Thermal Analysis on Module Level in an Automotive Battery Package

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Thermal Analysis on Module Level in an Automotive Battery Package Ziyi Wu M.Sc. 13

1 Thermal Analysis on Module Level in an Automotive Battery Package Ziyi Wu M.Sc FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

2 Content Motivation Ground Model Internal Cooling Fin External Water Cooling Summary FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH 13.1.

Motivation Individual batteries have their own Capacity Retention (%) operational temperature ranges Many Li-Ion cells do not function well above

AHR17M1Ultra graphite/lifepo cell from A3 Systems 1 9 7 6 5 3 1 1-1 - -3 C-Rate 6 1 C 1 3 5 6 7 Cycle Numbers 5 C 6 C C [Source: photo, ebaracus.

3 Motivation Individual batteries have their own Capacity Retention (%) operational temperature ranges Many Li-Ion cells do not function well above 6 C A good understanding of the thermal behavior of the batteries has its significance during designing safe and robust battery packages AHR17M1Ultra graphite/lifepo cell from A3 Systems C-Rate 6 1 C Cycle Numbers 5 C 6 C C [Source: photo, ebaracus.com] [Source: Linden s Handbook of Batteries] FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

Ground Model - Battery Module V battery module with a least

from K Energy - K165P1 Gap between + Pole and active material

Z [Source: K ENERGY] X Y FH AACHEN UNIVERSITY OF APPLIED

4 Ground Model - Battery Module V battery module with a least number of cells 15 identical cells High capacity power cell from K Energy - K165P1 Gap between + Pole and active material Current Conductor + Pole Cover - Pole Mandrel Cell Spacer Case Z [Source: K ENERGY] X Y FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH 13.1.

5 Ground Model - Load Profile Load profile is derived from the technical data Charging at C-rate Discharging at C-rate Cell Heating: Q Cell = I R Simulation duration: 1 3 second Current [A] SOC [%] SPECIFICATION Nominal C/5 (Ah) 1.5 Average Operating C/5 (V) 3. Internal 1kHz, AC (mω) <19 RECOMMENDED OPERATING CONDITIONS Continuous Discharge (A) 5. Charge Current (A) 1.5 High Operating Temp ( C) Low Operating Temp ( C) - MAXIMUM OPERATING CONDITIONS Continuous Discharge (A) 1 Charge Current (A). High Operating Temp ( C) 5 Low Operating Temp ( C) - [Source: K ENERGY] FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

Ground model Results Temperature - T ext = T = C Convective Heat Flux - q = h T ext T Constant htc = W (m K) 36 Temperature Gain of Hottest Cell Objective 1: T Cell T recommended operation Objective

6 Ground model Results Temperature - T ext = T = C Convective Heat Flux - q = h T ext T Constant htc = W (m K) 36 Temperature Gain of Hottest Cell Objective 1: T Cell T recommended operation Objective : T Cell_Max T CellMin 3 K ICF_ 3 T between Hottest and Coldest Cell XY-Cross Section s (K) FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

Internal Cooling Fin - Concept Temperature: T

T) Constant htc = W (m K) * Internal Cooling

Objective : T Cell_Max T Cell_Min < 3 K ICF_1

Fin (ICF) Concepts XY-Cross Section (mm ) 11.95.

5 FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES

7 Internal Cooling Fin - Concept Temperature: T ext = T = C Convective Heat Flux: q = h (T ext T) Constant htc = W (m K) * Internal Cooling Fin Objective 1: T Cell T recommended operation Objective : T Cell_Max T Cell_Min < 3 K ICF_1 ICF_ ICF_3 ICF_ ICF_5 ICF_6 Internal Cooling Fin (ICF) Concepts XY-Cross Section (mm ) Circumference (mm) FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

Internal Cooling Fin - Results ICF_1 ICF_ ICF_3 ICF_ ICF_5 ICF_6 36 Temperature Gain of Hottest Cell ICF_ 3 ICF_1_1 T between Hottest and Coldest Cell 1 1 1 6 ICF_3_1 ICF 1 ICF_5_1

8 Internal Cooling Fin - Results ICF_1 ICF_ ICF_3 ICF_ ICF_5 ICF_6 36 Temperature Gain of Hottest Cell ICF_ 3 ICF_1_1 T between Hottest and Coldest Cell ICF_3_1 ICF 1 ICF_5_1 ICF_6_1 ICF XY-Cross Section s (K) FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH 13.1.

ICF ICF_5_ ICF_6_ ICF 1 3.7 3.9 31. XY-Cross Section ICF @ s (K) 317.3 31.6 317.

9 Internal Cooling Fin - Results * Internal Cooling Fin 36 Temperature Gain of Hottest Cell ICF_ 3 ICF_1_1 T between Hottest and Coldest Cell ICF_3_1 ICF 1 ICF_5_1 ICF_6_1 ICF_1_ ICF_3_ ICF ICF_5_ ICF_6_ ICF XY-Cross Section s (K) FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

ICF_3_ ICF ICF_5_ ICF_6_ ICF 1 ICF 313.6 31. 3.5 XY-Cross Section ICF @ s (K) 313.9 31.5 31.

10 Internal Cooling Fin - Results ICF_1 ICF_ ICF_3 ICF_ ICF_5 ICF_6 36 Temperature Gain of Hottest Cell ICF_ 3 ICF_1_1 T between Hottest and Coldest Cell ICF_3_1 ICF 1 ICF_5_1 ICF_6_1 ICF_1_ ICF_3_ ICF ICF_5_ ICF_6_ ICF 1 ICF XY-Cross Section s (K) FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

11 ICF & External Water Cooling External Water Cooling * ICF_ Temperature - T ext = T = C Velocity: U W = 1 m s 1 Temperature Gain of Hottest Cell 3 T between Hottest and Coldest Cell ICF 1 1 ICF FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

12 ICF & External Water Cooling External Water Cooling * ICF_ Temperature - T ext = T = C Velocity: U W = 1 m s 1 Temperature Gain of Hottest Cell 3 T between Hottest and Coldest Cell ICF 1 1 ICF -3 ICF FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH 13.1.

13 Summary Simulative thermal analysis contributes in gaining knowledge of the cell heating during operational conditions a helpful step before conducting actual tests The simulation results show, the temperature distribution in the ground model of the battery module is greatly uneven differences in cell cycle life within the same battery module a shortened cycle life of the entire module Cooling systems for the battery module shall be considered as an indispensable component in battery systems for automotive applications Combine systems with different cooling principle shall be involved for large battery module a homogenous temperature distribution ensure the function of all cells FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

14 Thank you! FH Aachen University of Applied Sciences Faculty of Aerospace Engineering - Energy Storage Systems Ziyi Wu M.Sc. Hohenstaufenallee 6 56 Aachen Germany T F Wu@fh-aachen.de Prof. Dipl.-Ing. Hans Kemper Hohenstaufenallee 6 56 Aachen Germany T F H.Kemper@fh-aachen.de FH AACHEN UNIVERSITY OF APPLIED SCIENCES LES Lehrgebiet Energiespeichersysteme COMSOL CONFERENCE MUNICH

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