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Lightweighting Strategies for Optimized Thermal Energy Storage: Topology Optimization of Heat Exchanger Fins

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SSRN 2024年

作者： Wu, Chongtian Yuan, Xiaolu Yuan, Nenglin Li, Yonghao Kong, Benben Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft Environment Control and Life Support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

This study introduces topology optimization (TO) to enhance the efficiency of thermal energy storage systems (TESS) by optimizing fins, addressing the low thermal conductivity of phase change materials (PCM). Fins are simplified to a "Y+T" configuration based on TO results, improving TESS performance. Additionally, the paper first incorporates the mass(m) factor into TESS optimization, emphasizing its significance in the design process. Divided into two steps for efficiency, the optimization process explores nine fin scenarios, favoring distribution optimization over increasing fin numbers. The optimal model, with three branches and θ=90°, reduces melting time and enhances efficiency compared to finless TESS. A lightweight design approach adjusts root length and width ratio, achieving efficiency gains and reducing melting time. This study introduces the mass factor and provides a rational fin configuration through TO and optimization. Named "TO Typical Structure Extraction+Parameter Sensitivity Analysis + Entropy Weighted-TOPSIS Multi-Objective Optimization," it elucidates thermal storage mechanisms, facilitating rapid optimization and offering insights for TESS fin optimization and lightweight design. © 2024, The Authors. All rights reserved.

关键词： Heat storage

An Innovative Hybrid Air-Cooled and Liquid-Cooled System for Condensation Prevention

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SSRN 2024年

作者： Zhang, Bixiao Yuan, Nenglin Kong, Benben Zou, Yitao Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft Environment Control and Life Support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

Addressing the issue of condensation susceptibility in lithium battery thermal management systems operating in high-humidity environments, this paper proposes an innovative hybrid air and liquid cooling system. This system incorporates a specially designed return air structure to enhance the thermal stability and safety of the batteries. Computational fluid dynamics (CFD) simulations were utilized to analyze the thermal management performance under varying airflow velocities and temperature conditions, leading to the optimization of the return air structure to mitigate condensation. The research findings reveal that the proposed hybrid system reduces the condensation area by approximately 39.68% at an airflow velocity of 0.5 m/s compared to traditional liquid cooling systems. Furthermore, the introduction of flow deflectors significantly improves the anti-condensation effect in high-humidity environments, achieving the objective of dew-free operation throughout the entire area. Lastly, employing the entropy weight-TOPSIS method and nonlinear surface fitting, a comprehensive evaluation of multiple schemes was conducted regarding heat dissipation, anti-condensation measures, and energy consumption. It was determined that when Vair = 1.29 m/s and Vwater = 0.22 m/s, the thermal management system of the battery module exhibits optimal comprehensive performance, with corresponding values of T, Tmax, Enair, and Enwater being 3.98 K, 302.36 K, 0.15806 J, and 0.19203 J. The outcomes of this paper not only enhance the thermal management efficiency of lithium-ion batteries in high-humidity environments but also offer practical solutions for electric vehicles and other fields requiring efficient thermal management, demonstrating significant engineering application value. © 2024, The Authors. All rights reserved.

关键词： Condensation

Numerical Investigations of Phase Change Material (Pcm)-Based Battery Thermal Management System (Btms) Under Variable Gravity Environment

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SSRN 2023年

作者： Wu, Chongtian Qiu, Chenghui Yuan, Xiaolu Yuan, Nenglin Zhang, Bixiao Li, Yonghao Qin, Liwei Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft Environment Control and Life Support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

