Light-duty Vehicle Test Cycle Research Articles

Simulation Study on Factors Affecting the Output Voltage of Extended-Range Electric Vehicle Power Batteries

The power battery configuration of an extended-range electric vehicle directly affects the overall performance of the vehicle. Optimization of the output voltage of the power battery can improve the overall power and economy of the vehicle to ensure its safe operation. Factors affecting the output voltage of power batteries under different operating conditions, such as nominal voltage and the number of series and parallel connections of the battery cells, have been studied. This study uses AVL Cruise to establish an overall model of an extended-range electric vehicle to simulate the output voltage characteristics under the different operating conditions of the NEDC (New European Driving Cycle), WLTC (World Light Vehicle Test Cycle) and CLTC (China Light Duty Vehicle Test Cycle). The influence of the output voltage of the power battery under different operating conditions is studied to ensure that the power battery can output energy with high efficiency. The operating conditions have an impact on the output voltage with an idle voltage fluctuation of the operating conditions. The nominal voltage variation and the number of series and parallel connections of the battery cells affect the frequency and time of breakdown.

Domain generalization for machine compound fault diagnosis by Domain-Relevant Joint Distribution Alignment

In machine fault diagnosis, domain generalization methods have gained significant attention due to their advantage in non-requirement of priori target domain distribution. However, they pose great challenges in domain-relevant feature learning and incurs inferior unseen-domain classification when large domain divergence exists. To address this issuse, we propose a novel distribution alignment strategy named DRJDA (Domain-Relevant Joint Distribution Alignment) that matches the domain-joint distribution and domain-relevant distribution for domain generalization fault diagnosis. Specifically, the α-PE divergence is employed to minimize the distribution discrepancy, which is demonstrated to be explicitly derived as the maximum value of a quadratic function. Additionally, a parameter-free plug-and-play data augmentation module that performs feature-level instance mixture and style transfer to increase the generalization ability. Finally, data from the China Light-duty Vehicle Test Cycle (CLTC) tests are used as case studies, and the experiments carried out across 14 different domains prove the proficiency of the proposed DRJDA in learning domain-invariant feature when significant domain divergence exists, indicating its remarkable potential in compound fault diagnosis for industrial machinery.

Minimum loss modulation method for various power factor angles

In recent years, the energy crisis has prompted widespread attention to electric vehicles (EVs). As a core component of electric drive system in EV, motor controller has a significant impact on vehicle energy consumption. In such situation, this paper proposes a minimum loss modulation method for all power factors and reduces current THD by dead-band compensation. Firstly, the mechanism model of the controller is established for loss calculation, and the relationship between the clamping region and the current peak is analyzed based on the traditional modulation methods. Secondly, a discontinuous pulse width modulation considering power factor angle method (CPFA-DPWM) is proposed to ensure that clamping region always falls at the peak current at all power factors. Furthermore, the adoption of current vector method instead of direct sampling for current polarity determination effectively reduces judgment error and avoids false dead-band compensation. The effectiveness of the proposed method is verified by simulation and thermal measurement experiment. Under China Light-duty Vehicle Test Cycle (CLTC), the controller loss of CPFA-DPWM is reduced by 18.61 % compared to SVPWM.

Dynamic performance of a polygonal thermoelectric generator using sickle-shaped fins for automotive application

About 40 % of automotive fuel energy is lost in the form of heat through exhaust gas, the utilization of thermoelectric power generation technology presents a direct conversion of thermal to electric energy. A thermoelectric generator (TEG) system was designed in this study, comprising a polygonal heat exchanger using sickle-shaped fins to enhance waste heat recycling. Additionally, a transient Computational Fluid Dynamics (CFD)-analysis model was introduced to investigate its dynamic response utilizing the instantaneous variations of exhaust gas and coolant under the China Light-Duty Vehicle Test Cycle (CLTC) as transient inputs. The TEG system exhibits an average power output of 24.48 W and a conversion efficiency of 1.12 % throughout the CLTC. After heating from ambient temperature to normal operating temperature, the power rises to 34.48 W and efficiency to 1.57 %, showing enhanced output performance. A comparison of the transient and steady-state analysis results indicates that the transient analysis reflects the hysteresis effect of heat transfer more accurately. Through experimental verification, the mean absolute percentage errors of the transient model are calculated to be 5.57 % and 8.28 % respectively, proving the credibility of the simulated results. The proposed dynamic model allows for evaluating the actual behavior of the TEG system under intricate driving cycles and offers a robust reference for TEG system optimization and its automotive applications in future.

