Level set topology optimization of load carrying battery packs

Abstract

In this study, the optimum design of load carrying battery packs that can also exchange heat with a coolant is presented. The level set topology optimization method is used as the design tool. The flow is modeled using the Darcy potential flow, and the heat transfer is modeled using the convection-diffusion equation. The displacement field is computed using a thermo-elasticity model. A multi-objective optimization is used that minimizes a linear combination of structural compliance, average temperature of the battery cells, and the pressure drop across the coolant. As numerical examples, we present a design study of a load carrying battery pack module that is placed inside an aircraft wing. The efficiency of the optimized designs are demonstrated by showcasing their multifunctional nature—they reduce the temperature in the battery cells by exchanging the heat generated with a coolant all the while sustaining a given load.