PCMs are widely employed in electronic thermal control systems for spacecraft because of their substantial energy storage competencies. Therefore, the influence of gravitational acceleration (GA) on PCM thermal performance is of particular importance. Simultaneously, considering the spacecraft's center of gravity, attitude control, and structural design, the selection of an appropriate battery orientation becomes crucial to maximize the utilization of available space. This study employs numerical simulation to assess PCM heat transfer efficiency and thermal behavior of BTMS cooled under varying gravitational environments (0.05 g, 0.1 g, 1 g, 10 g, and 20 g) and different inclination angles (θ=90°, 45°, 0°) via the enthalpy-porosity method. Research results indicate that as gravity increases from 0.05 g to 20 g, the melting time of PCM shortened by 15%, reducing from 95.05 s to 81.30 s. This phenomenon can be explained by the enhanced convective heat transfer capability, increasing the maximum velocity (Vmax) of the liquid PCM (PCMl) by over 12 times. Particularly, when GA= 10 g, increasing θ from 45° to 90° reduces PCM melting time by 59.05s (9.66% reduction) compared to θ=45°, while at θ=0°, it decreases by 65.75 s (10.75% reduction). Notably, at θ=45°, some unmelted solid PCM accumulates in the lower right corner of the enclosure hindering the BTMS heat transfer. Based on the characteristics of PCM melting and accumulation effects, three optimization structures for different θ are proposed in this study. It can be observed at t=240s that the enhancement of PCM melting phenomenon is particularly prominent with the presence of fins. Furthermore, by comparing CHTC curves before and after optimization, it is evident that the accumulated effect has been effectively eliminated after optimization. In conclusion, this paper conducted an in-depth investigation into the correlation between the enhancement of CHTC and fin mass, as well as the volume ratio(γ) between PCM and

关键词： Phase change materials

Innovative Liquid Cooling Channel Enhanced Battery Thermal Management (Btm) Structure Based on Stepwise Optimization Method

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SSRN 2023年

作者： Wu, Chongtian Yuan, Xiaolu Kong, Benben Zou, Yitao Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft Environment Control and Life Support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

Lithium-ion batteries have garnered significant attention in the field of new energy technologies owing to their remarkable high energy density characteristics. This paper proposes a compact battery liquid-cooling system and perform structural optimization based on a stepwise optimization concept, aimed at comprehensively enhancing the performance of the Battery Liquid Cooling System (BLCS). Firstly, this paper conducts an energy consumption optimization of the flow velocity (V), diameter (D), and the contact angle (θ). Subsequently, the entropy weighted-TOPSIS method is utilized for objective optimization, thereby obtaining the optimal configuration based on comprehensive considerations of power consume (Pc), maximum temperature (Tmax) and maximum temperature difference (ΔT), with V=0.4 m/s, D=3 mm, θ=75°. When the initial temperature=25 ℃ and discharge rate=3 C, this structure yields the following results: Tmax =28.089 ℃, ΔT=2.884 ℃, and Pc=19.484 J. Furthermore, in the re-optimization phase, a lightweight design is applied to the system. In this phase, we optimize three parameters for the layered conductive fin: the number of layers (L), the height of each layer (Lh), and the thickness (Lw). By enumerating Lw=0, thirteen operating conditions are considered with L ranging from 1 to 4 layers, and Lh taking values of 5 mm, 7 mm, 9 mm, and 11 mm. Employing the entropy weight-TOPSIS method, the optimal solution is determined by comprehensively considering δ, Tmax, and ΔT. Under this condition, the weights for δ, Tmax, and ΔT are 41.02%, 30.82%, and 28.16%, respectively. Following comprehensive evaluation, the optimal solution is attained: L=3, Lh=7. Under these conditions, the BLCS achieves Tmax=29.196 ℃, ΔT=3.753 ℃, and δ=0.755, resulting in a weight reduction of 61 g (20.7%) for components of BLCS excluding the battery. This research through a stepwise optimization method, has accomplished a comprehensive enhancement of both energy consumption and mass for the BLCS,

关键词： Structural optimization

Simulation of Hybrid Air-Cooled and Liquid-Cooled Systems for Optimal Lithium-Ion Battery Performance and Condensation Prevention in High-Humidity Environments

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SSRN 2024年

作者： Zhang, Bixiao Yuan, Nenglin Kong, Benben Zou, Yitao Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft environment control and life support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

