ENHANCING EV SAFETY PERFORMANCE THROUGH ADVANCED BATTERY THERMAL MANAGEMENT .pptx

Electric Vehicles (EVs) have emerged as one of the most promising solutions to address
the growing concerns of environmental pollution, fossil fuel depletion, and the urgent need for
sustainable transportation. Among the different components of an electric vehicle, the lithium�ion battery pack is the most vital, as it determines the vehicle’s driving range, performance,
reliability, and safety. However, the efficiency and durability of lithium-ion batteries are highly
sensitive to temperature variations. Excessive heating during charging or discharging cycles
can lead to performance degradation, reduced energy output, shorter lifespan, and in extreme
cases, dangerous phenomena such as thermal runaway. Therefore, effective Battery Thermal
Management Systems (BTMS) play a crucial role in regulating temperature, maintaining
uniform heat distribution, and ensuring safe operation across diverse environmental
conditions.This seminar report provides an in-depth analysis of different battery cooling
strategies employed in EV.including air cooling, liquid cooling, refrigerant-based cooling,
and the use of Phase Change Materials (PCM). Air cooling systems, though simple and cost�effective, are less efficient for high-capacity battery packs where intense heat removal is
required. Liquid cooling systems, on the other hand, provide superior heat transfer due to the
higher thermal conductivity of liquids and are widely used in modern EVs. Refrigerant-based
cooling techniques directly use refrigerants for battery temperature regulation, offering highly
efficient thermal control in extreme climates. Meanwhile, Phase Change Materials are gaining
significant attention for their ability to absorb and release large amounts of heat without major
temperature fluctuations, thereby enhancing passive cooling performance.The report
emphasizes the importance of selecting suitable cooling techniques to improve energy
efficiency, prevent overheating, and extend the overall life cycle of the battery. Furthermore,
it highlights how advancements in hybrid cooling systems—where two or more methods are
integrated—are paving the way for next-generation EVs with enhanced safety, reliability, and
performance. By exploring these cooling methodologies, this study underlines the necessity of
efficient thermal management systems for accelerating the adoption of EVs globally and
supporting the transition towards a cleaner and sustainable future of mobility

1. ENHANCING EV SAFETY PERFORMANCE THROUGH ADVANCED BATTERY THERMAL MANAGEMENT www.nrcmec.org BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING PRESENT ED BY MR. VOOTLA.MAHESH 23X05A0358 POWER POINT PRESENTATION ON

2. Electric Vehicle Battery Cooling Systems: An In-depth Seminar Join us for an insightful seminar delving into the critical aspects of electric vehicle battery cooling systems, essential for enhancing performance, longevity, and safety of EV batteries.

3. Understanding Heat Generation in Lithium-ion Battery Packs Heat generation in Li-ion batteries is primarily due to internal resistances and electrochemical reactions during charging and discharging cycles. Effective thermal management is vital to prevent thermal runaway. 1 Ohmic heating due to current flow through cell components. Internal Resistance 2 Degradation Effects Exothermic and endothermic reactions contributing to heat. Electrochemical Reactions Increased heat with battery ageing and capacity fade. 3

4. Air Cooling Passive (natural convection) Active (forced convection with fans) Liquid Cooling Direct (coolant in contact with cells) Indirect (coolant via cold plates) Classification of EV Battery Cooling Systems Battery cooling systems are categorised based on the medium and method used to dissipate heat, ensuring optimal operating temperatures for EV batteries. Phase Change Materials (PCMs) Classified Into Three Main Categories:- 1)Organic 2)In-Organic 3)Eutectics

5. Refrigeration Cooling System Active cooling with refrigerant cycles Highly effective for extreme conditions Ensures optimal battery performance Heat Pipe Cooling Efficient heat transfer mechanism Utilises phase change of working fluid Compact and reliable solution

6. Air Cooling Systems: Passive and Active Approaches Passive Air Cooling Active Air Cooling Relies on natural convection, suitable for low-power applications due to limited heat transfer capabilities. Natural airflow around cells Simple design, low cost Less effective Limited cooling capacity Uses fans or blowers to force air over battery cells, enhancing heat removal, ideal for moderate power outputs . Forced air circulation. Improved cooling efficiency. Requires power and can be noisy

7. Liquid Cooling Systems: Direct and Indirect Methodologies Coolant directly contacts battery cells, offering superior heat transfer, often using dielectric fluids. Direct Liquid Cooling Coolant flows through channels or plates adjacent to cells, transferring heat via a cold plate. Indirect Liquid Cooling Excellent temperature uniformity. Complex sealing requirements. Widely adopted for safety. Slightly less efficient than direct. High thermal conductivity. Separates coolant from cells.

8. Advanced Cooling Phase Change Materials Phase Change Materials (PCMs) absorb and release large amounts of latent heat during phase transitions (e.g., solid to liquid), maintaining battery temperature within an optimal range. PCMs melt to absorb excess heat from batteries. Does not require external power or complex controls. Maintains consistent battery temperature during operation. Latent Heat Absorption Temperature Stabilisation Passive & Reliable 1 2 3

9. Hybrid Battery Cooling Systems Air + PCM Liquid + PCM Air + Heat Pipe Utilises airflow with passive heat absorption. Liquid circulation combined with PCM's latent heat. Air cooling augmented by efficient heat pipe transfer.

10. Integration of Cooling Systems with Battery Management Systems (BMS) The BMS plays a crucial role in monitoring battery health and actively controlling the cooling system to ensure optimal thermal performance and safety. BMS monitors individual cell temperatures in real-time. Temperature Sensing BMS activates and regulates cooling components (pumps, fans). Cooling Control Fault Detection Identifies overheating risks and triggers safety protocols.

11. Integration of Cooling Systems with Battery Management Systems (BMS) Temperature Sensing BMS monitors individual cell temperatures to identify hot spots and prevent thermal runaway. Safety Protocols BMS initiates emergency shutdowns or power reductions if temperatures exceed safe limits. Control Algorithms BMS activates and regulates cooling systems (fans, pumps) based on real- time temperature data. Data Communication Seamless data exchange between thermal sensors and cooling actuators for precise control.

12. Challenges and Future Trends in EV Battery Thermal Management Despite advancements, challenges remain in optimising thermal management systems, paving the way for innovative future trends. Current Challenges Future Trends Energy consumption of active cooling. Cost of advanced materials. Ensuring uniform temperature distribution. Integration of thermoelectric coolers. Modular and scalable cooling solutions. AI-driven predictive thermal management. Solid-state cooling technologies. Weight and volume of cooling systems.

13. Optimising Battery Performance and Safety Effective thermal management is paramount for extending battery lifespan, enhancing charging/discharging efficiency, and preventing critical safety incidents like thermal runaway. Maintaining optimal temperatures reduces degradation. Extended Lifespan Stable temperatures improve charge acceptance and power output. Prevents overheating and thermal runaway events. Safety Assurance Enhanced Efficiency

14. Conclusion Robust battery cooling systems are indispensable for the sustainable development and widespread adoption of electric vehicles, directly impacting their performance, reliability, and safety. Critical Role: Thermal management is fundamental to EV battery longevity. Diverse Solutions: Air, liquid, and advanced cooling methods address varied needs. Future Outlook: Innovation continues to drive more efficient and safer systems.

15. THANK YOU