Experimental testing in automotive development sometimes relies on ad hoc approaches like ‘One Factor at a Time’, particularly in time- and resource-limited situations. While widely used, these approaches are limited in their ability to systematically capture parameter interactions and system complexities, which poses significant challenges in safety-critical applications like high-voltage battery systems. This study systematically investigates the factors influencing thermal runaway in lithium-ion battery cells using a statistical full-factorial experimental design. Key parameters, including state of charge, cell capacity and heating trigger power, have been analyzed under controlled conditions with an autoclave setup, enabling precise measurement of thermal and mechanical responses. The use of automotive-grade lithium-ion cells ensures relevance for next-generation applications. By employing factorial regression and statistical analysis, the study identifies critical temperatures

Ceylan, Deniz, Kulzer, André Casal, Winterholler, Nina, Weinmann, Johannes, Schiek, Werner

Design and Analysis of a Battery Thermal Management System for Fast Charging in Extreme Hot Condition

2025-01-0322

07/02/2025

Fast charging of lithium-ion batteries presents significant thermal management challenges, due to the high demanding conditions of high C-rates, particularly at extreme ambient temperatures. This study explores the thermal behavior of a cylindrical lithium-ion cell during fast-charging scenarios designed to achieve a full charge in 15 minutes or less (SOC: 0%–100%), across a wide range of ambient temperatures. The analysis covers a broad spectrum of ambient temperatures, from 303 K to 333 K, addressing real-world operational challenges faced by electric vehicles and energy storage systems. A validated thermal model, calibrated with experimental data on the open circuit voltage (OCV) and internal resistance of the cell across varying conditions, is employed to accurately predict the temperature distribution of the cell at different states of charge (SOC). The model also includes scenarios involving high initial cell temperatures to assess their effect on thermal performance during fast

Jahanpanah, Jalal, Mahmoudzadeh Andwari, Amin, Babaie, Meisam, Konno, Juho, Akbarzadeh, Mohsen

SAE TOMORROW TODAY - The Hidden Role of Battery Vents in EV Safety and Adoption

1351906/13/2025

One failure can reshape public trust in EVs overnight. That's why every detail matters--and why collaboration across the entire EV ecosystem is critical. Even small components like battery pack vents play an outsized role in preventing thermal runaway events, explosions, and fires. The SAE Battery Pack Venting Committee understands this challenge and answered the call with the new SAE J3325(TM) Technical Information Report a guide to designing, testing, and integrating battery vents that perform when it matters most. To dive deeper, we spoke with Dr. Michael Harenbrock, Principal Expert of Electric Mobility at MANN+HUMMEL GmbH, and chair of the SAE Battery Pack Venting Committee about how SAE J3325 is helping engineers enhance EV battery safety--and how their work evolves to keep pace with emerging ventilation technologies and trends. Want to help shape the future of EV safety? Join an SAE Committee today! Contact Standards Specialist Dante Rahdar at dante.rahdar@sae.org. We'd love to

Hineman, Marcie

Application of a Chemical Kinetic Modeling Approach within a Fully Coupled Computational Fluid Dynamics Simulation of Battery Cells during Thermal Runaway

14-14-02-0014

06/11/2025

The objective of the current study is to systematically evaluate the battery thermal runaway heat release rate through chemical kinetics and then study its effect on battery module and pack level. For this purpose, a chemistry solver has been developed, capable of simultaneously solving the thermal runaway kinetics in multiple battery cells with the cell-specific chemistry model and battery active material compositions. This developed solid body chemistry (SBC) solver assumes a homogeneous system in the specified geometrical selection. A 3D representation can be achieved by setting up multiple solver selections in one solid domain (battery cell) as the SBC solver is capable of handling multiple selections, chemistry models, and battery active material compositions. Further, the SBC solver is fully integrated in a commercial three-dimensional computational fluid dynamics (3D-CFD) code. Thus, enabling to simulate the real-life thermal runaway applications covering the battery module and

Chittipotula, Thirumalesha, Eder, Lucas, Uhl, Thomas

Integrating for Safety – A Proposed Approach to the Integration of Propulsion Battery Systems in Hybrid Electric Aviation

2025-01-0148

05/02/2025

The authors have witnessed a notable surge in the number of designs and in the guidance material for electric and hybrid aircraft. FAA and EASA have continued to evaluate the safety of Propulsion Battery Systems (PBS), with a focus on thermal runaway containment testing. As a result, a harmonization white paper [7] was issued to provide a certification path for Thermal Runaway (TR) Hazards, followed by an EASA certification memorandum on the acceptable approaches for the certification of Electric/Hybrid Propulsion Systems (EHPS). Recently, an FAA Advisory Circular (draft) was issued for the “powered-lift” aircraft that feature these propulsion battery systems. Despite the advances made by electric/hybrid aircraft manufacturers and the aviation authorities, there is still a missing piece of the puzzle. Mainly, engineering work still needs to be done to properly integrate the EHPS architecture to achieve safety objectives. The burden is still on systems engineering to propose their own

Hanna, Michael, Walker, Cherizar

Assessing Lithium-ion Battery Functionality Post-Thermal Management with Water Mist

