The Design and Investigation of a Cooling System for a High Power Ni-MH Battery Pack in Hybrid Electric Vehicles

• Main Authors: Aihua Chu, Yinnan Yuan, Jianxin Zhu, Xiao Lu, Chenquan Zhou
• Format: Article
• Language: English
• Published: MDPI AG 2020-03-01
• Series: Applied Sciences
• Subjects: hybrid electric vehicle; high power battery; liquid-cooling system; ni-mh; heat calculation and simulation
• Online Access: https://www.mdpi.com/2076-3417/10/5/1660

High power cylindrical Ni-MH battery cells have a heavy heat load because of their high discharge rate and large equivalent internal resistance. This heavy heat load, together with an imbalanced flow in parallel liquid cooling systems, can lead to variances in the temperature of each cell in the entire battery pack, thereby reducing the life cycle of the battery pack. In this paper, a parallel-series combined liquid cooling system for a 288V Ni-MH battery pack was designed, and several parameters that influence the flow balance of the system by heat transfer and fluid dynamics were calculated. Then, a thermal-fluid simulation was executed with different parameters using StarCCM+ software, and the simulation results were validated by a battery pack temperature experiment on a bench and in a vehicle. The results indicate that the cell’s temperature and temperature differences can be kept within an ideal range. We also determined that within the battery power requirements and structural spacing limits, the total flow rate of the cooling liquid, the cross-sectional area ratio of the main pipe to the branch pipes, and the number of internal supporting walls in each branch pipe need to be large enough to minimize the cell’s maximum temperature and temperature differences.