Standalone Battery Pack Thermal Behavior Simulation and Experimental Correlation in a Controlled Environment

Battery thermal management is crucial for ensuring the safety, efficiency, and longevity of lithium-ion battery packs, particularly in electric vehicles (EVs). The primary purpose of a lithium-ion battery in an electric vehicle is to store and provide electrical energy for vehicle propulsion while maintaining safety under different operating conditions. This work proposes a thermal correlation between 1D CFD simulation and experimental test data under passive environmental heat exchange conditions without active coolant flow of a battery pack comprising four modules. An environmental exchange test was conducted using a 50% state of charge (SOC) battery pack, which is stabilized at 25°C to assess passive heat dissipation, thermal soak behavior, temperature distribution, and potential thermal runaway risks. The simulation predictions correlate well within a 1.5°C range compared to test results using ambient temperature and flow inputs, which confirms the reliability of the modeling approach. The simulation work was carried out using the GT-SUITE software. This study improves battery thermal management strategies by enhancing predictive accuracy and optimizing simulation frameworks for real-world applications. It minimizes overheating risks in practical scenarios, such as prolonged exposure to high ambient temperatures.