2024-32-0122

04/18/2025

The danger of lithium-ion batteries in electric vehicles (EVs) is intensified when they are used at inappropriate temperatures, leading to self-heating and eventually contributing to thermal runaway. Nevertheless, there is uncertainty through the safety of reusing batteries after they have been exposed to heat damage and water mist from fire extinguishers. To address these concerns, this study aimed to experimentally investigate the impact of temperature on batteries and introduce a thermal management using a water mist. Subjecting a battery to a temperature of 100°C for a duration of 39 minutes can immediately detect inoperability from a sudden drop in voltage. The use of water mist was proposed to rapidly mitigate the heat production inside the battery. The state of health (SOH) and the impedance were employed to confirm the battery’s functionality after exposure to thermal abuse and water spraying. The SOH of fresh cells was measured as a reference line for comparison to tested

Trinuruk, Piyatida, Patthathum, Pathomporn, Jumnongjit, Apiwit

Research on Heat Dissipation of Cabinet of Electrochemical Energy Storage System

2025-01-8193

04/01/2025

With the increasingly prominent environmental problems and energy crisis, wind power, solar power and other new energy has been rapid development, and energy storage technology is of great significance to the development of new energy. Compared with the power batteries applied in electric vehicles, battery energy storage systems gather a larger number of batteries and a larger scale, usually up to megawatts or 100 megawatts. During the operation of the energy storage system, the lithium-ion battery continues to charge and discharge, and its internal electrochemical reaction will inevitably generate a lot of heat. If the heat is not dispersed in time, the temperature of the lithium-ion battery will continue to rise, which will seriously affect the service life and performance of the battery, and even cause thermal runaway leading to explosion. It is of great significance for promoting the development of new energy technologies to carry out research on the thermal model of lithium-ion

Chen, Jianxiang, Li, Liping, Zhou, Fupeng, Li, Chuncheng, Shangguan, Wen-Bin

3D Modeling of Thermal Runaway in Pouch Cells: Effects of Surface Heating and Heating Rates

2025-01-8559

04/01/2025

Thermal runaway in battery cells presents a critical safety concern, emphasizing the need for a thorough understanding of thermal behavior to enhance battery safety and performance. This study introduces a newly developed AutoLion 3D thermal runaway model, which builds on the earlier AutoLion 1D framework and offers significantly faster computational performance compared to traditional CFD models. The model is validated through simulations of the heat-wait-search mode of the Accelerating Rate Calorimeter (ARC), accurately predicting thermal runaway by matching experimental temperature profiles from peer-reviewed studies. Once validated, the model is employed to investigate the thermal behavior of 3D LFPO cells under controlled heating conditions, applying heat to one or more surfaces at a time while modeling heat transfer from non-heated surfaces. The primary objective is to understand how these localized heating patterns impact temperature profiles, including average core temperatures

Hariharan, Deivanayagam, Gundlapally, Santhosh

Impact of Thermal Gradients on Calorimetry Testing of Battery Cells

2025-01-8175

04/01/2025

Detailed modeling of battery thermal runaway and propagation often requires a source term that represents the chemical heat release of the cell as a function of temperature. The shape of this heat release trend typically comes from cell testing data. Accelerating rate calorimetry (ARC) tests provide concise information on cell self-heating, since the cell is kept nearly isothermal and adiabatic. Also, compared to differential scanning calorimetry (DSC) tests of battery component materials, it contains all interactions between components. Converting the temperature rise rate data to heat release rate is theoretically very simple, only requiring the heat capacity of the cell. Practically, however, careful analysis is required to avoid artifacts arising from limitations of the test setup. This study uses a simple one-dimensional transient heat transfer model to illustrate the runaway process inside a cell and describe two error sources present in many ARC tests. As the cell temperature

Vanderwege, Brad, Petersen, Ben

Nail Penetration Adapter for Li-Ion Battery Testing

TBMG-52814

04/01/2025

Innovators at NASA Johnson Space Center have designed a pneumatic nail penetration trigger system that drives a Li-ion battery cell into thermal runaway using a tungsten nail. By creating a targeted rupture in a battery cell’s outer casing, researchers can initiate an exothermic chain reaction within the battery, much like a short circuit, causing a spike in temperature that can lead to battery failure, fire or explosion.

Effectiveness of Nail Penetration for Thermal Propagation Test in Battery Packs and Vehicles

2025-01-8128

04/01/2025

The number of electric vehicles (EVs) has significantly increased in recent years. Safety performance of EVs is at least at the same level as that of conventional vehicles. To evaluate battery safety and ensure passenger protection, several standard tests and regulations for EV batteries have been established, including IEC 62660-3, ISO 6469-1, and UN/ECE/R100 Revision 3. ISO 6469-1:2019/Amd 1 specifies thermal propagation (TP) test to evaluate battery robustness against thermal runaway (TR) in a single cell. Moreover, UN/ECE/R100 Revision 3 aims to provide sufficient egress time to protect passengers in the event of a TR in a single cell. Typically, these tests initiate TR in a cell within a battery pack using either a heater or nail. In the heater method, if the gap between cells is larger than the heater’s thickness and there are no installation constraints due to components, almost any cell can be chosen as the initiating cell. However, if the gap between cells is smaller than the

Maeda, Kiyotaka, Takahashi, Masashi

Numerical Model of the Heat-Wait and Seek and Heating Ramp Protocol for the Prediction of Thermal Runaway in Lithium-Ion Batteries

