Design and Optimisation of Battery Thermal Management Systems in Electric Vehicles using Advanced Simulation Techniques
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Abstract
Efficient thermal management is essential for improving the safety, durability and performance of Electric Vehicle (EV) batteries. Even small temperature deviations can drastically affect battery life; for instance, a rise of just 1-2°C has been shown to accelerate cell degradation, making optimised cooling systems indispensable. This study investigates four fin configurations - no fins, rectangular, elliptical and irregular fins to identify the most effective solution for heat dissipation in EV battery chambers. Using CATIA for design and ANSYS coupled with CFD for simulation, each configuration was evaluated for temperature control, heat flux, airflow behaviour and turbulence characteristics. The results reveal meaningful differences in performance. The irregular fin design, for example, achieved the lowest battery temperature of 46.77°C, a noticeable improvement compared to 46.889°C without fins, illustrating how even fractional changes can significantly stabilise battery operation during continuous vehicle use. It also produced the highest total heat flux (0.82196 W/m²), indicating stronger overall heat removal capacity. Conversely, the elliptical fins delivered the highest directional heat flux (0.095758 W/m²) and the lowest eddy viscosity (7.185), resulting in smoother airflow and reduced energy losses - an advantage in systems where airflow efficiency is a priority. By combining thermal and flow metrics, this study highlights that while irregular fins maximise raw cooling performance, elliptical fins offer a balanced and energy-efficient alternative. These insights provide a practical pathway for designing next-generation battery thermal management systems that are both thermally robust and aerodynamically optimised.
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