Electric Battery Cell Thermal Analysis Design Project | ANSYS Transient Thermal | Full Simulation

[@dhyandpatel132]

Video Timestamps 00:00 Introduction 00:39 Project Aim 01:09 Outline 01:53 Cell Geometry | CAD Modelling 02:42 Battery Module 03:44 Various Boundary Conditions 06:35 Steady State + Transient ANSYS Thermal Simulation 07:45 Various Conditions of Simulations 09:12 Mesh Optimization 13:38 Simulation Results and Discussions 14:36 Parametric Study on Convective Heat Transfer 16:42 Future Work

[@rockingsachin3800]

Great work

[@alperenuiucak5872]

Hello my friend. Thanks a lot for this video. I need to thermal analysis of wood. This analysis should look like yours (6:29). How can I do it. Dimensions of cylindrical wood Diameter:20cm length:50cm

[@dhyandpatel132]

Hello, the thermal analysis would be very much same as what we have done irrespective of the electric cell or a wood. If you want any specific help with the analysis, please comment your email and contact details. Me and my team will find a mutually convenient time for any discussions.

[@rahulmittal4392]

Very good and realistic project. Hope to see more like these...

[@saifalid2364]

Brother please make a full video on how to design this cell in ansys and how to perform thermal analysis in ansys

[@dhyandpatel132]

Sure. I would work on it. But if you have any specific query for your project, let me know right away. Because with my current schedule, I am not sure how soon I can get a complete design and simulation video.

[@sssghostbgmi1195]

@@dhyandpatel132 Brother currently I am working on same project BTMS so I want to simulate battery pack which is shown by you in vedeo serpentine tube with many number of cells in series and parallel I don't know how to simulate it in Ansys please make a vedeo in ansys for me for atleast 4s 4p pack with full details it will be very helpful request you brother please I really appreciate your work

[@dhyandpatel132]

@@sssghostbgmi1195 hello, Thank you for appreciating. Actually I am currently working on another project, so I am not getting enough time to work on battery project.

[@rockingsachin3800]

Awesome😊

[@neileapenninan384]

Learnt a lot guys!

[@f1pedia.]

Nice explanation, I would like to know why you decided to use surface cooling rather than axial cooling.

[@dhyandpatel132]

Thanks buddy. I am not sure what are you referring as axial cooling. But anyways, the surface cooling would provide more surface area for heat transfer to occur. I agree, if you though so, that the core material has larger conductivity in height-wise direction and hence we should put cooling mechanism at the top and bottom face rather than the lateral surface. But in this case, the assembly of cells in a module with cooling mechanism becomes tough because we have electrode tab connections and busbars also at the top and bottom face. Let me know if your query is resolved otherwise can discuss more on it.

[@NeerajKumar-bt6gb]

Dhyan, can you please answer the following two questions- 1. Did you consider the thermal contact resistance in your simulation? 2. How did you calculate internal heat generation rate in the cells?

[@dhyandpatel132]

Thanks for contacting me. Answer to Question 1: no, thermal contact resistance between the current collector to the busbar or an electrical wire is not considered. Answer to Question 2: There could be multiple approach. What we have used is as follows. We have used the concept of Joule's heating. As per the requirement of the vehicle, we know the total power requirement. And based on the used electric cell characteristics, we know the voltage and internal resistance of the cell. As per the arrangement of cell in our module, we know the voltage drop and current flowing in each cell. So, we can use the relationship ( Heat Generated = Current * Current * Resistance ), to find the heat generated.

[@rohitbele3713]

Hi, do you have the cad model of cylindrical cells battery module with s shaped cooling duct?

[@dhyandpatel132]

Hey, Could you please be clear about the 'S' shape? Are you referring to the module shown around 3:22?

[@rohitbele3713]

@@dhyandpatel132 yes, that module. Do you have that CAD model?

[@dhyandpatel132]

@@rohitbele3713 I will have a look in my drive and let you know

[@rohitbele3713]

@@dhyandpatel132 yeah 👍🏻

[@dhyandpatel132]

Sorry buddy, I do have that stored with me. I will have to check with my friend.

[@adityabelawadi2811]

For the analysis of the li-ion cylindrical cell, what material input did you consider? For example, for the outer casing of the cell, the two terminals, etc

[@dhyandpatel132]

For the thermal simulations, we have made a single part of cell body and not differentiated between the casing, terminals and bus bars. In general our first choice will be for The outer casing - Aluminium Cell body - Standard Li-ion cell Electrodes - High Conducting Material but otherwise less reactive like carbon Busbars - High Conducting Metal like copper or brass I hope, I have clarified your query.

