Numerical Analysis and Multiobjective Optimization of Pin-Fin Cold Plates for Battery Modules Under Extreme Operating Conditions
INTERNATIONAL JOURNAL OF ENERGY RESEARCH, cilt.2026, sa.1, 2026 (SCI-Expanded, Scopus)
- Yayın Türü: Makale / Tam Makale
- Cilt numarası: 2026 Sayı: 1
- Basım Tarihi: 2026
- Doi Numarası: 10.1155/er/8734019
- Dergi Adı: INTERNATIONAL JOURNAL OF ENERGY RESEARCH
- Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Aerospace Database, Compendex, Environment Index, INSPEC, Directory of Open Access Journals, Academic Search Ultimate (EBSCO), Natural Science Collection (ProQuest), Earth, Atmospheric, & Aquatic Science Collection (ProQuest), Engineering Source (EBSCO), Materials Science & Engineering Collection (ProQuest), Technology Collection (ProQuest)
- Anahtar Kelimeler: battery thermal management, CFD, cold plate, latin hypercube, lithium-ion battery, metamodeling, multiobjective optimization, Taguchi
- Bursa Uludağ Üniversitesi Adresli: Evet
Özet
This study investigates the optimal design parameters and operating conditions of a pin-fin cold plate to minimize thermal-runaway risk under a worst-case scenario (130 A discharge current, 20% state of charge [SOC], 40 degrees C ambient temperature) for EVs. Cold plate thickness was fixed at 3 mm to meet weight constraints. Temperature-dependent fluid properties were considered to improve simulation accuracy. A novel and scalable Nusselt correlation for pin-fin cold plates was developed, with an R2 of 0.982 and a root mean squared error (RMSE) of 0.7078. Through NSGA-II coupled with regression-based surrogate models trained on the L25 numerical dataset, the optimum design was obtained with a pin-fin diameter of 26.31 mm, a volumetric flow rate of 4.66 L/min, and an inlet temperature of 23.12 degrees C. The optimum design achieved a maximum battery contact-surface temperature of 31.87 degrees C, keeping the battery within the ideal operating range (15 degrees C-35 degrees C) and safety limit (50 degrees C). Compared with the reference Case 1 configuration (Delta Tcs = 11.18 degrees C, Delta P = 343.38 Pa), the optimum design reduced Delta Tcs to 5.66 degrees C (about 49% improvement), achieving a balanced trade-off between thermal performance and hydraulic loss at a pressure drop of 1073.87 Pa. The proposed methodology provides a scalable framework to streamline battery thermal management system (BTMS) design.