2025-01-8127

04/01/2025

Interest in Battery-Driven Electric Vehicles (EVs) has significantly grown in recent years due to the decline of traditional Internal Combustion Engines (ICEs). However, malfunctions in Lithium-Ion Batteries (LIBs) can lead to catastrophic results such as Thermal Runaway (TR), posing serious safety concerns due to their high energy release and the emission of flammable gases. Understanding this phenomenon is essential for reducing risks and mitigating its effects. In this study, a digital twin of an Accelerated Rate Calorimeter (ARC) under a Heat-Wait-and-Seek (HWS) procedure is developed using a Computational Fluid Dynamics (CFD) framework. The CFD model simulates the heating of the cell during the HWS procedure, pressure build-up within the LIB, gas venting phenomena, and the exothermic processes within the LIB due to the degradation of internal components. The model is validated against experimental results for an NCA 18650 LIB under similar conditions, focusing on LIB temperature

Gil, Antonio, Monsalve-Serrano, Javier, Marco-Gimeno, Javier, Guaraco-Figueira, Carlos

Investigation of Impedance Evolution for Lithium Plating Detection during Multi-Stage Constant Current Fast Charging of Lithium-Ion Batteries

2025-01-8124

04/01/2025

aThe lengthy charging time of lithium-ion batteries for electric vehicles (EVs) significantly affect their acceptance. Reducing charging time requires high-power fast charging. However, such fast charging can trigger various side reactions, leading to safety and durability issues. Among these, lithium plating is a major concern as it can reduce battery capacity and potentially cause internal short circuits or even thermal runaway. Currently, multi-stage constant current charging (MCCC) protocols are widely adopted. However, the difficulty in effectively detecting lithium plating during the MCCC process significantly limits the charging power. Therefore, it is urgent to explore a method to detect lithium plating during the MCCC process. In this study, the impedance evolution during the MCCC procedure was first investigated. Then a method based on the impedance variation patterns was proposed to detect lithium plating. Besides, the reason for the behavior of impedance changes was further

Shen, Yudong, Wang, Xueyuan, Wu, Hang, Wei, Xuezhe, Dai, Haifeng

Bio-Based Phase Change Material for Electric Vehicle Battery Thermal Management using Copper Fins: A Numerical Investigation

2025-01-8171

04/01/2025

Electric vehicles (EVs) are gaining popularity due to their zero tailpipe emissions, superior energy efficiency, and sustainable nature. EVs have various limitations, and crucial one is the occurrence of thermal runaway in the battery pack. During charging or discharging condition of battery pack may result in thermal runaway condition. This promotes the requirement of effective cooling arrangement in and around the battery pack to avoid localized peak temperature. In the present work, thermal management of a 26650 Lithium iron phosphate (LFP) cell using natural convection air cooling, composite biobased phase change material (CBPCM) and its combination with copper fins is numerically investigated using multi-scale multi dimension - Newman, Tiedenann, Gu and Kim (MSMD-NTGK) battery model in Ansys Fluent at an ambient temperature of 306 K. Natural convection air cooling was found effective at discharge rates of 1C to 3C, maintaining cell temperature below the safe limit of 318 K for 80

Srivastav, Durgesh, Patil, Nagesh Devidas, Shukla, Pravesh Chandra

Experimental and Simulation-Based Characterization of Thermal Runaway in Lithium-Ion Batteries Using Altair SimLab®

2025-01-8146

04/01/2025

Thermal runaway is a critical phenomenon in lithium batteries, characterized by a self-sustaining process due to internal chemical reactions, that is triggered once a certain temperature is reached within the cell. This event is often caused by overheating due to charge and discharge cycles and can lead to fires or explosions, posing a significant safety threat. The aim of this study is to induce thermal runaway on single cells in different ways to characterize the phenomenon and validate the simulation models present in Altair SimLab®. The work was conducted in several key phases. Initially, an experimental test was performed in a calorimeter (EV ARC HWS test) to collect temperature data of the Molicel 21700 P45B cell during thermal runaway under adiabatic conditions. These data were used for a simulation on a single cell, allowing a detailed comparison with the experimental results. Subsequently, a test was conducted on a single cell under operational conditions, overheated using a

Giuliano, Luca, Scrimieri, Luigi, Reitano, Simone, Berti Polato, Davide, Ferraris, Alessandro, Comerford, Andrew, Bhatnagar, Saakaar

Experimental Analysis of Battery Thermal Management Techniques for Electric Vehicle Lithium-Ion Batteries Using MATLAB Simulink, Simscape, and Stateflow Simulations

2025-01-8165

04/01/2025

The use of lithium-ion batteries in electric vehicles marks a major progression in the automotive sector. Energy storage systems extensively make use of these batteries. The extended life cycle, low self-discharge rates, high energy density, and eco-friendliness of lithium-ion batteries are well-known. However, Temperature sensitivity has an adverse effect on lithium-ion battery safety, durability, and performance. Thus, maintaining ideal operating conditions and reducing the chance of thermal runaway depend heavily on efficient thermal management. To address this, experimental study was conducted on various battery thermal management techniques, including active, passive, and hybrid approaches. These techniques were investigated for their cooling efficiencies under different operating conditions. The electro-thermal behavior of cylindrical lithium-ion battery cells, battery packs, and supervisory control techniques were simulated in the study using MATLAB Simulink, Simscape, and

Thangaraju, Shanmuganathan, N, Meenakshi, Ganesan, Maragatham

A Framework for Modeling Mechanically Induced Thermal Runaway in Lithium-Ion Batteries

