Design and thermal-flow analysis of battery thermal management systems in electric vehicles using advanced simulation techniques

The thermal management of batteries in electric vehicles (EVs) is crucial for ensuring optimal performance, safety, and longevity. Inefficient heat dissipation can cause thermal runaway, battery degradation, and reduced overall vehicle performance. This paper presents a comprehensive study on the design and thermal-flow analysis of battery casings with various fin configurations using advanced computational tools. The configurations include no fins, rectangular fins, elliptical fins, and irregular fins, designed with CATIA software. Thermal analysis was performed using ANSYS, and flow characteristics were studied using Computational Fluid Dynamics (CFD). The results showed that the elliptical fin design had superior heat dissipation and better cooling flow characteristics, making it the most effective configuration. This study highlights the importance of fin geometry in enhancing battery thermal management systems (BTMS) for EVs.