Department of Mechanical engineering

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Author: search.filters.author.Verma, SaketSubject: search.filters.subject.Electric vehicles (EVs)

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    Experimental and numerical investigation for optimization of a hybrid battery thermal management system based on phase change material and air convection
    (ASME, 2024-12) Verma, Saket
    This work presents the design and optimization of a phase change material (PCM)-based hybrid battery thermal management system (HBTMS). In the first stage, experiments are performed to measure the battery cell temperatures under various charge rates with and without the usage of PCM. Thereafter, a numerical model is developed to conduct a parametric study on the effect of the thickness of PCM layer around the battery cell. The results show that with the PCM thicknesses of 6–12 mm, the maximum cell temperature (36.35 °C) and thermal nonuniformity are within the safe range. In the second stage, a parametric study is conducted in the 6S1P battery module to optimize the spacing between the cells at constant inlet velocity. The result shows that an increase in cell spacing decreases the maximum temperature within the cells. The maximum temperature is within the optimal range when the cell spacing is 10 mm. At the constant cell spacing of 10 mm, an increase in inlet velocities from 0.25 m/s to 2.5 m/s gradually improves the thermal uniformity. The maximum temperature and thermal nonuniformity for the 6S1P battery module are found to be 42.07 °C and 1.17 °C respectively. In the third stage, the 6S1P battery module is optimized for PCM thickness, cell spacing, and inlet air velocity. It is found that effective thermal management is possible with PCM-based HBTMS at a low airflow rate of up to 1.5 m/s. The optimized PCM-based HBTMS shows 53.95% and 40% reductions in PCM mass and air flowrate, respectively.
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    Progress in design and development of battery thermal management system for electric vehicles
    (Springer, 2025-08) Verma, Saket
    Reversible electrochemical batteries having reasonable cyclic charging and discharging capabilities are commonly employed in portable applications. The battery technology has improved on various aspects such as high specific energy density, high nominal voltage (up to 3.7 V), long cycle life and low self-discharge, and reached to a level, where it can be incorporated in large-scale applications, e.g. Electric Vehicles (EVs). Lithium-ion (Li-ion) batteries are commonly used in light and heavy-duty vehicles nowadays due to its superior performance, long life, and high energy density. The battery is the most critical component in an EV, and its effectiveness decides the success of the vehicle. In terms of economics, the battery pack represents a significant portion of the overall cost of an EV. Therefore, not only optimum design but also operation and maintenance of the battery pack is considered crucial. In this regard, both high and low temperatures have a significant impact on the performance of the Li-ion battery. Temperature non-uniformity also leads to capacity differences among individual cells, ultimately affecting the overall performance of the battery pack. To enhance electrochemical performance, prolong battery life, and maintain optimal power performance, it is crucial to develop a Battery Thermal Management System (BTMS) that can effectively and reasonably regulate its temperature. Most of the electrical automobile industries have adopted active cooling systems, including both air and liquid cooling. Air cooling systems are simple and low maintenance. However, due to the low heat transfer coefficient, the core part of the battery generally reaches high temperatures, leading to high thermal non-uniformity. Liquid cooling, on the other hand, has a higher heat transfer coefficient, which helps in creating a more effective cooling system. However, liquid cooling requires an external cooling system and a very effective leak-proofing, making it generally costlier. The energy provided to the active system is extracted from the battery pack, compromising the vehicle’s range. Passive cooling systems come into play as they are capable of eliminating or reducing these issues. However, passive techniques alone cannot provide effective cooling during high discharge and charging conditions. It is recommended to use a combination of passive and active techniques in BTMS to achieve the desired maximum temperature and thermal uniformity.