Case Study report on Thermal Analysis of Lithium-Ion Battery Pack
SEM VI
DIV: A AY: 2024-25 Batch: A3
Name of Student Roll No. PRN
Ayush Bhalerao 52 202302090015
Om Vitole 78 202302090016
Vedant Paunikar 58 202302090031
Aditya Gaikwad 71 202302090062
Guided by,
Prof. Sudesh Powar
A Report Submitted To MIT AOE Alandi(D)Pune
An Autonomous Institute Affiliated Savitribai Phule Pune University
Partial Fulfilment of the Requirements of Mechanical Simulation Course
THIRD YEAR BACHELOR OF TECHNOLOGY
School of Mechanical Engineering MIT Academy of Engineering
(An Autonomous Institute Affiliated to Savitribai Phule Pune University)
ALANDI(D), PUNE – 412105
CERTIFICATE
It is hereby certified that the work is being presented in the Third Year case
study entitled “Thermal Analysis of Lithium-Ion Battery Pack”,
submitted to the School of Mechanical Engineering of MIT Academy of
Engineering Alandi(D), Pune, affiliated to Savitribai Phule Pune
University (SPPU),
Pune, is an authentic record of work carried out during Academic Year
20242025 Semester VI, under the supervision of Prof. Sudesh Powar,
School of Mechanical Engineering.
Prof. Sudesh Powar Dr. Abhijeet Malge
Course Teacher Dean, SME
Thermal Analysis of Lithium-Ion Battery Pack
Abstract
This report presents a comprehensive thermal analysis of a lithium-ion battery pack,
aimed at understanding temperature distribution, heat generation, and thermal behavior
during charging and discharging cycles. As lithium-ion batteries are widely used in electric
vehicles and energy storage systems, managing their thermal performance is essential to
ensure operational safety, extend battery life, and maintain performance efficiency. The
study investigates key factors influencing heat generation, including current load, cell
configuration, and ambient temperature. Both simulation and analytical approaches are
employed to evaluate the thermal response under various operating conditions. The
effectiveness of passive and active cooling methods is assessed, highlighting the
importance of uniform temperature distribution to prevent thermal runaway. Results
demonstrate that optimized thermal management significantly enhances battery safety
and performance. Recommendations are provided for designing efficient thermal
management systems for large-scale battery applications, emphasizing the need for
continuous monitoring and control strategies.
1. Introduction
The increasing demand for efficient and reliable energy storage systems has driven
the widespread adoption of lithium-ion batteries, particularly in electric vehicles
(EVs), portable electronics, and renewable energy applications. Despite their high
energy density and long cycle life, lithium-ion batteries are prone to heat generation
during operation, which can lead to uneven temperature distribution, reduced
performance, and even safety hazards such as thermal runaway.
Thermal management is therefore a critical engineering challenge that requires
detailed understanding and control of heat generation and dissipation within a
battery pack. Simulation plays a vital role in this context by enabling engineers to
predict thermal behavior under different operating conditions without the need for
extensive physical testing. It allows for optimization of cell arrangement, cooling
strategies, and material selection to enhance overall system performance.
The objective of this case study is to perform a thermal analysis of a lithium-ion
battery pack using simulation techniques. The primary goal is to evaluate temperature
distribution and identify effective thermal management strategies. The simulation
domain for this study is heat transfer, focusing on conduction, convection, and, where
applicable, radiation within the battery pack environment.
2. Literature Review
Husam Abdulrasool Hasan et al. (2023) investigated the effect of spacing between
lithium-ion batteries within an air-cooled battery pack. Using CFD simulations, they
analyzed how airflow distribution impacts the thermal regulation of battery packs.
Their study found that optimal spacing enhances cooling efficiency by improving
airflow distribution, reducing localized heat accumulation. However, their work lacks
a comparative analysis with liquid cooling systems, which are known for superior heat
dissipation. Lip Huat Saw et al. (2016) conducted a comprehensive CFD study on air
cooling for a 38,120- cell battery pack used in electric vehicles (EVs). Their
methodology included both numerical simulations and experimental validation of
heat generation during charging. They established a correlation between the Nusselt
number and Reynolds number to predict heat transfer efficiency. While their study
provided valuable insights into battery temperature management, it did not explore
hybrid cooling methods such as phase change materials (PCM) or liquid cooling.
Prashant Jindal et al. (2022) introduced an innovative approach by incorporating
Graphene Nanoplatelets (GNPs) into the coolant mixture for enhanced thermal
conductivity. Their CFD simulations demonstrated that adding GNPs to an ethylene
glycol (EG) and water mixture significantly lowered the battery pack’s operating
temperature. Their research focused on different battery configurations (one-tier,
two-tier, and three-tier) to optimize cooling effectiveness. However, the study did not
compare GNP-based cooling with conventional liquid cooling methods. Falcone et al.