[@namratamohanty1964]

Dhyan I am a beginner to this concept. Can you help me how to start with battery thermal modelling?

[@dhyandpatel132]

Sure. What kind of help do you expect?

[@AbhimanyuSingh-rj4rw]

Can you make a tutorial for your project on ANSYS

[@dhyandpatel132]

Sure, I will try to get the tutorial video soon

[@MegaAkshi]

How to do meshing in lithium ion 18650 battery pack can you help me in this sir

[@dhyandpatel132]

Hello, Can you please look at a discussion uploaded on the channel? I have given step-by-step procedure for the meshing. I would appreciate if you can look at the video and let me know if that help or not. Later we can definitely have a discussion. Thank You This video and the upcoming 2 videos in this playlist: kzbin.info/www/bejne/m5aqm4aElNJopdE

[@Tejeshwarreddy111]

Is there any video of complete thermal analysis of the cylindrical cell?

[@dhyandpatel132]

I have had many discussions with people similar to you who asked about thermal analysis of a cell. What kind of details do you want? I have some meeting recordings which I can upload as a video.

[@Tejeshwarreddy111]

@@dhyandpatel132 18650 cell. i wanna know how to do steady state/transient thermal analysis

[@Tejeshwarreddy111]

for EV's, I want the video of the thermal analysis video of the above report.

[@Tejeshwarreddy111]

And am employing air cooling BTMS

[@dhyandpatel132]

@@Tejeshwarreddy111 We can discuss about this or I can also share a video about this. How much time do you have? Is it urgent?

[@suzannemiller4336]

Awesome Project! I have a question, have you considered putting in any or the reaction s that occur in Thermal runaway into your experiment? If so how did you do so?

[@dhyandpatel132]

Thank you for the appreciation. Sadly I have not considered any situation of thermal runaway. Because primarily our objective was to check for highest temperature which can occur in a general cell which has common power requirements. The secondary goal was to reverse the simulation data to find how much convection heat transfer is required in case our power requirements increase beyond a point. Also, I did not have the required knowledge on modelling thermal runaways. I am still working to improve this project. So, I would be rather interested if you can share the knowledge you have regarding thermal runaway. Let me know your thoughts.

[@GARSAN777]

Congrats for the great work! A question: how did you define the tabs for Cylindrical cell? Thank you already

[@dhyandpatel132]

Till we perform a direct thermal analysis, we need not define tabs as we directly provide heat generation value. But for any module where I need to provide electrical inputs such as C rate, current required, internal resistance, etc. I will put the tabs at top and bottom faces. If you need further clarification, please ask. Thank you for the compliment. Would you mind subscribing to my channel.

[@Ahil4421]

@@dhyandpatel132 would u split the body of positive and negative terminals of a cylindrical battery such as the one who in the video? Also should I make the tabs as frozen in material section?

[@dhyandpatel132]

@@Ahil4421 If I have the data, yes. I would have separate body for terminals. Yes, you can make the tabs as frozen. I am not sure about the exact effect it has on model and solution procedure but so far whatever I read, some did froze the tabs in design modeller.

[@shreeharshaprasad1017]

What is the material you gave cell?

[@dhyandpatel132]

It's lithium ion material.

[@shreeharshaprasad1017]

@@dhyandpatel132 did you give same material while analysing? And its properties?

[@dhyandpatel132]

@@shreeharshaprasad1017 I used values from some reference papers of the material in the cell. I entered the same values in the ANSYS Material input.

[@kevingeorge4997]

Hello brother, this is a great work. It would be helpful if you could tell me the heat generation rate you selected for the steady state analysis, as i am doing a similar project.

[@dhyandpatel132]

Hello, Nice to learn that you are also working on such a project. We used multiple values such as 2W per cell to 5W per cell. Let me know if you have any other query. Best Luck, Dhyan

[@kevingeorge4997]

@@dhyandpatel132 Which paper did you refer for the transient heat generation values?

[@dhyandpatel132]

@@kevingeorge4997 You can check out this paper: Yoshitaka Inui, Satoshi Hirayama,Denki Gakkai Ronbunshi B, “Detailed estimation method of heat generation during charge/discharge in lithium‐ion battery using equivalent circuit”, Volume 139 Number 10, pages 610-619, DOI: 10.1541/ieejpes.139.610 of IEEJ Transactions on Power and Energy)

[@kevingeorge4997]

@@dhyandpatel132 Thankyou brother for your time. Do you have any comments on using an user defined function for transient analysis. I don't know much about it. It would be helpful if you could give some insights.

