Thermal Analysis for Electric vehicle Battery Tray with Modified Material using Numerical Method:
No Thumbnail Available
Date
2025-02
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Addis Ababa University
Abstract
Today, Electric vehicles (EV) are an interesting current and future option helps to reducing environmental impact by decreasing emissions and greenhouse gases. Electric vehicle face challenges related to safety, functionality, and operation. One of the key issues is the growing need for effective battery cooling to prevent potential thermal stability problems caused by extreme temperatures due to the traditional use of steel in battery enclosures. Letin Mengo (Anna 200) electric vehicle battery trays are made up of AISI 4031 steel materials that ensures the rigidity or solidity required to support the weight of an assembly of cells. However, steel has heavy weight, low thermal conductivities (TC) and high coefficient of thermal expansion (CTE) values that result in induced thermal stresses which can cause the device to fail permantly. This induces the overheating of the EV battery components, thermal stress and leads to reduce the overall efficiency of the battery’s performance and life time.
Metal Matrix Composites are designed in order to have the combined properties of both metals and ceramics and have excellent mechanical and thermal properties. Due to its excellent thermophysical properties, including low coefficient of thermal expansion (CTE), high thermal conductivity, and improved mechanical properties, Al metal matrix reinforced by sic is used for heat-sensitive components. Therefore, the study focused on numerical analysis on thermal behavior of Aluminum Silicon Carbide (AlSiC) metal matrix composite materials for Anna 200 EV battery trays with cold plate cooling system. ANSYS work bench software are used to determine the surface temperature distribution of the EV battery tray.
According to the results, the AlSiC MMC material can reduce the maximum surface temperature from 83.47°C (for 4130 steel) to 69.64°C. Additional temperature reduction is possible with the help of liquid cooling system and this can maintain the battery tray surface temperature at around 33.1℃. In addition, result shows that the cooling system can safely maintain the battery surface temperature at a discharge rate of up to 3 C. in the explicit dynamic analysis the deformation and equivalent (von misses) stress of AlSiC tray is less than the convectional steel4130 EV tray.
Description
Keywords
AlSiC, CTE, TC, State of charging, Cooling, Surface temperature