Integrated thermal and battery management for electric vehicles: Experimental validation and simulation-based optimization of lithium-ion batteries
Pujari Harish Kumar, G.K.S Prakash Raju, Mohit Bajaj, N. Chinna Alluraiah, Pasala Gopi, Sunil Kumar Pulumithi, Reshma Gopi Remabhai, Rashmi Gangadhar, Євген Зайцев
Abstract
Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, and long-term efficiency challenges. This study proposes an integrated thermal and battery management system that combines a water–ethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, and safety. Through COMSOL multiphysics simulations, this study examines LIB thermal behavior under varying operational conditions. The results indicate a 20% reduction in temperature peaks, with the battery maintaining an optimal temperature range of 15°C to 35°C, thus mitigating the risks of thermal runaway. Experimental validation using infrared thermography and thermal imaging confirms the system's efficiency, showing a maximum recorded battery temperature of 43.48°C under load conditions, significantly lower than unmanaged battery systems. Beyond thermal management, this work integrates advanced battery management strategies, including state-of-charge estimation, predictive fault diagnostics, active energy optimization, and cell balancing. Experimental analysis further reveals that the proposed system improves heat dissipation, resulting in a more uniform temperature distribution across the battery pack and reduced internal resistance-related losses. Additionally, infrared thermographic measurements demonstrate a 2°C to 3°C temperature uniformity improvement across battery cells, preventing localized overheating. This novel approach bridges the gap between cutting-edge cooling techniques and intelligent battery management, offering a scalable and cost-effective solution for next-generation EV battery systems. The findings have significant implications for enhancing battery safety, improving operational efficiency, extending battery lifespan, and accelerating global EV adoption.