[@dhyandpatel132]

@@kevingeorge4997 No problem. Keep asking, I may not know. But surely, we will learn and grow together. In ANSYS Mechanical, steady or transient state thermal analysis, there are limited options to use user defined function. For any input condition, you can find an option of 'Function' under the value option. But there you would be only allowed to use limited number of variables. More flexibility is in ANSYS APDL, there you need to code and hence enter any user defined function. The same could be done using ABAQUS CAE where you can use a subroutine file to define your function. I hope you got an idea. Let me know, whether I cleared your query or not.

[@Kartikk_Mishra]

I am amazed by the quality of content that we get to absorb these days. Fantastic job. I am going to work on a similar topic for my dissertation. This helped a lot. I have sent you a follow request on LinkedIn. Please have a look. I will be glad to know more about this particular topic than i have already gotten to know. Keep it up and Thanks. Godspeed.

[@dhyandpatel132]

Nice to connect with you.

[@UltimateTeamTipsHD]

Hi Dhyan, I am currently doing a very similar topic for my project. I was wondering where and how you got the experimental/theoretical data for the different C rates and temperatures to model your ansys model. Help would be appreciated, thank you :)

[@dhyandpatel132]

Hello, We used below resources for our project and other knowledge gained from coursework. Let me know if you other help. [1] H. Liu, Z. Wei, W. He and J. Zhaoa, "Thermal issues about Li-ion batteries and recent progress in battery thermal management systems: A review," Energy Conversion and Management 150, pp. 304-330, 2017. [2]T. Wang, K. Tseng, J. Zhao and Z. Wei, "Thermal investigation of lithium-ion battery module with different cell arrangement structures and forced air-cooling strategies," Applied Energy 134, pp. 229-238, 2014. [3]C. P. Rajib Mahamud, "Reciprocating air flow for Li-ion battery thermal management to improve temperature uniformity," Journal of Power Sources 196, p. 5685-5696, 2011. [4]Yoshitaka Inui, Satoshi Hirayama,Denki Gakkai Ronbunshi B, “Detailed estimation method of heat generation during charge/dischargein lithium‐ion battery using equivalent circuit”, Volume 139 Number 10, pages 610-619, DOI: 10.1541/ieejpes.139.610 of IEEJTransactions on Power and Energy) [5]Seyed Mazyar Hosseini Moghaddam, “Designing battery thermal management systems(BTMS) for cylindrical Lithium-ion battery modules using CFD”,Master of Science Thesis KTH School of Industrial Engineering and Management, 2019

[@detaalmas-2872]

Hello sir, now i’m currently starting to learn ANSYS in my university and I want to try to do this kind of battery heat simulation. May I know the thickness that you are using for the cooling duct sir? And how you determine of the geometry of it sir? Thank you in advance

[@dhyandpatel132]

Hello, We used the duct thickness of 0.5 mm. While this can be varied and optimized to cost vs. heat transfer capacity. Geometry of cooling duct is thought from the type of cell we used and aiming to have highest amount of heat transfer surface. Hence, for the cylindrical cell, having that curved shaped cooling duct attached at the lateral surface can have high heat transfer area, allowing for high potential to cell cooling. I hope this helps. If you are just starting to learn ANSYS, you might want to look at this playlist of mine: kzbin.info/aero/PL4vsnY9LsA43-du6AKOPM1ULLJWbXdnLA Let me know if you need any help.

[@kmmannie38]

How to create model bat in program ex material

[@dhyandpatel132]

Hey, I am not familiar with the program you are referring to.

[@kmmannie38]

can tell ref me,please . I can't find@@dhyandpatel132

[@picassoart8023]

Sir, I liked your seminar. Can you send me a hard copy of the seminar if it is not difficult? (Iee Reference paper Pdf & ppt file)

[@dhyandpatel132]

Sending hardcopy may not be easy in this times. May I ask what is the purpose of asking for the paper and slides? And what's your postal mail address?

[@PankajKumar-ClassMate_Academy]

Good Morning, Myself Pankaj Kumar, If it is possible please send me your simulation file or tell me how to simulate it fully. please its argent...

[@sairamab2304]

Hi dhyan, I am working on Newman p2d model for my work- thermal inertia of cylindrical lifepo4 cell . Actually I want to know about the parameters used in that model. Could you help me with that.

