Hybrid Thermal Management Systems for EV Batteries

The thermal management system (TMS) of electric vehicles (EVs) plays a pivotal role in vehicle performance, driving range, battery lifespan, and passenger comfort. Precise control compressor speed, informed by real-time sensor data, is essential for improving TMS efficiency extending EV range. This study proposes strategy based on the PID Search Algorithm (PSA), ensuring optimal an integrated cabin TMS. A co-simulation platform combining AMESim Simulink developed validation, utilizing various sensors to monitor performance. Simulations are conducted under target temperatures 20 C 25 replicate operating conditions. optimized compared with most commonly used controllers, fuzzy strategies. results demonstrate that PSA-Optimized significantly outperforms other three For C, shows minimal temperature overshoot 0.012 COP improvements 0.06, 0.04, 0.03 strategies, respectively. further reduced 0.010 while coefficient performance (COP) increases 0.14, 0.01, 0.07 relative same benchmarks. Overall, indicate effectively utilizes data reduce overshoot, stabilize speed fluctuations, slow decay ... Read More

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Electric vehicle thermal management system that improves safety and efficiency compared to traditional systems. The system has two loops for cooling/heating the battery and driving motor. A release mechanism allows converging the two loops when a battery thermal runaway occurs, with both fluids released into the battery to cool/extinguish it. During normal operation, a heat exchanger transfers heat from the driving motor to the battery loop. This uses motor waste heat to warm the battery instead of external power.

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To address the challenges of high flow resistance and poor temperature uniformity in conventional PCMliquid cooling hybrid heat exchangerswhich significantly impair performance lifespan electronic devicesa topology optimization approach was adopted. A dual-objective function, aimed at minimizing average pressure drop, introduced to reconstruct channel layout PCM filling region. two-dimensional transient thermo-fluid model coupling solidliquid phase-change process with coolant transfer established, alongside development an experimental platform. comprehensive comparison performed against a liquid plate straight channels. The results showed that topology-optimized exhibited drop 15.80 Pa pumping power 1.19 104 W, representing reductions 38.28% 38.02%, respectively. solidification time shortened by 6 min. Under these conditions, convective coefficient (hw) evaluation criterion (j/f) optimized reached 1319.06 W/(m2K) 0.56, which corresponded increases 60.71% 47.5%, configuration improved overall performance. As inlet velocity increased from 0.05 m/s 0.2 m/s, hw 38.65%... Read More

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This study presents a Model Predictive Control (MPC) strategy for the Battery Thermal Management System (BTMS) in electric vehicles (EVs) to optimize energy efficiency while maintaining battery temperature within optimal range. Due complexity of BTMS dynamics, high-fidelity model was developed using MATLAB/Simscape(2021a), and an artificial neural network (ANN)-based designed achieve high accuracy with reduced computational load. To mitigate oscillatory control inputs observed conventional MPC, infinity-horizon MPC framework introduced, incorporating value function that accounts system behavior beyond prediction horizon. The proposed controller evaluated simulation environment against rule-based under varying ambient temperatures. Results demonstrated significant savings, including 78.9% reduction low-temperature conditions, 36% moderate temperatures, 27.8% high-temperature environments. Additionally, effectively stabilized actuator operation, improving longevity. These findings highlight potential ANN-assisted enhancing performance minimizing consumption EVs.

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Solid-state battery module for efficient temperature control using resonant wireless charging. The module has the battery, a resonant capacitor, and wireless power circuitry all mounted on one side of a substrate. This allows the capacitor to directly heat the battery using resonant charging. The capacitor is sandwiched between low thermal conductivity components to isolate and concentrate the heat. A thermally conductive path connects the capacitor to the battery. This enables efficient battery heating using wireless charging without needing a separate heating element.

