Hybrid Thermal Management Systems for EV Batteries

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 system’s 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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<div class="section abstract"><div class="htmlview paragraph">The electric vehicle thermal management system is a critical sub-systems of vehicles, and has substantial impact on the driving range. The objective this paper to optimize performance heat pump air conditioning system, battery, motor by adopting an integrated design. This approach expected effectively improve COP (Coefficient Performance) cabin heating. An model established using AMEsim. Key parameters, such as refrigerant temperature, pressure, flow rate at outlet each component are compared with measured data verify correctness in paper. Using model, compressor speed heating comfort under high-temperature conditions summer was studied, control strategy for rapid passenger compartment cooling proposed. Additionally, hybrid address priority issues battery cooling, traditional strategies terms time accuracy. results demonstrate that capable simultaneously if ambient temperature 40°C. Compared methods prioritize either or enables while maintaining comfort, significantly reduces discomfort passengers 64.25%.</... Read More

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<div class="section abstract"><div class="htmlview paragraph">Efficient thermal management is essential for maintaining the performance and safety of large-capacity battery packs. To overcome limitations traditional standalone air or liquid cooling methods, which often result in inadequate uneven temperature distribution, a hybrid air-liquid structure was designed. A three-dimensional model developed, heat transfer fluid flow characteristics were analyzed using computational dynamics (CFD) simulations. Experimental validation carried out through discharge rise tests on individual cells resistance plate. The system compared to that methods under various rates. results indicated significantly enhanced performance, reducing maximum difference by 5.54°C 3.37°C, peak 11.66°C 4.5°C, cooling, respectively, at 0.8C rate. effects key parameters, such as coolant rate, fan speed, channel width, depth, investigated. turbulence-inducing proposed further improve efficiency. optimized maintained temperatures differences below 35°C 5°C, 0.5C with reduction pressure drop 14.50 kPa. ... Read More

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Battery module for electric vehicles that has a secondary cooling system to quickly and effectively cool individual cells with thermal runaway to prevent catastrophic failures. The module has two coolant circuits, one inside the module and another connected to an external refrigeration unit. The internal circuit has a heat exchanger that cools the cells. If a cell overheats, the internal heat exchanger is activated. If it still overheats, the external circuit is activated to bring the cell temperature down faster. This prevents thermal runaway propagation and cell damage.

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Thermal management system for mobile vehicles like electric cars that eliminates the need for a separate battery heater. It uses the existing drive motor to heat the coolant circuit instead. When battery heating is needed, the motor is run with a current that causes it to generate heat. This heat is then transferred to the battery coolant through a heat exchanger. This allows battery temperature control without adding a separate heater.

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Modular thermal management system for electric machines like mining trucks that provides variable levels of cooling for batteries based on temperature and load conditions. The system uses independently operable cooling modules to selectively activate and balance cooling capacity based on battery temperature. This allows efficient and flexible cooling without overcooling or undercooling the battery. The cooling modules can be turned on/off and cycled to optimize cooling performance for different load profiles. The system also monitors battery temperature and identifies the optimal module configuration for active cooling.

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Battery pack module with improved cooling efficiency for electric vehicles. The cooling system has parallel coolant circulation bypasses for each battery pack, controlled by valves, along with temperature sensors. The valves are opened/closed based on pack temperature to selectively route coolant through the bypass or main line. This allows targeted cooling of individual packs based on actual temperature needs, instead of overall cooling.

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Battery pack cooling system with intelligent thermal management for electric vehicle batteries. The system uses a thermoelectric generator and semiconductor refrigeration modules to quickly dissipate heat during high-rate discharge and prevent heat accumulation. The modules are dynamically controlled by an electronic module. The thermoelectric generator absorbs heat from the battery and converts it to electrical energy. The refrigeration module rapidly cools the battery using electric refrigeration. This dual heat absorption/dissipation structure stabilizes battery temperatures during high-rate discharge.

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Thermal management system for vehicles that improves efficiency and functionality of the system for cooling batteries and cabin air conditioning. It uses multiple heat exchange circuits and a controller to optimize heat transfer based on battery temperature. The battery has separate circuits with heat exchangers, and the controller selects which circuit(s) to use. This allows customized heat exchange for different battery areas. The controller can also control a storage device to supplement circuits as needed. This adaptive multi-circuit design improves battery cooling efficiency and reduces energy consumption compared to a single circuit.

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An active liquid cooling system for electric vehicle battery packs using high thermal conductivity aluminum cold plates with unique design features to improve cooling performance, uniform temperature distribution, and avoid thermal runaway. The cold plates have a height of 30-60 mm and a contact angle of 120-150 degrees between the plates and battery cells. This design lowers the highest pack temperature, provides uniform cooling, and handles rapid discharge and load changes. The increased plate height and angle in the flow direction enhances cooling by lowering temperature gradients and providing more surface area.

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Battery thermal management system that integrates phase change materials, thermoelectric cooling, and liquid cooling to efficiently dissipate and preheat the battery pack in both hot and cold environments. The system has a core control module, temperature sensors, power supply module, thermoelectric module, and liquid cooling module. It switches between three working modes: refrigeration, shutdown, and heating based on battery temperature. In hot environments, the thermoelectric module cools the pack. In normal temps, the module stops. In cold, the module switches current direction to preheat. The power supply adjusts flow rate based on module heat capacity. This adaptive mode switching meets cooling/heating requirements in varying temps.

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