2025-01-8134

04/01/2025

Battery safety is a paramount concern in the development of electric vehicles (EVs), as failures can lead to catastrophic consequences, including fires and explosions. With the rapid global adoption of EVs, understanding how battery cells perform under extreme conditions such as mechanical or thermal abuse is crucial for ensuring vehicle safety. This study investigates the abuse response of lithium-ion batteries under high-speed mechanical loading. Our research systematically examines the response of these cells at different states of charge (SOC) through controlled dynamic tests. These tests offer insights into the failure response of the cells. By analyzing the data, we gain a deeper understanding of the conditions that could trigger thermal runaway under mechanical abuse loadings, representative of EV crashes, a critical safety concern in EV battery systems. The experimental setup and methodologies are presented in this paper, alongside key findings that highlight the importance of

Patanwala, Huzefa, Kong, Kevin, Challa, Vidyu, Darvish, Kurosh, Sahraei, Elham

Influence of Performance Degradation on the Thermal Runaway of Lithium Batteries: A Review

2025-01-8562

04/01/2025

As the main power source for modern portable electronic devices and electric vehicles, lithium-ion batteries (LIBs) are favored for their high energy density and good cycling performance. However, as the usage time increases, battery performance gradually deteriorates, leading to a heightened risk of thermal runaway (TR) increases, which poses a significant threat to safety. Performance degradation is mainly manifested as capacity decline, internal resistance increase and cycle life reduction, which is usually caused by internal factors of LIBs, such as the fatigue of electrode materials, electrolyte decomposition and interfacial chemical reaction. Meanwhile, external factors of LIBs also contribute to performance degradation, such as external mechanical stresses leading to internal structural damage of LIBs, triggering internal short-circuit (ISC) and violent electrochemical reactions. In this paper, the performance degradation of LIBs and TR mechanism is described in detail, as well

Zhou, Jingtao, Zhong, Xiongwu, Wang, Kunjun, Zhou, Youhang, You, Guojian, Tang, Xuan

Battery Thermal Runaway Propagation: A CFD Approach to Cell and Module Analysis

2025-01-8164

04/01/2025

This Paper will focus on simulating thermal runaway propagation within a battery cell and module. The thermal runaway model parameters are derived from accelerating rate calorimeter (ARC). The simulation involves a thermal runaway propagation model that converts the stored energy of the battery materials into thermal energy, thereby simulating the propagation of thermal runaway. The initiation of thermal runaway is modelled through a nail penetration event, represented by a heat profile in the nail region. The resulting temperature rise in this area triggers the short propagation model, leading to the spread of thermal runaway. For the single-cell simulation, the 1-equation thermal runaway model is used, focusing on the direct energy conversion and propagation within the cell. In contrast, the module simulation involves a more complex scenario. Here, an initial temperature rise near the nail region activates a short propagation model, which subsequently triggers the 4-equation thermal

Wakale, Anil, Ma, Shihu, Hu, Xiao

Multiscale Modeling and Validation of Thermal Runaway Propagation in Immersion-Cooled Battery Systems with Full-Scale Application

2025-01-8166

04/01/2025

Thermal management is a key challenge in the design and operation of lithium-ion batteries (LIBs), particularly in high-stress conditions that may lead to thermal runaway (TR). Immersion cooling technology provides a promising solution by offering uniform cooling across all battery cells, reducing the risk of hotspots and thermal gradients that can trigger TR. However, accurately modeling the thermal behavior of such systems, especially under the complex conditions of immersion cooling, presents significant challenges. This study introduces a comprehensive multiscale and Multiphysics modeling framework to analyze thermal runaway and its propagation (TRP) in battery systems cooled by immersion in dielectric fluids. The model integrates both 1D and 3D simulations, focusing on calibrating energy terms at the single-cell level using 3D Computational Fluid Dynamics (CFD). The calibration process includes a detailed analysis of cell chemistries, exothermic heat release, and thermal runaway

Negro, Sergio, Tyagi, Ramavtar, Kolaei, Amir, Pugsley, Kyle, Atluri, Prasad

Multiphysics-Multiscale Reduced Order Model based Design Optimization of the Immersion Cooled Battery System

2025-01-8185

04/01/2025

A vital aspect of Ultra-Fast Charging (UFC) Li-Ion battery pack is its thermal management system, which impacts safety, performance, and cell longevity. Immersion cooling technology is more effective compared to indirect cold plate as heat can dissipate much quicker and has a potential to mitigate the thermal runaway propagation, improve pack overall performance, and cell life significantly. For design optimization and getting better insight, high fidelity Multiphysics-Multiscale simulations are required. Equivalent Circuit Model (ECM) based electro-thermally coupled multi-physics CFD simulations are performed to optimize the innovative busbar design, of a recently developed immersion cooled battery pack, which enables the capability to remove individual cell. Further, high fidelity 3D transient flow-thermal simulations have helped in optimizing the coolant flow direction, inlet positions, cell spacing and separator design for efficient flow distribution in the module. While high

Tyagi, Ramavtar, Negro, Sergio, Baranowski, Alex, Atluri, Prasad

Extreme-Fast Charging Performance Optimization of Immersion-Cooled Battery Systems with Cylindrical Cells

