Intelligent Thermal Management of Electric Vehicle Batteries Using Controlled Liquid Immersion Cooling System

Thermal runaway in electric vehicle (EV) batteries poses a significant challenge, often leading to reduced performance, safety hazards, and increased operational costs. As EV adoption grows, ensuring efficient thermal management is crucial to prevent battery degradation and extend lifespan. At the same time, there are concerns about battery deterioration when the temperature drops, especially due to lithium plating. This phenomenon can severely impact battery capacity and performance, further complicating thermal management and safety in cold climates. Traditional cooling systems often fail to address the rapid temperature fluctuations experienced during various driving conditions, leading to inefficiencies and potential safety risks. To address these challenges, this research introduces a novel intelligent active liquid immersion cooling system designed specifically for EV batteries. This system has been meticulously designed and validated using Ansys simulation software, providing critical insights into its performance under different operating conditions. The simulation results were further employed to train an Artificial Neural Network (ANN) controller, which dynamically adjusts PID controller gain values in real-time to optimize the cooling process. This integration of ANN with PID controllers in a MATLAB Simulink environment ensures that the cooling system adapts to varying thermal loads, thereby enhancing battery performance while optimizing HVAC power consumption. By maintaining optimal battery temperatures, this system not only improves energy efficiency but also significantly mitigates the risk of thermal runaway and lithium plating, contributing to safer and more reliable EV operation across different vehicle types.