 and also shown in the magnified view. As the effect of ζcc is
500 and sharply reduces from there onwards. For Re> 750, found to be negligible on Nuavg, the lines overlap. The fact
the difference in Pavg remains very minimal. Hence, there is behind this is that the difference between interface tempera-
no advantage in simply increasing Re in terms of pressure ture T̅Y=Ws and the fluid mean temperature T̅f, m reduces, and
|
drop. Also seen from the past observations that at higher also the derivative 𝜕T | decreases significantly with an
𝜕Y |
Re the difference in temperature obtained is very less. As |Y=Ws
concluded earlier from Fig. 7 that simply increasing Re will increase in ζcc which is evident from the previous results.
not be advantageous for reducing the temperature; combined This reduction in both the quantities is in such a way that
with this increasing Re will also cause no improvement in their ratio remains constant locally. However, ­Nuavg can be
pressure reduction. Henceforth, this puts a strict restriction improved by decreasing the W̅f as the fluid mean temperature
on the limit of higher Re. decreases, driving more heat to transfer from the cell sur-
Figure 14 provides the variation of average pressure face. For larger W̅f, the effect of presence of another parallel
drop (Pavg) along with Re and for increasing fluid width cell is not felt and the thermal boundary layer does not get
(W̅f) domain, i.e., the spacing between the battery cells. developed, and hence, the problem becomes like an external
W̅f is varied from 0.06 to 0.14, and for each fluid width, flow situation in which the fluid mean temperature is low
Re is increased from 250 to 2000. It is quite apparent to less. Therefore, in either cases, i.e., pressure variations and
note that with increasing Re the Pavg reduces drastically Nuavg, the effect of both Re and W̅f is significant. However,
and a sharp drop in seen from Re = 250 to 750 for all W̅f, increasing Re has its upper limit for larger W̅f whereas for
which is also evident from previous Fig. 13, then onwards Nuavg investigation is required.
remain smooth. Next, when W̅f is slowly increased in the

13
Thermal management of modern electric vehicle battery systems (MEVBS)

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