Integrated thermal and battery management for electric vehicles: Experimental validation and simulation-based optimization of lithium-ion batteries

Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, and long-term efficiency challenges. This study proposes an integrated thermal and battery management system that combines a water–ethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, and safety. Through COMSOL multiphysics simulations, this study examines LIB thermal behavior under varying operational conditions. The results indicate a 20% reduction in temperature peaks, with the battery maintaining an optimal temperature range of 15°C to 35°C, thus mitigating the risks of thermal runaway. Experimental validation using infrared thermography and thermal imaging confirms the system's efficiency, showing a maximum recorded battery temperature of 43.48°C under load conditions, significantly lower than unmanaged battery systems. Beyond thermal management, this work integrates advanced battery management strategies, including state-of-charge estimation, predictive fault diagnostics, active energy optimization, and cell balancing. Experimental analysis further reveals that the proposed system improves heat dissipation, resulting in a more uniform temperature distribution across the battery pack and reduced internal resistance-related losses. Additionally, infrared thermographic measurements demonstrate a 2°C to 3°C temperature uniformity improvement across battery cells, preventing localized overheating. This novel approach bridges the gap between cutting-edge cooling techniques and intelligent battery management, offering a scalable and cost-effective solution for next-generation EV battery systems. The findings have significant implications for enhancing battery safety, improving operational efficiency, extending battery lifespan, and accelerating global EV adoption.