Thermal Management of Electric Vehicle Battery Systems

Ibrahim Dincer is a full professor of Mechanical Engineering and director of Clean Energy Research Laboratory at UOIT. Renowned for his pioneering works in the area of sustainable energy technologies, including clean transportation options, he has authored/co-authored many books, book chapters, and refereed journal and conference papers. He has chaired national and international conferences, symposia, workshops and technical meetings and delivered many keynote and invited lectures. He is an active member of various international scientific organizations and societies, and serves as editor-in-chief, associate editor, regional editor, and editorial board member on various prestigious international journals. He is a recipient of several research, teaching and service awards, including the Premier's research excellence award in Ontario, Canada. He has recently been recognized by Thomson Reuters as one of The Most Influential Scientific Minds in Engineering.Halil S. Hamut is a Chief Senior Researcher at The Scientific and Research Council of Turkey (TÜBITAK) and the project manager for developing Turkey’s first brand of national electric vehicles. He received his PhD from the Faculty of Engineering and Applied Science, University of Ontario Institute of Technology in Canada, in 2013. He has previously collaborated with General Motors Company in Oshawa, Canada and worked for Ford Motor Company in Michigan, U.S.A He has published many journals and conference papers and has been a reviewer for several journals. His research interests are primarily concerned with exergy, exergoeconomic and exergoenvironmental analyses of electric and hybrid electric vehicle thermal management systems.

• Preface xiiiAcknowledgements xvii1 Introductory Aspects of Electric Vehicles 11.1 Introduction 11.2 Technology Development and Commercialization 21.3 Vehicle Configurations 41.3.1 Internal Combustion Engine Vehicles (ICEV) 41.3.2 All Electric Vehicles (AEVs) 61.3.3 Hybrid Electric Vehicles (HEVs) 71.3.4 Fuel Cell Vehicles (FCVs) 101.4 Hybridization Rate 101.4.1 Micro HEVs 111.4.2 Mild HEVs 111.4.3 Full or Power-Assist HEVs 121.4.4 Plug-In HEVs (or Range-Extended Hybrids) 121.5 Vehicle Architecture 131.5.1 Series HEVs 141.5.2 Parallel HEVs 141.5.3 Parallel/Series HEVs 141.5.4 Complex HEVs 151.6 Energy Storage System 151.6.1 Batteries 151.6.2 Ultracapacitors (UCs) 171.6.3 Flywheels 181.6.4 Fuel Cells 181.7 Grid Connection 201.7.1 Charger Power Levels and Infrastructure 201.7.2 Conductive Charging 211.7.3 Inductive Charging 221.7.4 Smart Grid and V2G/V2H/V2X Systems 231.8 Sustainability, Environmental Impact and Cost Aspects 271.9 Vehicle Thermal Management 281.9.1 Radiator Circuit 291.9.2 Power Electronics Circuit 291.9.3 Drive Unit Circuit 301.9.4 A/C Circuit 301.10 Vehicle Drive Patterns and Cycles 331.11 Case Study 341.11.1 Introduction 341.11.2 Research Programs 341.11.3 Government Incentives 351.11.3.1 Tax Benefits 351.11.3.2 EV Supply Equipment and Charging Infrastructure 361.11.3.3 EV Developments in the Turkish Market 361.11.3.4 HEVs on the Road 381.11.3.5 Turkey’s Standing in the World 391.11.3.6 SWOT Analysis 431.12 Concluding Remarks 43Nomenclature 44Study Questions/Problems 44References 452 Electric Vehicle Battery Technologies 492.1 Introduction 492.2 Current Battery Technologies 492.2.1 Lead Acid Batteries 512.2.2 Nickel Cadmium Batteries 522.2.3 Nickel Metal Hydride Batteries 522.2.4 Lithium-Ion Batteries 542.3 