A Novel Approach for Enhancing Thermal Performance of Battery Modules Based on Finite Element Modeling and Predictive Modeling Mechanism

Electric vehicles (EVs) are estimated as the most sustainable solutions for future transportation requirements. However, there are various problems related to the battery pack module and one such problem is invariable high-temperature differences across the battery pack module due to the discharging and charging of batteries under operating conditions of EVs. High-temperature differences across the battery module contribute to the degradation of maximum charge storage and capacity of Li-ion batteries which ultimately affects the performance of EVs. To address this problem, a finite element modeling (FEM) based automated neural network search (ANS) approach is proposed. The research methodology constitutes of four stages: design of air-cooled battery pack module, setup of the FEM constraints and thermal equations, formulating the predictive model on generated data using ANS, and lastly performing multi-objective response optimization of the best fit predictive model to formulate optimum design constraints for the air-cooled battery module. For efficient thermal management of the battery module, an empirical model is formulated using the mentioned methodology for minimizing the maximum temperature differences, standard deviation of temperature across the battery pack module, and battery pack volume. The results obtained are as follows: (1) the battery pack module volume is reduced from 0.003279 m3 to 0.002321 m3 by 29.21%, (2) the maximum temperature differences across the eight cells of battery pack module declines from 6.81 K to 4.38 K by 35.66%, and (3) the standard deviation of temperature across battery pack decreases from 4.38 K to 0.93 K by 78.69%. Thus, the predictive empirical model enhances the thermal management and safety factor of battery module

Thermal Management of Electrified Vehicles—A Review

Vehicle electrification demands a deep analysis of the thermal problems in order to increase vehicle efficiency and battery life and performance. An efficient thermal management of an electrified vehicle has to involve every system of the vehicle. However, it is not sufficient to optimize the thermal behavior of each subsystem, but thermal management has to be considered at system level to optimize the global performance of the vehicle. The present paper provides an organic review of the current aspects of thermal management from a system engineering perspective. Starting from the definition of the requirements and targets of the thermal management system, each vehicle subsystem is analyzed and related to the whole system. In this framework, problems referring to modeling, simulation and optimization are considered and discussed. The current technological challenges and developments in thermal management are highlighted at vehicle and component levels

Optimal battery thermal management for electric vehicles with battery degradation minimization

The control of a battery thermal management system (BTMS) is essential for the thermal safety, energy efficiency, and durability of electric vehicles (EVs) in hot weather. To address the battery cooling optimization problem, this paper utilizes dynamic programming (DP) to develop an online rule-based control strategy. Firstly, an electrical–thermal-aging model of the LiFePO4 battery pack is established. A control-oriented onboard BTMS model is proposed and verified under different speed profiles and temperatures. Then in the DP framework, a cost function consisting of battery aging cost and cooling-induced electricity cost is minimized to obtain the optimal compressor power. By exacting three rules ”fast cooling, slow cooling, and temperature-maintaining” from the DP result, a near-optimal rule-based cooling strategy, which uses as much regenerative energy as possible to cool the battery pack, is proposed for online execution. Simulation results show that the proposed online strategy can dramatically improve the driving economy and reduce battery degradation under diverse operation conditions, achieving less than a 2.18% difference in battery loss compared to the offline DP. Recommendations regarding battery cooling under different real-world cases are finally provided

Optimal Scheduling to Manage an Electric Bus Fleet Overnight Charging

Electro-mobility is increasing significantly in the urban public transport and continues to face important challenges. Electric bus fleets require high performance and extended longevity of lithium-ion battery at highly variable temperature and in different operating conditions. On the other hand, bus operators are more concerned about reducing operation and maintenance costs, which affects the battery aging cost and represents a significant economic parameter for the deployment of electric bus fleets. This paper introduces a methodological approach to manage overnight charging of an electric bus fleet. This approach identifies an optimal charging strategy that minimizes the battery aging cost (the cost of replacing the battery spread over the battery lifetime). The optimization constraints are related to the bus operating conditions, the electric vehicle supply equipment, and the power grid. The optimization evaluates the fitness function through the coupled modeling of electro-thermal and aging properties of lithium-ion batteries. Simulation results indicate a significant reduction in the battery capacity loss over 10 years of operation for the optimal charging strategy compared to three typical charging strategies

Calibration Optimization Methodology for Lithium-Ion Battery Pack Model for Electric Vehicles in Mining Applications

