IJSDIP | International Journal of System Design & Info Processing

Optimization of Electric Vehicle Battery Cooling Systems: Improving thermal management using advanced fluid dynamics simulations

Paper ID:

IJSDIP_2025_VOLUME 13_ISSUE 4_87-93

Author's Name:

Dr. J. Pavalavana Pandian, Dr. Ch. Tirumala Rao, Dr. E .Manikandan, Dr. Rabi J

Volume:

Issue:

Issue 4

Year:

2025

Pages:

87-93

Abstract

The thermal management of electric vehicle (EV) batteries is an essential point when it comes to the safety, performance, and life of the battery. The higher the power density of lithium-ion battery packs, the less the ability of traditional air and liquid cooling methods to deliver uniform temperature distribution to the battery pack, reducing the efficiency and causing a risk of thermal runaway. In this paper, the researcher has introduced optimization-based study based on the application of advanced Computational Fluid Dynamics (CFD) simulation to improve cooling in EV battery thermal management system. A number of cooling arrangements were modeled and compared such as liquid cold plate, phase change materials and hybrid convection conductive. The parameters, which are targeted by the study are the coolant flow rate, channel geometry, and material thermal conductivity that would reach the optimal level of temperature uniformity and energy efficiency. The findings show that the optimum serpentine microchannel liquid cooling design minimized the peak cell temperature by up to 28 percent relative to the traditional designs with minimum pressure drop. Yet, the practical constraints are a higher level of complexity of the system, the higher cost of manufacturing, and the issue of coolant maintenance. Further studies to create nanofluid-based coolants, adaptive control systems coupled with real-time temperature measurements, and scalable manufacturable geometries should be focused in future work in order to create a balance between performance and cost and scalability.

Keywords

Electric Vehicle (EV); Battery Thermal Management System (BTMS); Computational Fluid Dynamics (CFD); Liquid Cooling; Thermal Optimization; Energy Efficiency; Microchannel Design

References

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DOI: https://doi.org/10.64971/j.cph.ijsdip.v13.i4.13.2025