Optimization of an innovative cooling system for motorsport application

Martellucci, Leone; Capata, Roberto · 2024 · DOAJ

DOI: 10.1016/j.ijft.2024.100944

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Summary

This study addresses the critical challenge of thermal management in high-performance electric vehicle battery packs, specifically within the context of Formula Student motorsport applications. These applications are characterized by high power-to-energy ratios and demanding charge/discharge cycles that generate significant heat via the Joule effect. The authors propose and optimize an innovative hybrid cooling system that combines forced air convection with Phase Change Materials (PCM) to maintain lithium-ion cylindrical cells within their optimal operating temperature range (20–40°C) and prevent thermal runaway. The research methodology involved a two-phase approach using Computational Fluid Dynamics (CFD) simulations via ANSYS Fluent. First, the team optimized the forced-air cooling configuration for a battery module containing 126 Sony US18650VTC6 cells arranged in an 18s7p configuration. Key variables optimized included the radial gap between cells (tested at 1.5 mm, 2 mm, and 2.5 mm) and airflow velocity (ranging from 3 m/s to 11 m/s). Simulations were conducted under constant current discharge conditions at 1.5 C-rate and 3 C-rate. Second, the study integrated PCM pouches placed on the module busbars to act as a thermal booster, leveraging the high axial thermal conductivity of the cylindrical cells to absorb latent heat. The CFD results demonstrated that minimizing the cell spacing to 1.5 mm yielded the best thermal performance by improving airflow uniformity and convective heat transfer. At a 1.5 C-rate, a 1.5 mm gap with 6 m/s airflow resulted in a maximum cell temperature of 23.7°C and a temperature difference (ΔT) of 2.5°C. At a 3 C-rate, the optimal configuration (1.5 mm gap, 11 m/s airflow) achieved a maximum temperature of 32.4°C and a ΔT of 6.2°C. However, experimental validation during the 2022 Formula Student Endurance test revealed discrepancies; cells reached nearly 60°C due to higher-than-simulated heat generation (1.3 W/cell vs. 1.2 W), high ambient temperatures (35°C), and delayed fan activation. These findings motivated the integration of PCM for the 2023 season to passively absorb excess heat and delay the onset of critical temperatures. The significance of this work lies in the development of a low-cost, lightweight, and reliable thermal management solution suitable for high-performance electric racing. By combining active forced-air cooling with passive PCM storage, the system aims to mitigate the limitations of air cooling alone, such as sensitivity to ambient conditions and airflow delays. The study provides specific design parameters for cell spacing and airflow rates, offering a validated framework for optimizing battery thermal performance in applications where weight and cost constraints preclude liquid cooling systems.

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