2025-01-8169

04/01/2025

Efficient and robust optimization frameworks are essential to develop and parametrize battery management system (BMS) controls algorithms. In such multi-physics application, the tradeoff between fast-charging performance and aging degradation needs to be solved while simultaneously preventing the onset of thermal runaway. To this end, a multi-objective optimization framework was developed for immersion-cooled battery systems that provides optimal charging rates and dielectric flowrates while minimizing aging and charging time objectives. The developed production-oriented framework consists of a fully coupled, lumped electro-thermal-aging model for cylindrical cells with core-to-surface and immersion-cooling heat transfer, the latter controlled by the dielectric fluid flowrate. The modeled core temperatures are inputs to a semi-empirical aging degradation model, in which a fast-aging solver computes the updated capacity and internal resistance over multiple timescales, which in turn

Suzuki, Jorge, Tran, Manh-Kien, Tyagi, Ramavtar, Meshginqalam, Ata, Zhou, Zijie, Nakhla, David, Atluri, Prasad

Battery Pack Venting

J3325_202503 (Current)

03/05/2025

The scope of this information report is battery packs containing lithium-ion battery cells with liquid electrolyte, focusing on automotive applications like passenger cars and trucks. Considering different operating conditions as well as durability and safety requirements, some of its contents might provide guidance for other applications. The same applies to battery cell chemistries not covered in this report (e.g., sodium-ion or solid-state battery cells).

Battery Pack Venting Committee

Prediction of Gear Defect Based on WPT & CEEMDAN & SVD

2025-01-7048

01/31/2025

After the defected gears are determined, a novel method, combined with wavelet packet decomposition, complementary ensemble empirical mode decomposition with adaptive noise and singular value decomposition, is put forward. It is utilized to exclude disturbance of irrelevant signals that generated by the defect gears. Firstly, wavelet packet decomposition is used to extract the defect signals and retain original features. The processed signal is called S1 and the irrelevant frequency bands could be filtered out. Secondly, complementary ensemble empirical mode decomposition with adaptive noise decomposes S1 into a series of intrinsic modal functions. The correlations between S1 and intrinsic modal functions are analyzed. The intrinsic modal functions that are highly correlated with S1 are screened out and reconstructed into a new signal, called S2. The disturbance of irrelevant signals could be further filtered out, but some of them still disturb the judgement. Thirdly, singular value

Gu, Junqing, Zuo, Yueyun, Zhang, Ni, Deng, Feng, Wu, Xiaolong

Fusion Control Strategy Based on Rule and Dynamic Objective of Heat Pump Type Thermal Management System for Electric Vehicles

2025-01-7023

01/31/2025

Thermal management system of electric vehicles (EVs) is critical for the vehicle's safety and stability. While maintaining the components within their optimal temperature ranges, it is also essential to reduce the energy consumption of thermal management system. Firstly, a kind of architecture for the integrated thermal management system (ITMS) is proposed, which can operate in multiple modes to meet various demands. Two typical operating modes for vehicle cooling in summer and heating in winter, which utilizes the residual heat from the electric drive system, are respectively introduced. The ITMS based on heat pump enables efficient heat transfer between different components. Subsequently, an ITMS model is developed, including subsystems such as the battery system, powertrain system, heat pump system and cabin system. The description of modeling process for each subsystem is provided in detail. The model is tested under world light vehicle test cycle (WLTC) condition of six different

Zhao, Luhao, Tan, Piqiang, Yang, Xiaomei, Yao, Chaojie, Liu, Xiang

Safety Analysis of Traction Batteries Based on Micro Internal Short Circuit Damage

2025-01-7017

01/31/2025

The internal short circuit of a traction battery is one of the most typical failure mechanisms that can lead to thermal runaway, potentially triggering thermal propagation across the entire battery system. This phenomenon poses significant safety risks, especially in electric vehicles and large-scale energy storage systems. Therefore, it is essential to explore and understand the internal short circuit behavior to mitigate these risks. One of the most effective testing methods for reproducing an internal short circuit is the penetration test, where specific test conditions must be carefully designed based on the failure behavior. Among these conditions, the penetration step length plays a crucial role, as it directly influences the short circuit dynamics. Despite the importance of penetration step length, there is currently no standardized test procedure that dictates how to select the appropriate step size for different battery samples. This gap in standardization complicates the

Wang, Fang, Sun, Zhipeng, Ma, Tianyi, Dai, Xiaoqian, Dai, Ce, Yan, Pengfei, Ma, Xiaole, Chen, Liduo, Ma, Haishuo, Shen, Shaopeng

Cooling Characteristics and Optimization of an Air-Cooled Battery Pack

2025-01-7016

01/31/2025

Lithium-iron phosphate batteries are widely used in energy storage systems and electric vehicle for their favorable safety profiles and high reliability. The designing of an efficient cooling system is an effective means of ensuring normal battery operation, improving cycle life, and preventing thermal runaway. In this paper, we proposed a forced-convection air cooling structure aiming at uniform temperature distribution and reducing the maximum temperature. The initial step was constructing a heating model for a single LiFeO4 battery. A source function was derived from the experimental data, which described the variation in heating power with discharge depth. This function was then used to create a dynamic loading of the battery heating model. Subsequently, a three-dimensional model of a 7-series and 2-parallel battery pack was constructed. Seven schemes were designed on the basis of the traditional Z-shaped structure, with the position of the air inlet and outlet altered. The