Battery Technologies under Development 572.3.1 Zinc-Air Batteries 592.3.2 Sodium-Air Batteries 602.3.3 Lithium-Sulfur Batteries 602.3.4 Aluminum-Air Batteries 612.3.5 Lithium-Air Batteries 612.4 Battery Characteristics 632.4.1 Battery Cost 632.4.2 Battery Environmental Impact 642.4.3 Battery Material Resources 682.4.4 Impact of Various Loads and Environmental Conditions 702.5 Battery Management Systems 722.5.1 Data Acquisition 752.5.2 Battery States Estimation 762.5.2.1 SOC Estimation Algorithm 762.5.2.2 SOH Estimation Algorithms 782.5.2.3 SOF Estimation Algorithms 782.5.3 Charge Equalization 782.5.3.1 Hierarchical Architecture Platform/Communication 802.5.3.2 Cell Equalization 802.5.4 Safety Management/Fault Diagnosis 812.5.5 Thermal Management 832.6 Battery Manufacturing and Testing Processes 832.6.1 Manufacturing Processes 832.6.2 Testing Processes 852.7 Concluding Remarks 88Nomenclature 88Study Questions/Problems 88References 893 Phase Change Materials for Passive TMSs 933.1 Introduction 933.2 Basic Properties and Types of PCMs 933.2.1 Organic PCMs 1003.2.1.1 Paraffins 1013.2.1.2 Non-Paraffins 1013.2.2 Inorganic PCMs 1023.2.2.1 Salt Hydrates 1023.2.2.2 Metals 1033.2.3 Eutectics 1043.3 Measurement of Thermal Properties of PCMs 1043.4 Heat Transfer Enhancements 1073.5 Cost and Environmental Impact of Phase Change Materials 1103.6 Applications of PCMs 1113.7 Case Study I: Heat Exchanger Design and Optimization Model for EV Batteries using PCMs 1143.7.1 System Description and Parameters 1143.7.1.1 Simplified System Diagram 1143.7.1.2 PCM Selection For the Application 1153.7.1.3 Nano-Particles and PCM Mixture For Thermal Conductivity Enhancement 1163.7.1.4 Thermal Modeling of Heat Exchanger 1173.7.2 Design and Optimization of the Latent Heat Thermal Energy Storage System 1193.7.2.1 Objective Functions, Design Parameters and Constraints 1193.7.2.2 Effective Properties of the PCM and Nanotubes 1193.7.2.3 Combined Condition 1213.7.2.4 Model Description 1213.7.2.5 Sensitivity Analysis 1213.7.2.6 Helical Tube Heat Exchanger 1273.8 Case Study 2: Melting and Solidification of Paraffin in a Spherical Shell from Forced External Convection 1283.8.1 Validation of Numerical Model and Model Independence Testing 1303.8.2 Performance Criteria 1333.8.3 Results and Discussion 1353.9 Concluding Remarks 141Nomenclature 141Study Questions/Problems 143References 1434 Simulation and Experimental Investigation of Battery TMSs 1454.1 Introduction 1454.2 Numerical Model Development for Cell and Submodules 1464.2.1 Physical Model for Numerical Study of PCM Application 1464.2.2 Initial and Boundary Conditions and Model Assumptions 1474.2.3 Material Properties and Model Input Parameters 1484.2.3.1 Li-ion Cell Properties 1484.2.3.2 Phase Change Material (PCM) 1494.2.3.3 Foam Material 1534.2.3.4 Cooling Plate 1534.2.4 Governing Equations and Constitutive Laws 1534.2.5 Model Development for Simulations 1554.2.5.1 Mesh Generation 1564.2.5.2 Discretization Scheme 1564.2.5.3 Under-Relaxation Scheme 1574.2.5.4 Convergence Criteria 1574.3 Cell and Module Level Experimentation Set Up and Procedure 1574.3.1 Instrumentation of the Cell and Submodule 1584.3.2 Instrumentation of the Heat Exchanger 1594.3.3 Preparation of PCMs and Nano-Particle Mixtures 1614.3.4 Improving Surface Arrangements of Particles 1634.3.5 Setting up the Test Bench 1644.4 Vehicle Level Experimentation Set Up and Procedure 1664.4.1 Setting Up the Data Acquisition Hardware 1664.4.2 Setting Up the Data Acquisition Software 1684.5 