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

Abstract

In the context of the global transition towards new energy vehicles, the thermal management of battery packs has become a critical technical challenge, particularly under fast-charging and extreme operating conditions. This study aims to address the thermal runaway risks associated with battery packs by developing a refined thermal management system model based on multi-physics coupling simulation technology. A three-dimensional geometric model incorporating battery cells, thermal interface materials, and cooling plates was constructed using CT scanning data to accurately represent the internal structure of the battery module. Through fluid-solid-thermal coupling simulations conducted with STAR-CCM+ software, the temperature distribution and heat dissipation patterns within the battery pack were analyzed under varying coolant flow rates and environmental temperatures. Furthermore, an optimization of the cooling plate channel structure was performed employing the particle swarm optimization algorithm, leading to the proposal of a dynamic thermal control strategy. The simulation results demonstrate that the optimized thermal management system effectively reduces the maximum temperature during fast charging and maintains a minimal temperature difference across the battery pack. These findings provide a reliable simulation basis for the engineering design of battery thermal management systems in new energy vehicles, contributing to enhanced safety and performance.