Thermal Management of Dry Batteries for Electric Vehicles

As electric vehicles (EVs) face increasing power demands, rapid charging requirements, and harsh operating conditions, efficient thermal management of lithium-ion batteries is critical for safety and performance. This study evaluates a liquid-cooled thermal management system for dry battery packs using computational fluid dynamics (CFD) simulations and experimentation. The battery pack was modeled in SolidWorks and analyzed using ANSYS Fluent. Simulation results showed a peak battery temperature of 47 °C, with coolant temperature rising from 17.1 °C to 37.4 °C, achieving a 10 °C reduction in battery temperature. Experimental validation yielded comparable outcomes, with a maximum battery surface temperature of 47.2 °C and coolant outlet temperature of 26.1 °C, indicating a 21.1 °C temperature drop. The strong correlation between simulation and experimental data confirms the system’s effectiveness in maintaining safe thermal conditions. Additionally, a low-cost prototype was developed, underscoring the practical viability and scalability of the proposed solution.