(2021) conducted a broad survey of lithium-ion battery thermal management systems
and provided new CFD results. They examined various cooling strategies, including
air, liquid, and hybrid cooling techniques. Their findings indicated that liquid cooling
offers superior thermal regulation compared to air cooling, while hybrid approaches
(such as PCMassisted cooling) provide promising results. However, their research did
not include a detailed numerical comparison of different liquid coolants.
3. Methodology
The thermal analysis of the lithium-ion battery pack was carried out using a simulation
based approach to model heat generation and distribution under realistic operating
conditions. The methodology encompasses the following key steps:
3.1 Geometry Creation
A 3D model of the battery pack was created, consisting of multiple cylindrical or prismatic
cells arranged in series and parallel configurations. The model also included supporting
components such as cell holders, cooling channels (if applicable), and the outer casing.
3.2 Material Properties
Thermal conductivity, specific heat capacity, and density were defined for each
component. Lithium-ion cells were modeled with anisotropic thermal properties to reflect
their layered structure. Metallic and plastic materials used in casings and supports were
assigned standard thermal values.
3.3 Governing Equations
The simulation was based on the transient heat conduction equation:
where ρ\rhoρ is density, cpc_pcp is specific heat, T is temperature, k is thermal
conductivity, and Q is the internal heat generation rate. In cases involving active cooling,
the Navier-Stokes equations for fluid flow were also solved in conjunction with the energy
equation.
3.4 Boundary Conditions
Convective boundary conditions were applied on external surfaces exposed to air or
cooling fluid, with defined heat transfer coefficients. Symmetry conditions were used
where applicable to reduce computational cost. Fixed temperatures were applied at points
of thermal contact with cooling plates or heat sinks.
3.5 Initial Conditions
The initial temperature of the entire battery pack was set uniformly, typically at ambient
temperature (e.g., 25°C), to simulate startup conditions.
3.6 Meshing Strategy
A structured or hybrid mesh was used depending on geometry complexity. Finer mesh
refinement was applied around hotspots, interfaces, and regions with steep temperature
gradients to ensure accuracy.
3.7 Solver Settings
A transient thermal solver was employed, with appropriate time stepping to capture
temperature evolution accurately. For coupled thermal-fluid simulations, a segregated
solver with convergence criteria based on residuals for energy and flow equations was
used.
4. Results and Discussion
1.Meshing
Fig No. 1 Meshing
2.Geometry
Fig No. 2 Geometry
3. Name Selection
Fig No. 3 Name Selection
4.Temperature Volume Rendering
Fig No. 4 Temperature Volume Rendering
5. Total Temperature
Fig No. 5 Total Temperature
5. Conclusion
The thermal analysis of the lithium-ion battery pack revealed critical insights into
temperature distribution and heat generation patterns during operation. The simulation
identified potential hotspots and demonstrated the importance of efficient thermal
management strategies, such as optimized cell layout and effective cooling methods.
Using simulation provided a cost-effective and time-saving approach to evaluate thermal
performance under various scenarios without physical prototyping. It enabled detailed
examination of internal thermal behaviour, which is difficult to achieve through
experiments alone.
However, the study faced limitations, including assumptions of uniform heat generation
and simplified cooling models. Material property variations and electrochemical
interactions were also not fully captured.
Future work could incorporate electro-thermal coupling and detailed battery aging models
to improve accuracy. Real-life applications of this analysis include battery design
optimization for electric vehicles, consumer electronics, and renewable energy storage
systems, where thermal reliability is crucial for performance and safety.
6. References
[1] G. Pistoia, Lithium-Ion Batteries: Advances and Applications. Amsterdam: Elsevier, 2014.
[2] J. Jaguemont, L. Boulon, and Y. Dube, "A comprehensive review of lithium-ion batteries
used in hybrid and electric vehicles at cold temperatures," Applied Energy, vol. 164, pp. 99–
114, Feb. 2016.
[3] M. Safari and C. Delacourt, "Modeling of a commercial graphite/LiFePO₄ cell," Journal of
The Electrochemical Society, vol. 158, no. 12, pp. A562–A571, 2011.
[4] ANSYS Inc., ANSYS Fluent Theory Guide, Release 2022 R1, Canonsburg, PA, USA, 2022.
[5] D. Bernardi, E. Pawlikowski, and J. Newman, "A general energy balance for battery
systems," Journal of the Electrochemical Society, vol. 132, no. 1, pp. 5–12, 1985.
