Advanced Thermal Management of Cylindrical Lithium-Ion Battery Packs in Electric Vehicles: A Comparative CFD Study of Vertical, Horizontal, and Optimised Liquid Cooling Designs

Battery packs found in electric vehicles (EVs) require thermal management systems to maintain safe operating temperatures in order to improve device performance and alleviate irregular temperatures that can cause irreversible damage to the cells. Cylindrical lithium-ion batteries are widely used in the electric vehicle industry due to their high energy density and extended life cycle. This report investigates the thermal performance of three liquid cooling designs for a six-cell battery pack using computational fluid dynamics (CFD). The first two designs, vertical flow design (VFD) and horizontal flow design (HFD), are influenced by existing linear and wavy channel structures. They went through multiple geometry optimisations, where parameters such as inlet velocity, the number of channels, and channel diameter were tested before being combined into the third and final optimal design (OD). All designs successfully maintained the maximum temperature of the cells below 306.5 K at an inlet velocity of 0.5 ms⁻¹, meeting the predefined performance thresholds derived from the literature. The HFD design was the only one that failed to meet the temperature uniformity goal of 5 K. The optimal design achieved a maximum temperature of 301.311 K, which was 2.223 K lower than the VFD, and 4.707 K lower than the HFD. Furthermore, it produced a cell temperature difference of 1.144 K, outperforming the next-best design by 1.647 K, thus demonstrating superior temperature regulation. The OD design can manage temperatures by using lower inlet velocities and reducing power consumption. However, the increased cooling efficiency comes at the cost of an increase in weight for the system. This prompts the decision on whether to accommodate the added weight for improved safety or to allocate it to the addition of more batteries to enhance the vehicle’s power output.