Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit

<div class="section abstract"><div class="htmlview paragraph">Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system.</div><div class="htmlview paragraph">dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed an 11% deviation between experimental and simulation results, confirming the system’s reliability.</div><div class="htmlview paragraph">This study emphasizes the importance of precise flow management for enhancing battery life and provides a scalable solution for optimizing the thermal management of electric vehicles.</div></div>