Abstract
Large-scale commercialization of electric vehicles (EVs) seeks to develop battery systems with higher energy efficiency and improved thermal performance. Integrating simulation-based design optimization in battery development process expands the possibilities for novel design exploration. This study presents a dual-stage multiphysics simulation optimization methodology for comprehensive concept design of Lithium-ion (Li-ion) battery packs for EV applications. At the first stage, multi-objective optimization of electrochemical thermally coupled cells is performed using genetic algorithm considering the specific energy and the maximum temperature of the cells as design objectives. At the second stage, the energy efficiency and the thermal performances of each optimally designed cell are evaluated under pack operation to account for cell-to-pack interactions under realistic working scenarios. When operating at 1.5 C discharge current, the battery pack comprising optimally designed cells for which the specific energy and the maximum temperature are equally weighted delivers the highest specific energy with enhanced thermal performance. The most favorable pack design shows 8% reduction in maximum pack temperature and 16.1% reduction in module-to-module temperature variations compared to commercially available pack. The methodology for design optimization presented in this work is generic, providing valuable knowledge for future cell and pack designs that employ different chemistries and configurations.
Highlights
Lithium-ion (Li-ion) batteries are increasingly attracting popularity in everyday life by becoming ubiquitous in a wide variety of applications such as portable electronic devices, renewable energy systems and transportation vehicles [1,2]
This section elaborates the cell design optimization (Subsection 3.1) and the corresponding pack performance (Subsection 3.2) providing a comprehensive analysis of the cell-pack interactions based on the developed multiphysics simulation framework (Subsection 3.3)
A comprehensive approach was developed in this research to evaluate the performance of the optimally designed Li-ion cells operating under battery pack working environment
Summary
Lithium-ion (Li-ion) batteries are increasingly attracting popularity in everyday life by becoming ubiquitous in a wide variety of applications such as portable electronic devices, renewable energy systems and transportation vehicles [1,2]. The cell thermal performance was neither considered as a separate objective function nor was the thermal behavior of the optimally designed cells delivering maximum specific energy/power evaluated for the battery pack operation. Campbell et al [7] developed an integrated multi-scale framework to optimally find the number of layers of Li-ion pouch cells to maximize the useable energy while addressing the fast charging and specific acceleration issues of plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs). Their methodology employed a top-down approach from the vehicle powertrain level to the cell electrode level. The simulations and optimizations are conducted in GT-AutoLion/GT-SUITE, a leading software for multiphysics system simulations [35]
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