Variable fidelity methodology for thermal battery modeling

Cell temperature is critical to the life and performance of a battery pack, therefore accurately modeling the complete thermal system is important. Traditional approaches use complex 3D heat transfer and CFD or use a 1D network solver for quick prediction of flow and thermal fields. The 1D and 3D models are linked to get an overall system model. However, this coupling procedure can be tedious and time-consuming. This paper introduces a complete thermal modeling methodology that offers approaches for modeling thermal management system combining the benefits of 1D and 3D models in a single system greatly reducing the model development and analysis time. A new software package, ADFlo, developed with the support of the US Army is used to demonstrate these benefits. This approach is applied to the thermal management system for a battery pack where flow balancing of the coolant has a significant impact on the performance of the system. Properly balanced flow will create an even temperature distribution increasing the performance and life of the system. This will be seen on a 3D solid model of the battery. The analyst can use this to study the effects of modification to the cold plate to ensure an even temperature.