Abstract

In this study, a liquid-cooled Battery Thermal Management System (BTMS) incorporating aluminum heat-conducting blocks was numerically investigated to enhance the thermal performance of lithium-ion battery modules used in electric vehicles. The proposed system was designed for a battery module consisting of cylindrical lithium-ion cells, and the effects of different geometric configurations on thermal behavior were analyzed using the Computational Fluid Dynamics (CFD) method. To efficiently evaluate the multi-parameter design space with reduced computational cost, a Taguchi L9 orthogonal experimental design was employed. The cooling channel configuration, aluminum heat-conducting block height, and battery pack geometry were considered as the primary design variables. The performance of each design configuration was assessed based on maximum temperature (Tmax) and temperature uniformity (ΔT). Furthermore, an Analysis of Variance (ANOVA) was conducted to quantify the influence of the design parameters on the thermal performance of the system. The results revealed that the configuration comprising eight cooling channels, a 65 mm aluminum block height, and a 1 + 8 cylindrical battery arrangement exhibited the best thermal performance, achieving a maximum temperature of 303.45 K and a temperature difference of 1.25 K. The optimal design configuration provided a more uniform temperature distribution within the battery module, thereby enhancing thermal safety and operational reliability. Overall, the integration of CFD and the Taguchi method offers a systematic and efficient optimization framework for BTMS design, enabling effective evaluation of design alternatives with a reduced number of simulations and shorter computational time.

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