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Testing and Thermal Management System Design of an Ultra-Fast Charging Battery Module for Electric Vehicles / Battery Module Thermal Management System DesignZhao, Ziyu January 2021 (has links)
This thesis consists of three main objectives: fundamental and literature review of EV batteries, experimental development, and validation of two liquid cooling battery modules, thermal modeling and comparison of the inter-cell cooling battery module. / The traditional vehicles with internal combustion engine have resulted in severe environmental pollution, which motivates the development of electric vehicles and hybrid electric vehicles. Due to a low energy density and long refueling time of the battery pack, it is still hard for electric vehicles and hybrid electric vehicles to be widely accepted by the consumers. As the batteries with a better ultra-fast charging capability are massively produced, the range anxiety issue is somewhat alleviated.
During a charging with large current magnitude, the battery generally has a great amount of heat generation and evident temperature rise. Therefore, a thermal management system is necessary to effectively dissipate the battery loss and minimize the degradation mechanisms caused by extreme temperature. The motivation of this thesis is to study the discipline of the battery thermal management system as an application for electric vehicles. The design methodologies are presented in both experiment test and numerical simulation.
For the comparative study between active liquid cooling methods for a lithium-ion battery module using experimental techniques, two battery modules with three Kokam Nickel Manganese Cobalt battery cells connected in parallel are developed. One has liquid coolant flowing along the edge of the model, and another with liquid coolant flowing between the cells. Several characterization tests, including thermal resistance tests, fast charging tests up to 5C, and drive cycle tests are designed and performed on the battery module. The inter-cell cooling module has a lower peak temperature rise and faster thermal response compared to the edge cooling module, i.e., 4.1⁰C peak temperature rise under 5C charging for inter-cell cooling method and 14.2⁰C for edge cooling method.
The thermal models built in ANSYS represent the numerical simulation of the inter-cell cooling module as a comparison with the experiment. A cell loss model is developed to calculate the battery heat generation rate under ultra-fast charging tests and a road trip test, which are further adopted as the inputs to the thermal models. The simulation of the 5C ultra-fast charging test gives the peak temperature rise just 0.47⁰C lower than the experimental measurement, it indicates that the FEA thermal models can provide an accurate temperature prediction of the battery module. / Thesis / Master of Applied Science (MASc) / With a demanding market of electric vehicles, battery technologies have grown rapidly in recent years. Among all the battery research topics, the development of ultra-fast charging, that can fully charge the battery pack within 15 minutes, is the most promising direction to address the range anxiety and improve the social acceptance of electric vehicles. Nevertheless, the application of ultra-fast charging has many challenges. In particular, an efficient thermal management system is significant to guarantee the safety and prolong the service life of the battery pack. This thesis contributes to study the fundamentals of the battery field, and design liquid cooling systems to observe the thermal behavior of a battery prototype module under fast charging and general use. FEA thermal modeling of the battery module is developed to provide a guide for further test validation.
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Testing, Characterization, and Thermal Analysis of Lithium-Ion Batteries Toward Battery Pack Design for Ultra-Fast ChargingHe, Melissa January 2018 (has links)
Ultra-fast charging of electric vehicles will soon be available to charge the batteries in less than 15 minutes to 80% state of charge. However, very few studies of batteries under these conditions exist. To design a battery pack with ultra-fast charging in mind, more information about batteries is needed, both electrically and thermally. In this thesis, the performance of three specific commercial lithium-ion batteries during ultra-fast charging is investigated and their thermal behaviour is simulated for use in the battery pack design process. The cells are charged at 1C to 6C current rates, or as high as 10C, and the surface temperature of each cell is measured. The loss calculated from the charging tests are used in a thermal analysis of the three batteries using finite element analysis. The batteries are modeled in a simple cooling apparatus to determine their thermal management requirements in a pack, i.e., how effectively must the heat be removed from the cells to obtain a specific temperature in a pack. Test results show that ultra-fast charging is possible with very little loss; but, it is dependent on the battery. The analysis illustrates important trade-offs between the battery type, charge rate, and the thermal management system. This thesis presents a holistic view to the study of the batteries for eventual use in the design of a battery pack. The thermal performance of the batteries is equally important as their electrical (charge) performance. It also attempts to justify the observed behaviour of the batteries by their underlying chemical behaviour. The work here can be used as a jumping-off point for further work on the ultra-fast charging of batteries or the design of a battery pack. / Thesis / Master of Applied Science (MASc) / Ultra-fast charging of electric vehicles, i.e., fully charging the vehicle in less than 15 minutes, will soon be more available. However, literature on the ultra-fast charging of the batteries used in these vehicles is limited. It is not widely known whether the batteries can effectively achieve ultra-fast charging or how the batteries behave under these conditions. Charging batteries this fast means that the battery cells will heat up. The temperature of the cell greatly impacts its longevity and safety. The thesis attempts to address these questions by studying three commercial lithium-ion batteries, selected for specific characteristics, that show potential for ultra-fast charging. The batteries are charged at different rates to ultra-fast charging levels and the charge performance at each rate is determined. The temperature of the batteries is simulated with different cooling systems to determine how effectively must heat be removed from the batteries to maintain the cells at a specific temperature.
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