[@dhyandpatel132]

Hello, We have done the steady state thermal and transient thermal analysis. I would have only brief knowledge on Newman model and the parameters. If you want, we can have a discussion for the same. I will try my best to help.

[@sairamab2304]

@@dhyandpatel132 yeah sure. I doubt in my geometry of cylindrical cell. If I get clarified in that part half of my doubts get cleared . Mail: [e-mail]

[@dhyandpatel132]

Okay I shall mail you as per my team's convenience.

[@Pavanbehra]

Could you please explain in ansys video

[@indrajithn7094]

Can you get an average temperature of the cell. On the heat distribution

[@dhyandpatel132]

Yes definitely. For the case of 2W of internal heat generation and coolant heat transfer coefficient of 100 W m^-2 C^-1 on the selected surface of pouch cell and ambient temperature of 25 degree Celsius, the maximum temperature is 33.4 degree Celsius, minimum temperature is 31.8 degree Celsius and average temperature is 32.75 degree Celsius. You should understand and appreciate the fact that since our analysis is completely parametrized, we can try will different conditions on our cell and get the output for average temperature, so the results (actual numbers) keeps varying but the trend remains the same. I hope, I made it clear.

[@tanishkalamkar18]

Hello Dhyan do you have the project report with you??

[@dhyandpatel132]

Hello Sarthak, Yes definitely. We have made the project report.

[@tanishkalamkar18]

Actually I am working on the same I just want to go through your project report!.

[@tanishkalamkar18]

Is it possible for you ?

[@tanishkalamkar18]

It's quite urgent!

[@tanishkalamkar18]

Email id : [e-mail]

[@bharatharavi6411]

Hey dhyan! I wanted to know how you got the various internal heat generation values with respect to time. Is it also possible to put out a video showing the entire procedure on ansys?

[@dhyandpatel132]

Hello, I got the values from a research paper. There, the authors had used a method of equivalent to electrical circuit to estimate heat generation with constant and pulsating current during charging and discharging. The values were validated using calorimeter. So, I have had no hand in actual calculation of the internal heat generation values.

[@tanishkalamkar18]

There are mainly 4 types of cooling, which type of cooling you guys have done?

[@dhyandpatel132]

We have simulated for indirect cooling using glycol. We have the coolant flow duct moving around the cells.

[@tanishkalamkar18]

What are the specifications of battery??

[@tanishkalamkar18]

Was it a tube cooling?

[@dhyandpatel132]

@@tanishkalamkar18 Yes it is tube cooling. Inside the tube we have coolant flowing. Tube will move around the cells in the module. View 3:00 to have a closer look at how the coolant duct/tube is.

[@dhyandpatel132]

@@tanishkalamkar18 We have assigned an approximated homogeneous material of Lithium ion cell. There are no internal resistance or electrical properties assigned as it is a thermal analysis.

[@nagrajnapa2189]

Hi dhyan, I need some information regarding this analysis. May I know which model you used for analysis. Currently Iam using NTGK model but facing some issues while charging. Can you please help me. Thank you.

[@dhyandpatel132]

Hello Nagraj, We have done the steady and transient state thermal analysis only. We did explore the fluent simulation in which you need to choose the models like the one you mentioned. So, I am unaware of exactly which model you need to choose in ANSYS Fluent Battery Module Add-on.

[@nagrajnapa2189]

@@dhyandpatel132 thank you for your reply, may I have your mail id or else contact number. I would like to interact with you.

[@dhyandpatel132]

@@nagrajnapa2189 comment down your contact detials and I shall contact you as per my team's convenience

[@nagrajnapa2189]

@@dhyandpatel132 [e-mail]

[@tanishkalamkar18]

Let me know your problem statement

[@dontaco5459]

Hi , great work , can we have the case files ? Can you show us the fitting curves ;c- rates curves ? :) experimental and simulation, and how they match ?

[@dhyandpatel132]

Hey, We have not generated the fitting curve or c-rate curve. Even we have not done any experiment.

[@dontaco5459]

@@dhyandpatel132 Hi Dhyan , Can you please explain with little bit of details how to: I have experimental data for a battery ( time vs surface temperature ) and I want to match the internal heat generation with time . Also , u did parametric study and it’s showing here but don’t know how You guys did it . Thank you

[@dhyandpatel132]

@@dontaco5459 sure. If you can explain me about your project. I may be able to clear your query.