Assessment of CH4 Emissions in a Compressed Natural Gas-Adapted Engine in the Context of Changes in the Equivalence Ratio

The results of diagnostic tests under steady-state speed conditions of an unloaded engine do not fully reflect the emissivity of vehicles adapted to run on natural gas. Therefore, it is reasonable to pay attention to the emissions performance of these vehicles under dynamic conditions. In this regard, the tests were carried out on a chassis dynamometer with the engine fueled by gasoline and natural gas. Due to the area of operation of natural gas vehicles being usually limited to urban areas, the urban phases of the NEDC (New European Driving Cycle) and WLTC (Worldwide harmonized Light-duty vehicles Test Cycle) were adapted. While CO2 emissions are lower when fueled by natural gas, CH4 emissions can be high, which is related to momentary changes in the composition of the combustible mixture. Although CH4 emissions are higher when the engine runs on natural gas, the CO2eq value is, depending on the driving cycle, about 15–25% lower than when running on petrol. Additionally, studies have shown that in engines adapted to run on CNG (compressed natural gas), it is advisable to consider the use of catalytic converters optimized to run on natural gas, as is the case with vehicles which are factory–adapted to run on CNG.

Development of a deep Q-learning energy management system for a hybrid electric vehicle

In recent years, Machine Learning (ML) techniques have gained increasing popularity in several fields thanks to their ability to find hidden and complex relationships between data. Their capabilities for solving complex optimization tasks have made them extremely attractive also for the design of the Energy Management System (EMS) of electrified vehicles. Among the plethora of existing techniques, Reinforcement Learning (RL) algorithms have unprecedented potential since they can self-learn by directly interacting with the external environment through a trial-and-error procedure. In this paper, a Deep Q-Learning (DQL) agent, which exploits Deep Neural Networks (DNNs) to map the state-action pair to its value, was trained to reduce the CO2 emissions of a state-of-the-art diesel Plug-in Hybrid Electric Vehicle (PHEV) available on the European market. The proposed methodology was tested on a virtual test rig of the investigated vehicle while operating on a charge-sustaining logic. A sensitivity analysis was performed on the reward to test the capabilities of different penalty functions to improve the fuel economy while guaranteeing the battery charge sustainability. The potential of the proposed control strategy was firstly assessed on the Worldwide harmonized Light-duty vehicles Test Cycle (WLTC) and benchmarked against a Dynamic Programming (DP) optimization to evaluate each reward. Then the best agent was tested on a wide range of type-approval and Read Driving Emission (RDE) scenarios. The results show that the best-performing agent can reach performance close to the DP reference, with a limited gap (7 %) in terms of CO2 emissions.

Experimental investigation on rotational oscillating heat pipe for in-wheel motor cooling of urban electric vehicle

To address the flexible functions and better driving experience of future urban electric vehicles, the wheel corner module (WCM) that integrates traction motors into each wheel has become a hotspot in recent years. Traditional cooling solutions of the motor generally used auxiliary cooling systems, which increase the cost of the WCM with multiple motors. It is necessary to cool each motor with low cost, good thermal performance solution and without auxiliary systems. A novel cooling solution based on a 3D rotational oscillating heat pipe (ROHP) is proposed, which depends on the gravity, centrifugal force and cooling air generated by motor rotation to ensure its thermal performance. The thermal performance is investigated experimentally. The result shows that the ROHP can operate normally under the extremely low rotation speed of 1 r/min. As the speed increases, the heat transfer performance is stable. Even at the maximum heating power of 300 W and the maximum speed of 450 r/min, the ROHP shows excellent thermal performance. The maximum temperature under the real driving cycles of the New European Driving Cycle and the World Light Duty Vehicle Test Cycle are 87.4 °C and 115.4 °C respectively, which are lower than the demagnetization temperature of 180 °C.