This study introduces an innovative hybrid air-cooled and liquid-cooled system designed to mitigate condensation in lithium-ion battery thermal management systems (BTMS) operating in high-humidity environments. The proposed system features a unique return air structure that enhances the thermal stability and safety of the batteries by recirculating air through the battery box, thereby utilizing residual heat to prevent condensation. Computational Fluid Dynamics (CFD) simulations were employed to analyze and optimize the system's thermal management performance under various airflow velocities and temperature conditions. The study results show that compared to traditional liquid cooling systems, the proposed hybrid system reduces the condensation area by approximately 39.68% at a wind speed of 0.5 m/s, and the temperature difference decreases by 0.35 K. The integration of flow deflectors further improves the anti-condensation effect, achieving a phase change rate greater than 0 in the cooling area, thereby enabling condensation-free operation throughout the entire cooling zone. A comprehensive evaluation using the entropy weight-TOPSIS method and nonlinear surface fitting was conducted to assess multiple schemes regarding heat dissipation, anti-condensation measures, and energy consumption. The optimal operating conditions were identified as an airflow velocity (Vair) of 1.29 m/s and a liquid flow velocity (Vwater) of 0.22 m/s, resulting in a maximum temperature difference (ΔT) of 3.98 K, a maximum temperature (Tmax) of 302.36 K, and energy consumption values (Enair and Enwater) of 0.158 J and 0.192 J, respectively. The proposed system not only addresses the thermal management challenges of lithium-ion batteries in high humidity environments, but also effectively ensures the insulation safety of electronic components. It provides a reliable solution for electric vehicles and other high-efficiency thermal management applications, demonstrating significant engineering a

关键词： Cooling systems

Simulation of Hybrid Air-Cooled and Liquid-Cooled Systems for Optimal Lithium-Ion Battery Performance and Condensation Prevention in High-Humidity Environments

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SSRN 2024年

作者： Zhang, Bixiao Yuan, Nenglin Kong, Benben Zou, Yitao Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft environment control and life support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

关键词： Cooling systems

An Innovative Hybrid Air-Cooled and Liquid-Cooled System for Condensation Prevention

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SSRN 2024年

作者： Zhang, Bixiao Yuan, Nenglin Kong, Benben Zou, Yitao Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft environment control and life support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

Addressing the issue of condensation susceptibility in lithium battery thermal management systems operating in high-humidity environments, this paper proposes an innovative hybrid air and liquid cooling system. This system incorporates a specially designed return air structure to enhance the thermal stability and safety of the batteries. Computational fluid dynamics (CFD) simulations were utilized to analyze the thermal management performance under varying airflow velocities and temperature conditions, leading to the optimization of the return air structure to mitigate condensation. The research findings reveal that the proposed hybrid system reduces the condensation area by approximately 39.68% at an airflow velocity of 0.5 m/s compared to traditional liquid cooling systems. Furthermore, the introduction of flow deflectors significantly improves the anti-condensation effect in high-humidity environments, achieving the objective of dew-free operation throughout the entire area. Lastly, employing the entropy weight-TOPSIS method and nonlinear surface fitting, a comprehensive evaluation of multiple schemes was conducted regarding heat dissipation, anti-condensation measures, and energy consumption. It was determined that when Vair = 1.29 m/s and Vwater = 0.22 m/s, the thermal management system of the battery module exhibits optimal comprehensive performance, with corresponding values of ∆T, Tmax, Enair, and Enwater being 3.98 K, 302.36 K, 0.15806 J, and 0.19203 J. The outcomes of this paper not only enhance the thermal management efficiency of lithium-ion batteries in high-humidity environments but also offer practical solutions for electric vehicles and other fields requiring efficient thermal management, demonstrating significant engineering application value. © 2024, The Authors. All rights reserved.