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Battery system with improved thermal management to increase efficiency, cell life, and uniformity. The system has a cell holder with a fluid circuit through the cell stack obstructed by the cells. An unobstructed fluid circuit runs alongside the stack. Valves allow controlling fluid flow to the cell stack vs. side channel. This allows separate cooling/heating of the stack vs. side channel. For example, a non-dielectric fluid can circulate around the cells during low load, while a dielectric fluid circulates inside the stack during high load. This provides flexibility in fluid selection and flow distribution for optimal thermal management.

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An electric motor with integrated cooling using a heat-transfer fluid to extract heat from the motor and transfer it to a heat engine or battery pack. The motor has an enclosed cavity with bearings and a bell-shaped lid covering the rear bearing. The lid has an internal chamber around the motor cavity with fluid inlet/outlet for circulating the heat-transfer fluid. This allows direct cooling of the motor without external connections. The fluid circuit connects the motor, heat engine, and batteries for efficient heat management.

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Vehicle drive device with improved cooling of high-voltage components like power lines and bus bars in electric vehicles. The device has an oil passage with an ejection hole to direct oil from the hydraulic pump toward the power lines and bus bars. This provides direct oil cooling of these hot components instead of relying on gravity flow from a closed oil passage. The ejected oil helps cool the components and prevent overheating, reducing the need for increased cooling capacity in the case. It also avoids issues like oil adherence and corrosion that can occur with immersion or oil applications.

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Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, long-term efficiency challenges. This study proposes an integrated battery management system that combines a waterethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, safety. Through COMSOL multiphysics simulations, this examines behavior under varying operational conditions. The results indicate 20% reduction temperature peaks, maintaining optimal range of 15C 35C, thus mitigating risks runaway. Experimental validation using infrared thermography imaging confirms system's efficiency, showing maximum recorded 43.48C load conditions, significantly lower than unmanaged systems. Beyond work integrates advanced strategies, including state-of-charge estimation, predictive fault diagnostics, active optimization, cell balancing. analysis further reveals proposed improves heat diss... Read More

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Abstract With the rapid development of liquid cooled charging technology, thermal management gun electric vehicle has also become an urgent challenge to be solved. In this paper, accurate simulation model is developed by correcting conductivity and heat generation through integration experimental results. Subsequently, experiment designed with current, coolant inlet flow, temperature, ambient temperature as variables, from which a series results are obtained. Utilizing these training set, reduced order for predicting established. The influence multi-layer perceptron model, response surface gaussian process on prediction accuracy then compared. indicate that compared other two models, more significant advantage in fitting nonlinear average error 1.61 C. This study holds importance intelligent devices.

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The rapid evolution of electronic systems and battery technologies in vehicles necessitates advanced thermal management strategies to ensure optimal performance safety. This paper presents a comprehensive review (TMS), comparing conventional methods such as air liquid cooling with emerging techniques like phase change materials (PCMs), heat pipes, systems. While traditional offer simplicity cost- effectiveness, they often struggle limited dissipation capacity inefficiencies under high loads. In contrast, modern TMS provide enhanced regulation, faster absorption, better adaptability varying conditions. study identifies key limitations, including implementation costs system complexity, while highlighting the scope for integrating nonmaterial's smart technologies. Methodologies, tools, simulation used development are outlined. Expected outcomes include improved lifespan, energy efficiency, vehicle concludes by emphasizing critical role innovative advancing automotive technology..

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Abstract: Electric vehicle battery performance and lifespan are critically dependent on effective thermal management, with excessive temperatures leading to accelerated degradation safety risks. While most existing systems employ active cooling methods, this study investigates an alternative approach using adaptive speed control as a means of passive regulation. The proposed model focuses controlling energy discharge rates through motor modulation based real-time temperature feedback, offering potentially simpler more energy-efficient solution compared conventional systems. This paper presents simulation-based implementation regulation system that adjusts in response variations. core innovation lies field-oriented (FOC) the traction limit current when critical thresholds. A mathematical establishes relationship between reduction consequent heat generation decrease, demonstrating how controlled power output can maintain safe operating temperatures. architecture incorporates sensor inputs processed by Arduino Uno microcontroller, which calculates appropriate references prevent overload... Read More

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Demand-responsive operation of an electric traction drive system that maximizes range and efficiency by dynamically managing cooling, heating, and lubrication. The traction drive has an electric motor-driven pump connected to multiple fluid outlets for cooling, heating, and lubrication. The pump can operate in two directions. By selectively opening and closing valves and switching pump direction, the fluid flow rate and volume can be optimized for each component based on operating conditions. This allows demand-responsive cooling, heating, and lubrication tailored to the electric motor's thermal needs at each power level.