Zhang, Junhong, Liu, Ting, Dai, Huwei, Lin, Jiewei

Multi-step Prediction of Battery Temperature and Thermal Fault Diagnosis Based on Informer

2025-01-7019

01/31/2025

Lithium-ion batteries are prone to thermal failures under extreme conditions, leading to thermal runaway and safety risks such as fire or explosion. Therefore, effective temperature prediction and diagnosis are crucial. This paper proposes a thermal fault diagnosis method based on the Informer time series model. By extracting temperature-related features and conducting correlation analysis, a 9-dimensional input parameter matrix is constructed. Experimental results show that the model can maintain an absolute temperature prediction error within 0.5°C when predicting 10 seconds in advance, with higher accuracy than the LSTM model. Additionally, a three-level warning mechanism based on the forgetting coefficient further enhances diagnostic accuracy. Validation using test data and real vehicle data demonstrates that this method can efficiently diagnose and locate thermal faults in batteries, with low computational costs, making it suitable for online applications.

Sun, Yefan, Zhu, Xiaopeng, Zhang, Zhengjie, Peng, Zhaoxia, Yang, Shichun, Liu, Xinhua

Experimental and Modeling Investigation on Thermal Runaway Propagation and Venting Gas in Cell-to-Chassis Lithium-Ion Battery System

2025-01-7011

01/31/2025

Thermal runaway propagation (TRP) within lithium-ion batteries (LIBs) poses critical barriers to the safe operation and large-scale application of cell-to-chassis (CTC) batteries. Such events can lead to severe safety incidents, including explosions and fires, in systems utilizing these batteries. However, there is a lack of research on the thermal runaway model coupled with vented gases at the CTC systems. In this study, a thermal runaway coupling model for the battery pack system was established utilizing Star-CCM+ software, allowing for the examination of thermal runaway propagation characteristics and vented gas characteristics a within power battery systems based on the measured parameters of battery thermal safety characteristic. The simulation results indicated that once thermal runaway becomes uncontrollable, combustible flue gases escape through the exhaust hole located on the side plate of the cell, thereby facilitating heat transfer to adjacent cells. The primary components

Ma, Niya, Zhang, Anwei, Zhou, Wentai, Zhou, You, Jia, Yuan, Fan, Zehong

Battery Development for Vehicles: Integration of 3D Finite Element Method and CFD for Effective Thermal Management

2024-36-0163

12/20/2024

With the growing demand for electric vehicles (EVs), ensuring the safety and efficiency of battery systems is critical. This paper presents a methodology integrating 3D Finite Element Methods (FEM) and Computational Fluid Dynamics (CFD) to analyze battery systems, effectively mitigating thermal runaway phenomena. By combining FEM and CFD, our methodology provides a comprehensive approach to assess thermal management strategies within battery systems. This integration enables engineers to accurately simulate thermal behavior, predict hotspots, and optimize cooling strategies, thereby mitigating the risk of thermal runaway. Furthermore, our methodology minimizes the reliance on costly and time-intensive physical prototypes and testing. By leveraging virtual simulations, engineers can rapidly iterate through design modifications, assess their impact on thermal performance, and make informed decisions early in the development process. This article demonstrates the efficacy and accuracy of

Melo, Caiuã Caldeira, Araujo, Pedro Henrique, Castro Orefice, Fabio, Cury, Davi Machado, Vieira, Tiago Augusto Santiago, Abdu, Aline Amaral Quintella, Monteiro, Henrique Carlos

TOC

99-06-06-0TOC

12/16/2024

TOC

Tobolski, Sue

Battery Digital Twin with Edge Deployment

2024-28-0120

12/05/2024

Today's battery management systems include cloud-based predictive analytics technologies. When the first data is sent to the cloud, battery digital twin models begin to run. This allows for the prediction of critical parameters such as state of charge (SOC), state of health (SOH), remaining useful life (RUL), and the possibility of thermal runaway events. The battery and the automobile are dynamic systems that must be monitored in real time. However, relying only on cloud-based computations adds significant latency to time-sensitive procedures such as thermal runaway monitoring. Because automobiles operate in various areas throughout the intended path of travel, internet connectivity varies, resulting in a delay in data delivery to the cloud. As a result, the inherent lag in data transfer between the cloud and cars challenges the present deployment of cloud-based real-time monitoring solutions. This study proposes applying a thermal runaway model on edge devices as a strategy to reduce

Sarkar, Prasanta, Pardeshi, Rutuja, Kharwandikar, Anand, Kondhare, Manish

Battery Digital Twin for Electric Vehicle Deployed on Cloud

2024-28-0153

12/05/2024

A BDT (Battery digital Twin) is a virtual representation of a vehicle's physical battery system, combining electrochemical and machine learning models to provide insights into key battery parameters like State of Charge (SOC), State of Health (SOH), Internal Resistance (IR), and Remaining Useful Life (RUL). This BDT model is calibrated using cell testing throughout its degradation process up to 80% SOH, alongside vehicle data for accurate predictions under diverse conditions. By continuously monitoring the battery under various operating scenarios, the BDT aids in effective battery management, identifying cells that degrade more quickly and the likely causes of this degradation. Current and temperature profiles offer insights into battery usage patterns. The BDT aggregates fleet-wide parameters and analyzes individual cell performance, providing critical information on SOC, SOH, IR, RUL, and voltage. Additionally, the BDT includes prognostic capabilities to alert users of potential