Large-scale introduction of electric vehicles (EVs) to the market sets outstanding requirements for battery performance to extend vehicle driving range, prolong battery service life, and reduce battery costs. There is a growing need to accurately and robustly model the performance of both individual cells and their aggregated behavior when integrated into battery packs. This paper presents a novel methodology for Lithium-ion (Li-ion) battery pack simulations under actual operating conditions of an electric mining vehicle. The validated electrochemical-thermal models of Li-ion battery cells are scaled up into battery modules to emulate cell-to-cell variations within the battery pack while considering the random variability of battery cells, as well as electrical topology and thermal management of the pack. The performance of the battery pack model is evaluated using transient experimental data for the pack operating conditions within the mining environment. The simulation results show that the relative root mean square error for the voltage prediction is 0.7–1.7% and for the battery pack temperature 2–12%. The proposed methodology is general and it can be applied to other battery chemistries and electric vehicle types to perform multi-objective optimization to predict the performance of large battery packs

Electrified Powertrains for a Sustainable Mobility: Topologies, Design and Integrated Energy Management Strategies

This Special Issue was intended to contribute to the sustainable mobility agenda through enhanced scientific and multi-disciplinary knowledge to investigate concerns and real possibilities in the achievement of a greener mobility and to support the debate between industry and academic researchers, providing an interesting overview on new needs and investigation topics required for future developments

Urban and extra-urban hybrid vehicles: a technological review

Pollution derived from transportation systems is a worldwide, timelier issue than ever. The abatement actions of harmful substances in the air are on the agenda and they are necessary today to safeguard our welfare and that of the planet. Environmental pollution in large cities is approximately 20% due to the transportation system. In addition, private traffic contributes greatly to city pollution. Further, “vehicle operating life” is most often exceeded and vehicle emissions do not comply with European antipollution standards. It becomes mandatory to find a solution that respects the environment and, realize an appropriate transportation service to the customers. New technologies related to hybrid –electric engines are making great strides in reducing emissions, and the funds allocated by public authorities should be addressed. In addition, the use (implementation) of new technologies is also convenient from an economic point of view. In fact, by implementing the use of hybrid vehicles, fuel consumption can be reduced. The different hybrid configurations presented refer to such a series architecture, developed by the researchers and Research and Development groups. Regarding energy flows, different strategy logic or vehicle management units have been illustrated. Various configurations and vehicles were studied by simulating different driving cycles, both European approval and homologation and customer ones (typically municipal and university). The simulations have provided guidance on the optimal proposed configuration and information on the component to be used

Advances in Batteries, Battery Modeling, Battery Management System, Battery Thermal Management, SOC, SOH, and Charge/Discharge Characteristics in EV Applications

The second-generation hybrid and Electric Vehicles are currently leading the paradigm shift in the automobile industry, replacing conventional diesel and gasoline-powered vehicles. The Battery Management System is crucial in these electric vehicles and also essential for renewable energy storage systems. This review paper focuses on batteries and addresses concerns, difficulties, and solutions associated with them. It explores key technologies of Battery Management System, including battery modeling, state estimation, and battery charging. A thorough analysis of numerous battery models, including electric, thermal, and electro-thermal models, is provided in the article. Additionally, it surveys battery state estimations for a charge and health. Furthermore, the different battery charging approaches and optimization methods are discussed. The Battery Management System performs a wide range of tasks, including as monitoring voltage and current, estimating charge and discharge, equalizing and protecting the battery, managing temperature conditions, and managing battery data. It also looks at various cell balancing circuit types, current and voltage stressors, control reliability, power loss, efficiency, as well as their advantages and disadvantages. The paper also discusses research gaps in battery management systems.publishedVersio

Investigating the impact of ageing and thermal management of a fuel cell system on energy management strategies

This paper studies the impact of two significant aspects, namely fuel cell (FC) degradation and thermal management, over the performance of an optimal and a rule-based energy management strategy (EMS) in a fuel cell hybrid electric vehicle (FCHEV). To do so, firstly, a vehicle's model is developed in simulation environment for a low-speed FCHEV composed of a FC stack and a battery pack. Subsequently, deterministic dynamic programming (DP), as an optimal strategy, and bounded load following strategy (BLFS), as a common rule-based strategy, are utilized to minimize the hydrogen consumption while respecting the operating constraints of the power sources. The performance of the EMSs is assessed at different scenarios. The first objective is to clarify the effect of FC stack degradation on the performance of the vehicle. In this regard, each EMS determines the required current from the FC stack for two FCs with different levels of degradation. The second objective is to evaluate the thermal management contribution to improving the performance of the new FC compared to the considered cases in scenario one. In this respect, each strategy deals with determining two control variables (FC current and cooling fan duty cycle). The results of this study indicate that negligence of adapting to the PEMFC health state, as the PEMFC gets aged, can increase the hydrogen consumption up to 24.8% in DP and 12.1% in BLFS. Moreover, the integration of temperature dimension into the EMS can diminish the hydrogen consumption by 4.1% and 5.3% in DP and BLFS respectively. © 2020 Elsevier Lt