Thermal-Electric Coupling Simulation Analysis of Battery Busbar

With the advancement of new energy technologies, busbars in battery systems, as critical connecting components, play a vital role in system safety and efficiency. This study establishes a thermal-electric coupling model theory and response surface method for busbar, employing ANSYS Fluent software for simulation analysis to evaluate temperature variations under different operating conditions. The results indicate that under variable current charging, and constant voltage charging conditions, the highest temperatures of the Al busbar all occur at the central connection sections and remain within safe limits. Under the extreme melting current charging condition, the melting current of the Al busbar is approximately 734 A, with an error rate of $1.8 \%$. This research provides theoretical support and simulation methods for the design and selection of Al busbar, holding significant theoretical and practical implications.