A Logic Threshold Control Strategy to Improve the Regenerative Braking Energy Recovery of Electric Vehicles

With increasing global attention to climate change and environmental sustainability, the sustainable development of the automotive industry has become an important issue. This study focuses on the regenerative braking issues in pure electric vehicles. Specifically, it intends to elucidate the influence of the braking force distribution of the front and rear axles on access to energy recovery efficiency. Combining the I curve of a pure electric vehicle and the boundary line of the Economic Commission of Europe (ECE) regulations, the braking force distribution relationship between the front and rear axles is formulated to satisfy braking stability. The maximum regenerative braking force of the motor is determined based on the motor torque characteristics and battery charging power, and the regenerative braking torque is optimized by combining the constraints of the braking strength, battery state of charge (SOC), and vehicle speed. Six road working conditions are built, including the New European Driving Cycle (NEDC), the World Light-Duty Vehicle Test Cycle (WLTC), Federal Test Procedure 72 (FTP-72), Federal Test Procedure 75 (FTP-75), the China Light-Duty Vehicle Test Cycle—Passenger (CLTC-P), and the New York City Cycle (NYCC). The efficiency of the regenerative braking strategy is validated by using the Simulink/MATLAB simulation. The simulation results show that the proposed dynamic logic threshold control strategy can significantly improve the energy recovery effect of electric vehicles, and the energy recovery efficiency can be improved by at least 25% compared to the situation without regenerative braking. Specifically, under the aforementioned road working conditions, the braking energy recovery efficiency levels are 27.69%, 42.18%, 49.54%, 47.60%, 49.28%, and 51.06%, respectively. Moreover, the energy recovery efficiency obtained by the current dynamic logic threshold is also compared with other published results. The regenerative braking control method proposed in this article makes the braking control of electric vehicles more precise, effectively reducing energy consumption and improving the driving range of electric vehicles.

Research on anode pressure control and dynamic performance of proton-exchange membrane fuel cell system for vehicular application

Reasonable anode pressure supply can not only improve the performance output of proton-exchange membrane fuel cell (PEMFC), but also effectively protect the proton-exchange membrane (PEM). In this article, a practicable feedforward-based proportional-integrative (FFPI) anode pressure control strategy is designed and successfully applied to a 100 kW-class automotive PEMFC system, where the current and anode purging are considered as interferences to apply feedforward compensation. The fuel cell system test bench exhibits good dynamic performance in load change experiments, the cell voltage consistency, power generation efficiency and hydrogen utilization of the system remain at a high level. To further suppress interference and reduce overshoot, oscillation and pressure response hysteresis, a control-oriented model of this 100 kW PEMFC system is constructed, and a novel second-order fuzzy active disturbance rejection controller (SOFADRC) is designed. Simulation results indicate that compared to FFPI controller and second-order ADRC (SOADRC), the maximum absolute error (MAE), average absolute error (AAE), and root-mean-square error (RMSE) of SOFADRC all reach the minimum values respectively under the step-load and China light-duty vehicle test cycle (CLTC) operating conditions, which are 6.51 kPa, 0.09 kPa, 0.42 kPa and 8.95 kPa, 0.62 kPa, 1.35 kPa respectively, showing the outstanding control effect.

Meta rule-based energy management strategy for battery/supercapacitor hybrid electric vehicles

Driving pattern recognition (DPR) is widely used to improve the robustness of rule-based energy management strategies (EMS). However, the number and quality of preset patterns limit further performance improvements. This paper proposes a meta rule-based EMS to replace the role of DPR, wherein the meta rule refers to a rule that determines the parameters of the energy management rule. Firstly, the power distribution rule pattern is derived through the analysis of dynamic programming results. Then, the value of the parameters is obtained through clustering. Subsequently, a feature screening method based on mutual information is proposed to select useful features of driving conditions and system states. The seagull optimization algorithm is then employed to find the mathematical expression of the meta rule. Finally, simulation results demonstrate the effectiveness of the meta rule-based EMS. Compared with DPR-based and long short-term memory-based EMS, the meta rule-based EMS can reduce the Ampere-hour throughput of Li-ion batteries by 17.0% and 9.7% respectively under the China light-duty vehicle test cycle, and by 3.4% and 16.6% respectively under a real-world driving condition. The meta rule-based EMS requires only dozens of milliseconds for each moment and is suitable for real-time systems.