[@dontaco5459]

@@dhyandpatel132 Hi bro , I have been working on battery simulation using Ansys fluent for sometime , many batteries with different chemistries and sizes and matched well with experiment . But I have this very small battery that I could not match the surface temperature and I think this model does not consider internal resistance or the results do not match the experimental results due to internal resistance . Now I have the surface temperature data of this small battery that I measured in the lab as well as discharge curves , and I want to do parametric study ; you know heat generation, internal resistance so that I can match the experimental surface temp as well as the discharge voltage curves That’s all

[@dhyandpatel132]

@@dontaco5459 great. We can try some trial and error boundary conditions to match the experimental data you have collected.

[@Antiheeroo]

Hello Dhyan, this is Shawon from NIT Durgapur. Hope you are doing safe. I am currently working on Li-BTMS incorporating heat pipes. I am stucked in meshing section. I am unable to produce a structured mesh on the cell surface. In this video, you and your team has produced an amazing mesh. Can you please help me out with it? I will highly appreciate your time! Thank you.

[@dhyandpatel132]

Hello Shawon. We will be glad to help you.

[@Antiheeroo]

@@dhyandpatel132Thank you for such a humble reply. 😊 Can you please mention your email? I will briefly discuss the issues accordingly.

[@dhyandpatel132]

@@Antiheeroo Welcome. Please comment down your email and contact details. I will coordinate with my team and contact you accordingly.

[@Antiheeroo]

@@dhyandpatel132 [e-mail] this is my email.

[@dhyandpatel132]

@@Antiheeroo I have mailed you for our further communication related to your project work. I have also shared my contact details for convenience.

[@tahreemhussain191]

Is it possible if you can provide your email address for contact as i am also doing battery simulation using ANSYS ?

[@dhyandpatel132]

Sure. You can connect me at [e-mail] You could have also found this in the About section of my channel.

[@SK-nt4rt]

I want to talk to related this topic pls some little conversation pls help brother its urgent

[@dhyandpatel132]

Yeah, how can I help you?

[@SK-nt4rt]

Actually i m engineering student final year mech We r working on btms in EV final YR PROJECT I want some help in my project can u do

[@dhyandpatel132]

@@SK-nt4rt I am not an expert in this field but I have got enough insights working on it for 10 month. You can ask, I will try my best to answer.

[@SK-nt4rt]

@@dhyandpatel132 bro i want ansys design on btms how can i get it

[@dhyandpatel132]

Battery Thermal Management System is a complete major subdivision on electrical vehicle. What exactly are you working on and what design are you doing?

[@Chitrang62]

Hey Dhyan great video. My self Chitrang. I work in silicon valley as an Embedded software engineer and I am from Surat Gujarat. Could you please provide your email if it is possible? Thanks Chitrang

[@dhyandpatel132]

Hey Thank you Chitrang for your feedback. We can definitely connect. It would be better if you comment your email address rather than myself doing it. It have faced issues if spam mailing because of openly sharing my mail. I hope you understand. Thank you If you have any issue, do mention.

[@Chitrang62]

We can connect on LinkedIn are you on LinkedIn?

[@dhyandpatel132]

@@Chitrang62 yeah You can find me as Dhyan Patel www.linkedin.com/in/dhyanpatel132000

[@Chitrang62]

Thanks you can now delete the comment

[@prashantgupta9210]

Sir you are like the ray of hope for me I want to ask some detail question from you study as I do have a bit of it similar but my research is different from yours. How can I contact you it would be great if you share your number

[@dhyandpatel132]

Sure. We can have a talk. Please share you contact number or send me a mail at [e-mail] (also there in the About section on my channel page)

[@kinjalrajeshjain1275]

Great Video! I am Kinjal Jain..i am working on design and analysis of lithuim ion battery for EV on ANSYS.Could you please provide your email id if it is possible!!! Thankyou

[@dhyandpatel132]

Hello Yeah sure. You should be able to find it in the channel's 'About' section. But anyways since you couldn't find, here it is: www[dot]dhyanpatel132[at]gmail[dot]com Make sure to ping me on this comment tread if you send me a mail, as I don't check the above email regularly.

[@kinjalrajeshjain1275]

@@dhyandpatel132 I had mailed you. please do check your mail.. Thankyou so much in advance!!!

[@dhyandpatel132]

@@kinjalrajeshjain1275 Yeah sure. It would be great to connect. Please give me some time to prepare. Until then you can continue the exploration from your side.

[@dhyandpatel132]

@@kinjalrajeshjain1275 Can you please check my mail. Kindly revert back if you still need any help.

[@mustafagelmez4293]

Great work

[@dhyandpatel132]

Thanks