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Battery

Cooling

System

1

VCC BATTERY COOLING SYSTEMS

Battery

Cooling

System

Dynamic Modelling of Battery Cooling

Systems for Automotive Applications

A master’s thesis carried out 2013 at VCC by:

Fabian Hasselby

fabian.hasselby@volvocars.com

Date created: 2014-05-16 2

Battery

Cooling

System

Agenda

• Project Background

• Calibration

• Component Modelling

• Conclusions

Date created: 2014-05-16 3

Background Calibration Component Modelling

Conclusions

Battery

Cooling

System

External HX

Chiller

Pump

Project Background

Date created: 2014-10-07 4

Battery

Battery

Cooling

System

Project Background

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Battery

Cooling

System

Project Background

• Thermal management of battery systems is vital

• Optimum temperature range for Li-ion cells: 20 - 40 °C

• Thermal generation in battery cells

• Reaction heat, Joule heating, Polarisation heat

Date created: 2014-05-16 6

Battery

Cooling

System

Project Background

Objective of this study

• Develop an accurate model of the battery cooling system

• Balancing task focused on reducing the energy demand of

the system

Methodology

• Gather information and data regarding the system and its

components

• Model system components separately and combine these

later to from the overall system.

• Apply calibration methods to improve model predictions

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Battery

Cooling

System

- Calibration

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Background Calibration Component Modelling

Conclusions

Battery

Cooling

System

Calibration

Correlating model predictions to empirical data

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Battery

Cooling

System

Calibration

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DOE (Design of Experiments)

Battery

Cooling

System

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- Component Modelling

Background Calibration Component Modelling

Conclusions

Battery

Cooling

System

Component Modelling – Chiller

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Chiller

Battery

Cooling

System

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1 Pass- 3 Pass Plate Heat Exchanger

Component Modelling – Chiller

Battery

Cooling

System

• Nusselt heat transfer correlation for single phase

[Coolant Turbulent Coefficient]

[Coolant Turbulent Exponent]

• Shah-Thome correlation for evaporation in two phase

[Refrigerant Heat Transfer Multiplier]

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Component Modelling – Chiller

Battery

Cooling

System

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Component Modelling – Chiller

Battery

Cooling

System

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Battery

Component Modelling

– Internal Battery Cooling

Battery

Cooling

System

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Component Modelling

– Internal Battery Cooling

Battery

Cooling

System

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Component Modelling

– Internal Battery Cooling

Battery

Cooling

System

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- Conclusions

Background Calibration Component Modelling

Conclusions

Battery

Cooling

System

• Building accurate battery cooling system models for early

vehicle development can be done using 1D CFD modelling

• Having reliable experimental data becomes exceedingly

important when validating and fine-tuning model behaviour

to a high level of accuracy.

• Rigours calibration may, however, not always be necessary

and strongly depends on the detail and the purpose of

modelled system.

• 1D simulation is indispensable when it comes to analysing

large and complex systems

Date created: 2014-10-07 20

Conclusions

Battery

Cooling

System

- Thank you for your attention

Date created: 2014-05-16 21