Regenerative Braking of Electric Vehicles Based on Fuzzy Control Strategy

Regenerative braking technology is a viable solution for mitigating the energy consumption of electric vehicles. Constructing a distribution strategy for regenerative braking force will directly affect the energy saving efficiency of electric vehicles, which is a technical bottleneck of battery-powered electric vehicles. The distribution strategy of the front- and rear-axle braking forces of electric vehicles that possess integrated front-wheel-drive arrangements is established based on the Economic Commission of Europe (ECE) regulations, which enables the clarification of the total braking force of the front axle. The regenerative braking torque model of the motor is adjusted to optimize the ratio of motor braking force to the whole front-axle braking force. The regenerative braking process of electric vehicles is influenced by many factors, such as driving speed and braking intensity, so regenerative braking presents characteristics of nonlinearity, time variability, delay, and incomplete models. By considering the impact of fuzzy controllers having better robustness, adaptability, and fault tolerance, a fuzzy control strategy is employed in this paper to accomplish the regenerative braking force distribution on the front axle. A regenerative braking model is created on the Simulink platform using the braking force distribution indicated above, and experiments are run under six specific operating conditions: New European Driving Cycle (NEDC), World Light-Duty Vehicle Test Cycle (WLTC), Federal Test Procedure 72 (FTP-72), Federal Test Procedure 75 (FTP-75), China Light-Duty Vehicle Test Cycle-Passenger (CLTC-P), and New York City Cycle (NYCC). The findings demonstrate that in six typical cycling road conditions, the energy saving efficiency of electric vehicles has greatly increased, reaching over 15%. The energy saving efficiency during the WLTC driving condition reaches 25%, and it rises to 30% under the FTP-72, FTP-75, and CLTC-P driving conditions. Furthermore, under the NYCC road conditions, the energy saving efficiency exceeded 40%. Therefore, our results verify the effectiveness of the regenerative braking control strategy proposed in this paper.

A component sizing prediction study for a series hybrid electric vehicle based on artificial neural network

In the present study, the predictive tool based on an artificial neural network is developed by means of the experimental data of two series hybrid electric vehicles. The experiments have been conducted on different driving conditions, including highways, traffic, and combined driving conditions. Then, the artificial neural network is developed to predict an arbitrary series hybrid electric vehicle’s required power. The instantaneous required power is divided into dynamic and steady power to size the combustion engine, electric motor, and high voltage battery of the series hybrid electric vehicle. The effects of different ambient conditions (including ambient temperature and altitude), the inverter and high voltage battery efficiencies, and the coast-down coefficients on the components sizing of the series hybrid electric vehicle are then investigated in different driving conditions. The results revealed that the maximum instantaneous power of the electric motor is associated with rapid acceleration in low-speed conditions, and the suburban driving route determines the combustion engine’s maximum power. Notably, the Worldwide Harmonized Light-duty vehicles Test Cycle is the most comprehensive among the available driving cycles, and most of the components’ sizes are determined by this cycle except the combustion engine’s maximum power. It is also realized that the cycle-wise investigation can be summarized into the Isfahan-Tehran route and Worldwide harmonized Light-duty vehicles Test Cycle calculations.

Which factor contributes more to the fuel consumption gap between in-laboratory vs. real-world driving conditions? An independent component analysis

A widening vehicle fuel consumption gap has been found between in-laboratory and real-world driving conditions, which can undermine policy-making concerning energy saving and greenhouse gas reduction. Various factors have been identified as contributors to the gap; however, their contributions have not been independently assessed, which hinders the gap's narrowing. This study confirmed an average gap of 42% based on 0.95 billion records of second-by-second vehicle operating (speed, acceleration, etc.) and fuel consumption data collected from 395 light-duty vehicles through On-board Diagnostics (OBD) devices in Beijing. Contributions of fuel consumption rate (FCR)-related, engine load-related, and road grade discrepancies between the in-laboratory test procedure vs. real-world driving conditions to the gap were independently assessed. Results indicated that the FCR-related, engine load-related, and road grade discrepancies contributed 20.7%, 17.0%, and 3.2% to the gap, respectively (only 1.0% of the gap has not been explained). Replacing the test cycle from the New European Driving Cycle (NEDC) with the China Light-duty vehicle Test Cycle (CLTC-P) has the potential to reduce the engine load-related gap from 17.0% to 6.9% in Beijing. Policies should focus on developing more local test procedures or recording real-world fuel consumption through onboard devices to evaluate vehicle economy with higher reality representation.