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Using electric vehicles (EVs) to precool buildings and optimize energy usage. The bi-directional EV can provide energy to a building during peak demand times when grid electricity costs are high. It can calculate the required energy to cool the building and start transferring it when the EV has enough battery charge. This allows the building to avoid drawing expensive grid power during peak hours. The EV can also precool the building before leaving, reducing the initial load on the HVAC system when it returns.

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Cooling electric vehicle components like motors and generators by integrating the cooling system into the vehicle structure instead of using external coolers. The cooling fluid passes through the components and then exchanges heat with a secondary fluid within the vehicle structure, like a strut between the component and the body. This allows cooling without needing external coolers or ducts.

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Batteries with improved performance, durability, and safety for electric vehicles and other applications. The batteries have features like phase change materials, thermally conductive articles, and housing designs that mitigate heat generation and cell expansion during charging/discharging. The phase change materials absorb excess heat from cells, cooling them. Thermally conductive articles align cells and facilitate heat transfer. Uniform pressure distribution is achieved by housing components. These features allow high energy density batteries with reduced deleterious effects of lithium metal cells.

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Scheduling battery conditioning of electric vehicles to optimize performance and range in cold temperatures without requiring specific knowledge of the battery chemistry or drivetrain configuration. A vehicle scheduler coordinates between the battery management system, thermal management system, and vehicle dynamics control to condition the battery to the right temperature for driving by having the vehicle dynamics request the required current demand, which the battery management system converts into a temperature requirement, and then the thermal management system heats the battery fluid to meet that temperature. This allows agnostic conditioning that works across different battery chemistries and drivetrain configurations.

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Battery system for electric vehicles with improved thermal management and containment during thermal runaway events. The system uses a cover plate with insulation layers between the cells to prevent contamination and arcing if venting gas escapes. The cover plate has a rigid structural layer sandwiched between thermal insulation layers. It covers the top of the cells and fixes to crossbeams between them. This prevents cell movement and allows venting through dedicated exits. The insulation layers protect against vented gas escaping onto the cells.

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Abstract Automotive industries showed keen interest in the temperature control system of batteries. There exist varieties commercial electric vehicles, which offer battery cooling technologies with active systems as potential solutions. The creation such devices would need careful consideration physical structure and arrangement cells. However, any case, it is fundamental to have a mechanism for safe operational working all In industry automotive conversion there exists strong passion Lithium-ion control. already considerable variety vehicles on market, offering that rely active-removal possible development will definitely demand pack's architecture be carefully re-examined. final analysis, clearly come out fact necessary batteries function 'safety' mode. current study aims review strategies using air thermal energy storage improve performance hybrid vehicles. comparison capacity management (BTMS) various designs thoroughly examined. This article tries helpful guidance designing air-cooled phase change material (PCM) cooled BTMS optimal performance.

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Abstract This paper proposes a gravity heat pipe-air hybrid temperature control system to address the inadequate dissipation in power batteries under high-rate discharge conditions when using single cooling methods. The systems performance was evaluated for series-arranged battery packs at rates above 5C. Results show that effectively meets thermal management requirements 3-cell 5C, but as number of cells increases seven, degrades, with uniformity exceeding 5 C threshold, leading failure. To resolve this, C-shaped configuration adopted improved pack arrangement. Further analysis demonstrates optimized manages up 7C within air span 20 35 C.

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