CFD and Thermal Analysis of Electric Vehicle Battery Pack

Effective thermal management is imperative for maximizing battery lifespan and enhancing safety in Electric Vehicles (EVs). This study investigates the optimization of battery thermal management systems using Computational Fluid Dynamics (CFD) analysis in Ansys platform. This paper focuses on three key factors influencing battery cooling: cell placement geometry within the battery pack, use of heat sinks and spacing in between the fins around the radiator. The simulations compare the square 16-cell battery pack and the honeycomb 16-cell pack, effectiveness of heat sink designs with fins as opposed to without fins and explore the thermal performance of different spacing between the fins (5mm, 7.5mm, 10mm and 12.5mm) in radiators. The findings demonstrate that honeycomb structure results in lesser number of hotspots but overall cooling is provided by inline square battery back and heat sinks with fins provide better cooling efficiency. Furthermore, 7.5mm spacing in between fins provides optimal heat dissipation for both square and circular designs. These results provide valuable insights for designing and implementing improved thermal management systems in EVs, leading to safer batteries with extended life and optimal performance.