Research on an Improved Rule-Based Energy Management Strategy Enlightened by the DP Optimization Results

Plug-in hybrid electric vehicles (PHEVs) have gradually become an important member of new energy vehicles because of the advantages of both electric and hybrid electric vehicles. A fast and effective energy management strategy can significantly improve the fuel-saving performance of vehicles. By observing the dynamic programming (DP) simulation results, it was found that the vehicle is in the charge-depleting mode, the state of charge (SOC) drops to the minimum at the end of the journey, and the SOC decreases linearly with the mileage. As such, this study proposed an improved rule-based (IRB) strategy enlightened by the DP strategy, which is different from previous rule-based (RB) strategies. Introducing the reference SOC curve and SOC adaptive adjustment, the IRB strategy ensures that the SOC decreases linearly with the driving distance, and the SOC drops to the minimum at the end of the journal, similar to the result of the DP strategy. The fuel economy of PHEV in the RB and DP energy management strategies can be considered as their worst-case and best-case scenarios, respectively. The simulation results show that the fuel consumption of the IRB strategy under the China Light-duty Vehicle Test Cycle is 3.16 L/100 km, which is 7.87% less than that of the RB strategy (3.43 L/100 km), and has reached 44.41% of the fuel-saving effect of the DP strategy (2.84 L/100 km).

Nonlinear model predictive control for efficient and robust airpath management in fuel cell vehicles

The fuel cell airpath multivariable control problem of optimally coordinating the electric compressor motor and the back-pressure valve to achieve efficient and safe conditions, for both steady state and transient operation, has not been completely addressed in the literature. This paper proposes a nonlinear model predictive control strategy, implemented via the Garrett Motion proprietary NMPC toolbox, to regulate the oxygen stoichiometry and the cathode pressure of an automotive fuel cell airpath system, while avoiding compressor surge and air starvation. The controller set-points are optimized, using the nonlinear model, to achieve the maximum system power as a function of the operating stack condition. The effectiveness and robustness of the proposed control strategy have been validated by means of a simulated World harmonized Light-duty vehicles Test Cycle (WLTC), under both state feedback and model parameters uncertainties.

Physicochemical Analysis of Particle Matter from a Gasoline Direct Injection Engine Based on the China Light-Duty Vehicle Test Cycle

This paper investigated the physical and chemical properties of gasoline direct injection (GDI) engine particulate matter (PM). The physical properties mainly included the particulate aggregate morphology, primary particle size, and internal nanostructure. High-resolution transmission electron microscopy (HRTEM) and scanning electron microscopy (SEM) were used to obtain particle morphology information and to conduct image processing and analysis. The chemical characterization tests included X-ray photoelectron spectroscopy (XPS), energy dispersive scanning (EDS), Raman spectroscopy, Fourier-transform infrared spectroscopy (FTIR), and thermal gravimetric analysis (TGA). XPS can be used to observe the content of carbon and oxygen components and the surface carbon chemistry status, EDS can be used to obtain the elemental composition of particles, and TGA is used to analyze the oxidative kinetics of particles. Samples were collected from the exhaust emissions of a passenger vehicle compliant with China’s VI emission standards under China Light-Duty Vehicle Test Cycle (CLTC) test conditions. The study found that the particle morphology mainly comprised primary particles stacked on top of each other to form agglomerate structures, and the primary particles exhibited a core–shell structure. Analysis showed that carbon and oxygen were the predominant components of the particles, with other metallic elements also present. The XPS observations agreed with the FTIR results, indicating a small amount of oxygen was present on the particle surface and that the carbon components consisted mainly of sp2 hybridized graphite and sp3 hybridized organic carbon. The TGA results indicated high characteristic temperatures and low oxidation activity.

Evaluating the Measurement Uncertainty of On-Road NOx Using a Portable Emission Measurement System (PEMS) Based on Real Testing Data in China

An evaluation of the measurement uncertainty of on-road NOx emissions using portable emission measurement system (PEMS) based on real local testing data collected in China was carried out as per the type B method defined in the EN 17507 standard. The aim of this work was to quantify the “absolute” measurement uncertainty of PEMSs, which excluded “PEMS relative to laboratory constant volume sampler (CVS)” uncertainty from the calculation of on-road NOx measurement uncertainty using PEMSs. PEMS instruments from three mainstream manufacturers were employed. The zero drift of the NOx analyzers was evaluated periodically during the real driving emissions (RDE) test, and it was noticed that there was neither a linear nor step model of zero drift, with no correlation with the boundary conditions or measurement principle. Additionally, from the 256 valid RDE tests, the zero drift always ranged from 3.8 ppm to −3.8 ppm, and more than 95% of the span drifts were within a range of 1.5%. Based on the laboratory testing of ten vehicles using the worldwide harmonized light-duty vehicle test cycle (WLTC), the type B uncertainty of PEMS NOx measurements corresponding to China-6a and China-6b limits was assessed. An uncertainty of 26.5% for China-6a was found (NOx limit = 60 mg/km over the WLTC), which is very close to the 22.5% from the EU evaluation results (NOx limit = 80 mg/km over the WLTC); the uncertainty with respect to China-6b was found to be 42.8% because the type-I limit was tuned down to 35 mg/km. This result indicates that, with the ever-tightening regulatory limits of vehicle NOx emissions, big challenges will be posed in terms of the reliability of PEMS measurements, which requires PEMS manufacturers to improve the performance of the instruments and policymakers to refine the test procedures and/or result calculation method to minimize the impacts.