Illustrative Example: Simulations and Experimentations on the Liquid Battery Thermal Management System Using PCMs 1724.5.1 Simulations and Experimentations on Cell Level 1744.5.1.1 Grid Independence Tests 1754.5.1.2 Effect of Contact Resistance on Heat Transfer Rate 1764.5.1.3 Simulation Results For Li-ion cell Without PCM in Steady State and Transient Response 1774.5.1.4 Simulation Results For PCM in Steady-State and Transient Conditions 1804.5.1.5 Cooling Effectiveness In the Cell 1854.5.2 Simulation and Experimentations Between the Cells in the Submodule 1864.5.2.1 Effective Properties of Soaked Foam 1874.5.2.2 Steady State Response of the Cells in the Submodule 1884.5.2.3 Transient Response of the Submodule 1894.5.2.4 Submodule with Dry and Wet Foam at Higher Heat Generation Rates 1914.5.3 Simulations and Experimentations on a Submodule Level 1924.5.3.1 Steady-State Response of the Submodule Without PCMs 1934.5.3.2 Steady-State Results of the Submodule with PCMs 1964.5.3.3 Transient Response of the Submodule 1974.5.3.4 Quasi-Steady Response of the Submodule 1984.5.3.5 Model Validation 2014.5.4 Optical Observations 2034.5.4.1 Thermal Conductivity Enhancement by Nanoparticles 2034.5.4.2 Data For the Case of Pure PCM (99% Purity) 2084.5.4.3 Optical Microscopy Analysis of the PCM and Nanoparticle Mixture 2084.5.5 Vehicle Level Experimentations 2144.5.5.1 Test Bench Experimentations 2154.5.5.2 Test Vehicle Experimentations 2184.5.6 Case Study Conclusions 2254.6 Concluding Remarks 226Nomenclature 227Study Questions/Problems 228References 2295 Energy and Exergy Analyses of Battery TMSs 2315.1 Introduction 2315.2 TMS Comparison 2325.2.1 Thermodynamic Analysis 2335.2.2 Battery Heat Transfer Analysis 2375.2.2.1 Battery Temperature Distribution 2375.2.2.2 Battery Temperature Uniformity 2395.3 Modeling of Major TMS Components 2405.3.1 Compressor 2425.3.2 Heat Exchangers 2435.3.3 Thermal Expansion Valve (TXV) 2455.3.4 Electric Battery 2465.3.5 System Parameters 2465.4 Energy and Exergy Analyses 2475.4.1 Conventional Analysis 2475.4.2 Enhanced Exergy Analysis 2535.5 Illustrative Example: Liquid Battery Thermal Management Systems 2565.6 Case Study: Transcritical CO2-Based Electric Vehicle BTMS 2695.6.1 Introduction 2705.6.2 System Development 2725.6.3 Thermodynamic Analysis 2755.6.4 Results and Discussion 2765.6.5 Case Study Conclusions 2815.7 Concluding Remarks 282Nomenclature 282Study Questions/Problems 284References 2856 Cost, Environmental Impact and Multi-Objective Optimization of Battery TMSs 2876.1 Introduction 2876.2 Exergoeconomic Analysis 2886.2.1 Cost Balance Equations 2886.2.2 Purchase Equipment Cost Correlations 2906.2.3 Cost Accounting 2916.2.4 Exergoeconomic Evaluation 2936.2.5 Enhanced Exergoeconomic Analysis 2936.2.6 Enviroeconomic (Environmental Cost) Analysis 2946.3 Exergoenvironmental Analysis 2956.3.1 Environmental Impact Balance Equations 2956.3.2 Environmental Impact Correlations 2966.3.3 LCA of the Electric Battery 2976.3.4 Environmental Impact Accounting 2996.3.5 Exergoenvironmental Evaluation 3006.4 Optimization Methodology 3016.4.1 Objective Functions 3016.4.2 Decision Variables and Constraints 3026.4.3 Genetic Algorithm 3036.5 Illustrative Example: Liquid Battery Thermal Management Systems 3066.5.1 Conventional Exergoeconomic Analysis Results 3076.5.2 Enhanced Exergoeconomic Analysis Results 3096.5.3 Battery Environmental Impact Assessment 3146.5.4 Exergoenvironmental Analysis Results 3166.5.5 Multi-Objective Optimization Results 3196.5.5.1 