Combined Experimental and Numerical Study of Active Thermal Control of Battery Modules

Lithium ion (Li-ion) batteries have been identified as a promising solution to meet the increasing demands for alternative energy in electric vehicles (EVs) and hybrid electric vehicle (HEVs). This work describes experimental and numerical study of thermal management of battery module consisting of cylindrical Li-ion cells, with an emphasis on the use of active control to achieve optimal cooling performance with minimal parasitic power consumption. The major contribution from this work is the first experimental demonstration (based on our review of archival journal and conference literature) and the corresponding analysis of active thermal control of battery modules. The results suggest that the active control strategy, when combined with reciprocating cooling flow, can reduce the parasitic energy consumption and cooling flow amount substantially. Compared with results using passive control with unidirectional cooling flow, the parasitic energy consumption was reduced by about 80%. This contribution was achieved in three steps, which was detailed in this dissertation in chapters 2, 3, and 4, respectively. In the first step, an experimental facility and a corresponding CFD model were developed to capture the thermal behavior of multiple battery cells. Based on the experimental and CFD results, a reduced-order model (ROM) was then developed for active monitoring and control purposes. In the second step, the ROM was parameterized and an observer-based control strategy was developed to control the core temperature of battery cells. Finally, based on the experimental facility and the ROM model, the active control of a battery module was demonstrated. Each of these steps represents an important facet of the thermal management problem, and it is expected that the results and specifics documented in this dissertation lay the groundwork to facilitate further study.