Sasi Kiran, Talabhaktula, Kondhare, Manish, Patil, Suyog, Nath, Subhrajyoti, CH, Sri Ram, Tank, Prabhu, Sarkar, Prasanta

Synthesis and Characterization of Advanced Multi Nanoparticle Based Nanofluid Stabilized by Surfactants

2024-28-0139

12/05/2024

Recently, there has been a growing emphasis on Thermal Management Systems (TMS) for Lithium-ion battery packs due to safety concerns related to fire risks when temperatures exceed operating limits. Elevated temperatures accelerate electrochemical reactions, leading to cell degradation and reduced electronic system performance. These conditions can cause localized hotspots and hinder heat dissipation, increasing the risk of thermal runaway due to high temperatures, flammable gases, and heat-producing reactions. To tackle these issues, many automotive manufacturers employ indirect liquid cooling techniques to maintain battery pack and electronic system temperatures within safe limits. Engineered nanofluids, particularly those containing multi-nanoparticles dispersed in water and ethylene glycol, are being explored to enhance electrical safety in case of accidental exposure to electrical systems in EVs. This paper focuses on the experimental characterization of nanofluid containing

Nahalde, Sujay, Honrao, Gaurav, More, Hemant

Electric Battery Cell, Module, and Battery Pack FE Modeling for Multiphysics Simulation

2024-28-0154

12/05/2024

Electrified powertrain is the essential need to meet the C02 and NOX emissions compliance. Thereby focus of automotive industry is shifting towards to Electric Vehicle (EV). Thermal Runaway (TR) is still a big challenge to the safety of the EV. The major cause of TR is internal short-circuit of batteries under external mechanical abuse. When Anode and cathode of the battery comes in contact and short circuit happens. Internal short circuit is causing high amount of current flow and energy generation which leads to high increase in temperature. The approach that is used till date by OEMs is to protect the battery pack from structural damage during crash resulting into overdesigning of the vehicle. In this paper, detailed FE modeling of the battery system is considered for evaluating internal short circuit and TR. Solid Randle circuit is used for Multiphysics coupling simulation in Ls-dyna. Solid Randle circuits solves this Multiphysics and derives these electrical and thermal parameters

Jain, Tripti, Bonala, Sastry, Dangare, Anand

A Predictive Controller for Battery Cooling and Air-Conditioning Systems to Tackle the Comfort-Safety-Efficiency Dilemma

2024-28-0147

12/05/2024

The advent of electric vehicles has increased the complexity of air conditioning systems in vehicles which now must maintain the safety and comfort of occupants while ensuring that the high voltage battery temperature is kept within safe limits. This new task is critical due to the influence of the cell and battery pack temperature on the efficiency. Moreover, high temperatures within the battery pack can lead to undesirable effects such as degradation and thermal runaway. Classical solutions to this problem include larger air conditioning components to support worst case scenario conditions where the cooling request from the battery and the cabin happen at the same time. In such conditions, for the safety of the battery, the cooling request is assigned to battery system which may cause discomfort to the passengers due the significant temperature increase in the cabin during such events. The probability of such events happening is certainly dependent on the weather conditions but in

Palacio Torralba, Javier, Kulkarni, Shridhar Diliprao, Shah, Geet, Jaybhay, Sambhaji, Kapoor, Sangeet, Locks, Olaf

Researchers Unveil Scalable Graphene Technology to Revolutionize Battery Safety and Performance

TBMG-52141

12/01/2024

This breakthrough promises to significantly enhance the safety and performance of lithium-ion batteries (LIBs), addressing a critical challenge in energy storage technology.

Heat Generation Behavior of LFP and NCM Batteries during Long-Term Storage: A Comparative Study

2024-01-7011

11/15/2024

The life and safety of a battery are closely linked to temperature. Designing an effective thermal management system relies on a thorough understanding and analysis of the thermal properties and mechanisms of the battery. Over time, as batteries are used, their thermal characteristics change due to variations in internal SEI thickness, the deterioration of the active material structure, gas production, and electrolyte consumption, all of which are associated with the aging process. In this paper, experiments on both NCM and LFP batteries were made to measure the heat generation characteristics by adiabatic calorimeter. The results showed that the impact of calendar aging on battery heat generation exhibited completely different patterns for the lithium-ion batteries of the two material systems mentioned above. This paper provides guidance for the optimization of heat generation characteristics of battery and the calibration of heat source in the design of battery thermal management

Li, Haibin, Zhao, Hongwei, Liu, Dinghong, Hu, Qiaosheng

Correlation between Cell Thickness Profile and Lithium Plating: Applications in Lithium Plating Detection and Capacity Rollover Diagnostics

2024-01-7009

11/15/2024

In the realm of low-altitude flight power systems, such as electric vertical take-off and landing (eVTOL), ensuring the safety and optimal performance of batteries is of utmost importance. Lithium (Li) plating, a phenomenon that affects battery performance and safety, has garnered significant attention in recent years. This study investigates the intricate relationship between Li plating and the growth profile of cell thickness in Li-ion batteries. Previous research often overlooked this critical aspect, but our investigation reveals compelling insights. Notably, even during early stage of capacity fade (~ 5%), Li plating persists, leading to a remarkable final cell thickness growth exceeding 20% at an alarming 80% capacity fade. These findings suggest the potential of utilizing cell thickness growth as a novel criterion for qualifying and selecting cells, in addition to the conventional measure of capacity degradation. Monitoring the growth profile of cell thickness can enhance the