Case Study Conclusions 3246.6 Concluding Remarks 325Nomenclature 326Study Questions/Problems 327References 3287 Case Studies 3297.1 Introduction 3297.2 Case Study 1: Economic and Environmental Comparison of Conventional, Hybrid, Electric and Hydrogen Fuel Cell Vehicles 3297.2.1 Introduction 3297.2.2 Analysis 3307.2.2.1 Economic Criteria 3307.2.2.2 Environmental Impact Criteria 3317.2.2.3 Normalization and General Indicator 3347.2.3 Results and Discussion 3357.2.4 Closing Remarks 3387.3 Case Study 2: Experimental and Theoretical Investigation of Temperature Distributions in a Prismatic Lithium-Ion Battery 3397.3.1 Introduction 3397.3.2 System Description 3407.3.3 Analysis 3417.3.3.1 Temperature Measurements 3417.3.3.2 Heat Generation 3427.3.4 Results and Discussion 3427.3.4.1 Battery Discharge Voltage Profile 3427.3.4.2 Battery Internal Resistance Profile 3437.3.4.3 Effect of Discharge Rates and Operating Temperature on Battery Performance 3447.3.4.4 Model Development and Validation 3447.3.5 Closing Remarks 3507.4 Case Study 3: Thermal Management Solutions for Electric Vehicle Lithium-Ion Batteries based on Vehicle Charge and Discharge Cycles 3517.4.1 Introduction 3517.4.2 System Description 3517.4.3 Analysis 3527.4.3.1 Design of Hybrid Test Stand For Thermal Management 3527.4.3.2 Battery Cooling System 3567.4.3.3 Sensors and Flow Meter 3567.4.3.4 Compression Rig 3567.4.3.5 Battery 3597.4.3.6 Thermal Management System – Experimental Plan and Procedure 3597.4.3.7 Data Analysis Method 3617.4.4 Results and Discussion 3647.4.4.1 Battery Surface Temperature Profile 3657.4.4.2 Average Surface Temperature of Battery 3667.4.4.3 Average Heat Flux 3687.4.4.4 Peak Heat Flux 3697.4.4.5 Heat Generation Rate 3697.4.4.6 Total Heat Generated 3737.4.4.7 Effect of Discharge Rate and Operating Temperature on Discharge Capacity 3737.4.5 Closing Remarks 3747.5 Case Study 4: Heat Transfer and Thermal Management of Electric Vehicle Batteries with Phase Change Materials 3757.5.1 Introduction 3757.5.2 System Description 3757.5.3 Analysis 3787.5.3.1 Exergy Analysis 3787.5.3.2 Numerical Study 3797.5.4 Results and Discussion 3797.5.4.1 CFD Analysis 3797.5.4.2 Part II: Exergy Analysis 3857.5.5 Closing Remarks 3887.6 Case Study 5: Experimental and Theoretical Investigation of Novel Phase Change Materials For Thermal Applications 3897.6.1 Introduction 3897.6.2 System Description 3907.6.2.1 Experimental Layouts 3937.6.2.2 Challenges 3977.6.3 Analysis 3977.6.3.1 Analysis of Constant Temperature Bath 4027.6.3.2 Analysis of Hot Air Duct 4027.6.3.3 Analysis of Battery Cooling 4037.6.3.4 Energy and Exergy Analyses 4037.6.4 Results and Discussion 4077.6.4.1 Test Results of Base PCM 4087.6.4.2 Results of Battery Cooling Tests 4107.6.4.3 Results of Energy and Exergy Analyses on Base Clathrate 4127.6.4.4 Results of Thermoeconomic Analysis 4157.6.5 Closing Remarks 417Nomenclature 419References 4238 Alternative Dimensions and Future Expectations 4258.1 Introduction 4258.2 Outstanding Challenges 4258.2.1 Consumer Perceptions 4258.2.2 Socio-Technical Factors 4278.2.3 Self-Reinforcing Processes 4298.3 Emerging EV Technologies and Trends 4318.3.1 Active Roads 4318.3.2 V2X and Smart Grid 4328.3.3 Battery Swapping 4338.3.4 Battery Second Use 4358.4 Future BTM Technologies 4378.4.1 Thermoelectric Materials 4378.4.2 Magnetic Cooling 4388.4.3 Piezoelectric Fans/Dual Cooling Jets 4388.4.4 Other Potential BTMSs 4408.5 Concluding Remarks 441Nomenclature 441Study Questions/Problems 441References 442Index 445