Numerical investigation on positional optimisation of extra air channels for conventional battery cooling models

Abstract Currently, as the use of electric vehicles is rapidly increasing, the battery pack that powers the system is one of the most important issues. Li-ion batteries are the most preferred battery type because of their high energy density, fast-charging capabilities, and long life. However, the heat generated by the current drawn by the system affects battery performance and poses safety risks. Effective battery thermal management systems (BTMSs) are required to quickly remove this heat from battery packs. For this purpose, three different models were created by adding extra air inlet channels to three points on the 4 × 6 battery module, and their cooling efficiency was investigated. Numerical analyses of the models were performed using the Ansys Fluent software package, and comparisons were made both among themselves and with the conventional model. The models (Basic Model, Model A, Model B and Model C) were analyzed at four different Reynolds numbers (10 4 , 2 × 10 4 , 3 × 10 4 , and 4 × 10 4 ) calculated according to the air velocity and channel cross sections. Based on these results, the calculated Nusselt number (Nu), temperature values, friction factor, pressure drop, and PEC (performance criteria) values were obtained. Compared to the Base Model, the most effective methods were determined as Model A, Model B and Model C, respectively. Adding extra cooling channels to the battery module resulted in at least a 23.86% increase in Nu numbers, 40% lower pressure drop, and a 3.5% PEC number.