Zhang, Jian, Zheng, Yiting

Ionization Based Sensor for Early Detection of Thermal Runaway Events in Lithium-Ion Batteries

2024-01-4326

11/05/2024

Lithium-ion and lithium-metal battery cells are susceptible to a phenomenon known as thermal runaway under failure conditions. Given their widespread use in applications such as electric vehicles, portable electronics, and energy storage systems, early detection of thermal runaway is crucial for ensuring the safety of these battery systems. Thermal runaway entails a rapid escalation in battery cell temperature accompanied by the emission of flammable lithium ions, particulates, electrons, hydrocarbons, and hydrogen gases. These gases pose a significant ignition risk, potentially leading to fires and endangering occupants and bystanders. Therefore, the timely detection of thermal runaway is paramount for ensuring safety in proximity to such battery systems. Traditionally, thermal runaway sensors comprise intricate assemblies of pressure, temperature, and gas sensors, strategically positioned at the pressure relief valve of battery modules. Calibration of all sensors is essential to

Mansour, Youssef

Letter from the Focus Issue Editors

14-13-03-0016

10/08/2024

Letter from the Focus Issue Editors

Shen, Ruiqing, Wang, Qingsheng

CFD Modeling of 18650 Lithium-Ion Cell to Predict Cell Gas Venting and Gas Phase Reactions during Thermal Runaway Event

2024-28-0091

09/19/2024

To understand effect of thermal hazards of LIBs during TR event, it is important to study flame propagation behaviour of LIBs during storage and transport applications. The process of flame propagation involves complex phenomena of gas phase behavior of LIBs. Present paper attempts a numerical investigation to portray this complex phenomenon. This paper investigates 18650 lithium cell considering two different chemistries NMC and LFP. A 3D numerical CFD model has been constructed to predict the gas phase behavior, threshold internal pressure, and cell gas venting of an 18650-lithium cell under thermal runaway conditions. The gas phase processes are modelled using the 4-equation thermal abuse model, while the cell's venting mechanism is modelled using Darcy's equation. Present work is divided into two parts: 1) Venting gas Internal pressure prediction 2) modeling thermal runaway event. Both procedures are implemented on two different cell chemistries to understand and evaluate following

Gudi, Abhay, Bonala, Sastry

Analysis of Electric Vehicle Battery Safety Enhancement Techniques Using Python

2024-28-0052

09/19/2024

Electric Vehicles numbers are increasing at a rapid pace in the Indian market. As per the different feedbacks from the customers and reports available in media, there is an increase in Electric Vehicle (EV) battery fire accidents. The same is because of increased EV numbers, malfunctioning of battery and improper handling of EV systems. EV industry is looking for a solution for preventing these mis happenings by using advanced safety technology. This includes improvement in existing safety system through advanced warning backed by artificial intelligence, programming tools using new computing languages such as Python, Java etc. In present work temperature which happens to be major contributor in battery fire cases is being monitored with the help of programming used in battery management systems. In this process algorithm is being developed with the help of python as programming language. The same was test run on the selected parameters for validation of the developed programs for

Vashist, Devendra, Sharma, Aryan, Anand, Aditya

Modelling Approach of Thermal Runaway Propagation and Gas Venting Process in Lithium-Ion Batteries: A Comprehensive Review

2024-28-0068

09/19/2024

With the growing popularity of electric vehicles (EVs) Lithium-ion batteries (LIBs) exhibit unique characteristics such as long life, high specific energy, significant storage capacity, and remarkable energy density. The continual difficulty temperature non-uniformity over the battery surface and inside the battery pack, remains a major barrier in battery technology, significantly contributing to the tendency towards Thermal Runaway (TR). The hot gases discharged from a lithium-ion cell’s safety vent during a thermal runaway event carry flammable elements. If ignited, these gases heighten the potential for thermal runaway to spread to other cells within a multi-cell pack configuration. The study scrutinizes the effects of TR on the venting process. It explores contemporary approaches to minimize it, employing a variety of modeling methodologies such as Multiphysics, Computational Fluid Dynamics (CFD), and electrochemical-thermal, in addition to experimental methods. The objective of

Nogdhe, Yogesh, Garg, Ravi, Singh, Shobit Kumar

A Comparative Analysis of Thermal Runaway Propagation in Different Modular Lithium-Ion Battery Configuration

2024-01-2901

05/06/2024

Thermal runaway is a critical safety concern in lithium-ion battery systems, emphasising the necessity to comprehend its behaviour in various modular setups. This research compares thermal runaway propagation in different modular configurations of lithium-ion batteries by analysing parameters such as cell spacing and applying phase change materials (PCMs) and Silica Aerogel. The study at the module level includes experimental validation and employs a comprehensive model considering heat transfer due to thermal runaway phenomena. It aims to identify the most effective modular configuration for mitigating thermal runaway risks and enhancing battery safety. The findings provide valuable insights into the design and operation of modular lithium-ion battery systems, guiding engineers and researchers in implementing best practices to improve safety and performance across various applications.

Garcia, Antonio, Monsalve-Serrano, Javier, Dreif, Amin, Guaraco-Figueira, Carlos

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