Modeling and Simulation of Thermal Management System for New Energy Vehicle Battery Pack in Vehicle Engineering

Abstract

Thermal management of battery packs is one of the most vital technical challenges leading towards any new energy vehicles in global transition, especially for fast-charging and extreme operating conditions. In this paper, the research for a fine thermal management system model by means of multi-physics coupling simulation technology is conducted to solve the safety defect of battery packs, which is thermal runaway. A 3D geometric model that accurately describes the internal structure of the battery module is built from CT scanning data, including: cell, thermal interface materials, and cooling plates. By means of the fluid-solid-thermal coupling simulations with STAR-CCM+ software, the distribution of temperature in the battery pack and its heat dissipation behavior at various coolant flow rates and environment temperatures were evaluated. Furthermore, a cooling plate channel structure optimization was carried out with an application of the particle swarm optimization algorithm and a new strategy for dynamic temperature treatment was proposed. The results of the simulation indicate that this configuration brings together a much-needed reduction in maximum temperature during fast charging, alongside maintenance of minimal temperature difference across the battery pack, for any ambient temperature. These results can be used as a reliable simulation basis for the engineering design of battery thermal management systems in new energy vehicles, and to improve their safety and efficiency.