Fast simulation and parameter tuning optimization for full three-dimensional modeling of wound lithium-ion battery

With the continuous advancement of lithium-ion battery (LIB) technology, simulation models have become essential for LIBs design, optimization, and applications. However, existing methods face challenges, including inadequate accuracy, high computational costs, and limited data dimensionality. To overcome these limitations, this study proposes a high-accuracy, full three-dimensional (3D) electrochemical-thermal coupled model for wound LIBs, using the 18650 LiFePO 4 (LFP) cell as the representative case. Furthermore, a strategy for fast simulation and parameter tuning optimization is proposed. First, a cross-dimensional (CD) mapping methodology is developed to bridge the pseudo-two-dimensional (P2D) model and the full 3D model, facilitating accelerated parameter tuning and screening. Second, a “medium-high temperature first, then low temperature” systematic tuning strategy is proposed, with critical sensitive parameters second fine-tuned to improve model accuracy. Compared to conventional methods, this approach reduces computational time by approximately 30 min per simulation. The results show that at 25 °C, the maximum error in terminal voltage is less than 12 mV, with the root mean square error (RMSE) below 4 mV, and the maximum error in temperature rise is less than 0.4 °C, with the RMSE below 0.17 °C. At 0 °C, the maximum error in terminal voltage is less than 10 mV, with the RMSE below 3.5 mV, and the maximum error in temperature rise is less than 0.3 °C, with the RMSE below 0.14 °C. These results demonstrate that the proposed simulation and parameter tuning strategy effectively enhances simulation efficiency, while the developed model accurately characterizes the electrochemical-thermal coupled behavior of LIBs. • Establishing the cross-dimensional relationship along the thickness direction • Proposing the “medium-high temperature first, then low temperature” tuning strategy • The full three-dimensional wound lithium-ion battery model shows very high-accuracy.