关键词： Condensation

An Innovative Hybrid Air-Cooled and Liquid-Cooled System for Condensation Prevention

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SSRN 2024年

作者： Zhang, Bixiao Yuan, Nenglin Kong, Benben Zou, Yitao Shi, Hong College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft environment control and life support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

This study introduces an innovative hybrid air-cooled and liquid-cooled system designed to mitigate condensation in lithium-ion battery thermal management systems (BTMS) operating in high-humidity environments. The proposed system features a unique return air structure that enhances the thermal stability and safety of the batteries by recirculating air through the battery box, thereby utilizing residual heat to prevent condensation. Computational Fluid Dynamics (CFD) simulations were employed to analyze and optimize the system's thermal management performance under various airflow velocities and temperature conditions. The research findings indicate that the hybrid system significantly reduces the condensation area by approximately 39.68% at an airflow velocity of 0.5 m/s compared to traditional liquid cooling systems. The integration of flow deflectors further improves the anti-condensation effect, achieving dew-free operation across the entire cooling area. A comprehensive evaluation using the entropy weight-TOPSIS method and nonlinear surface fitting was conducted to assess multiple schemes regarding heat dissipation, anti-condensation measures, and energy consumption. The optimal operating conditions were identified as an airflow velocity (Vair) of 1.29 m/s and a liquid flow velocity (Vwater) of 0.22 m/s, resulting in a maximum temperature difference (ΔT) of 3.98 K, a maximum temperature (Tmax) of 302.36 K, and energy consumption values (Enair and Enwater) of 0.15806 J and 0.19203 J, *** outcomes of this research not only enhance the thermal management efficiency of lithium-ion batteries in high-humidity conditions but also provide practical solutions for electric vehicles and other applications requiring efficient thermal management, demonstrating significant engineering application value. The proposed system addresses the critical challenge of condensation in BTMS, offering a robust and energy-efficient solution that could significantly improve th

关键词： Condensation

Multi-Objective Optimization of Integrated Lithium-Ion Battery Thermal Management System

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SSRN 2022年

作者： Shi, Hong Liu, Meinan Li, Yonghao Wang, Shuheng Qiu, Chenghui Cheng, Mengmeng Yuan, Jie Yang, Kaijie Kang, Chuanzhi College of Energy & Power Engineering Jiangsu University of Science and Technology 2 Mengxi Jingkou Zhenjiang212003 China Key Laboratory of Aircraft Environment Control and Life Support MIIT Nanjing University of Aeronautics & Astronautics 29 Yudao Street Nanjing210016 China

The heat generation rate of lithium-ion battery increases dramatically with the increase in the charge/discharge rate of the battery. Battery thermal management system (BTMS) based on phase change materials (PCM) are demonstrating great performance in the field of high heat flux heat dissipation. However, traditional hybrid PCM modules focus too much on their thermal performance and ignore the weight issue, which greatly reduces their wide application. In this paper, a BTMS integrated air-cooling channels, fins and PCM is proposed to improve the thermal performance of the battery. Based on the entropy weight-TOPSIS method, the balance of battery cells temperature uniformity and lightweight of lithium batteries is studied and the parameters of the optimal BTMS are obtained. The results demonstrate that the thermal performance of the battery is enhanced as the increase of PCM volume, but the weight of the system also increases significantly. When the height of the fins increases, the reasonable utilization of PCM increases and the PCM melts more evenly. Entropy weight-TOPSIS can help us to find the optimal solution between thermal performance and lightweight design. After the TOPSIS algorithm search, the optimal structural solution corresponding to the PCM thickness ( d ) = 7.5 mm and the fin height ( h ) = 65 mm has the smallest Euclidean distance Si+ from the positive ideal solution, and the largest Euclidean distance Si- from the negative ideal solution, thus it obtains a higher Ci and the highest priority. The corresponding maximum temperature ( Tmax), temperature difference (∆T) and weight (W) are 319.29 K, 0.0135 K and 5.13 kg respectively. © 2022, The Authors. All rights reserved.

关键词： Multiobjective optimization