Research on Multifractal Characteristics of Vehicle Driving Cycles

Vehicle driving cycles have complex characteristics, but there are few publicly reported methods for their quantitative characterization. This paper innovatively investigates their multifractal characteristics using the fractal theory to characterize their complex properties, laying the foundation for applications such as vehicle driving cycle feature identification, vehicle energy management strategies (EMS), and so on. To explore the scale-invariance of the vehicle driving cycles, the four vehicle driving cycles were analyzed using the Multifractal Detrended Fluctuation Analysis (MF-DFA) method, three of which are standard vehicle test cycles: the New European Driving Cycle (NEDC), the World-wide harmonized Light-duty Test Cycle (WLTC) and the China Light-duty Vehicle Test Cycle for Passenger Car (CLTC-P), and the other is the Urban Road Real Driving Cycle (URRDC), which was obtained by analyzing and processing vehicle driving data collected in actual urban driving conditions. The fluctuation functions, the generalized Hurst exponents, the mass exponent spectra, the multifractal singularity spectra, and the multifractal characteristic parameters were calculated to verify the multifractal characteristics, and to quantify the fluctuation singularities of different driving cycles as the time series. The results show that the fluctuations of all four driving cycles have long-range anticorrelations and exhibit significant multifractal characteristics. The results can provide a basis for the analysis of the complexity of the vehicle driving cycles.

A semiparametric clustering method for the screening of retired Li-ion batteries from electric vehicles

This study proposes a semiparametric clustering method (SPCM) to screen the batteries retired from electric vehicles (EVs) for echelon utilization. To quickly capture the static and dynamic battery characteristics, a hybrid test combining the low-current hybrid pulse power characterization (L-HPPC) test and China light-duty vehicle test cycle (CLTC) is designed. The pseudo-two-dimensional (P2D) model is combined with genetic algorithm (GA), and model parameters are identified by the hybrid test. Then, a clustering matrix containing sensitive model parameters is established and processed by principal component analysis (PCA). In SPCM, the Euclidean-distance-based clustering matrix is divided into high-density and low-density parts through a predetermined mixing proportion. For high-density data, hierarchical clustering (HC) is used to determine the initial cluster centers, and fuzzy C-means (FCM) method is utilized to determine the core clusters, while the low-density data is assigned to the nearest neighbours. Finally, 18 open-access datasets are employed to validate the effectiveness of the proposed SPCM. These results indicate that the proposed SPCM is superior to K-mean, K-medoid, and FCM in terms of normalized mutual information (NMI). Furthermore, the pulse testing and capacity testing of the re-grouped retired batteries further demonstrate the effectiveness of the SPCM in the screening of retired batteries.

Design and Optimization of a Liquid Cooling Thermal Management System with Flow Distributors and Spiral Channel Cooling Plates for Lithium-Ion Batteries

In this study, a three-dimensional transient simulation model of a liquid cooling thermal management system with flow distributors and spiral channel cooling plates for pouch lithium-ion batteries has been developed. The cooling plates play the role of uniforming temperature distribution and reducing the maximum temperature within each battery, while the flow distributors have the function of reducing the temperature difference between batteries in the battery module. The accuracy of the thermophysical properties and heat generation rate of the battery was verified experimentally. The optimal structure and cooling strategy of the system was determined by single factor analysis as well as orthogonal test and matrix analysis methods. The optimal solution resulted in a maximum battery module temperature of 34.65 °C, a maximum temperature difference of 3.95 °C, and a channel pressure drop of 8.82 Pa. Using the world-harmonized light-duty vehicles test cycle (WLTC) conditions for a battery pack in an electric car, the performance of the optimal battery thermal management system (BTMS) design was tested, and the results indicate that the maximum temperature can be controlled below 25.51 °C and the maximum temperature difference below 0.21 °C, which well meet the requirements of BTMS designs.