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Week 10 - Heat Transfer Analysis on BTMS for 4X2 Battery Set using Ansys

AIM:- A. To Perform a Heat Transfer Analysis on A battery set by Inlet Velocities and Gap Between the Batteries. B. The Explain the Relevant Results Generated by the Analysis. Given:- A. The Battery Set Geometry: - The Following are the Parameters for the Battery Set: - i. The…

Aditya Aanand
updated on 05 Nov 2022

AIM:-

A. To Perform a Heat Transfer Analysis on A battery set by Inlet Velocities and Gap Between the Batteries.

B. The Explain the Relevant Results Generated by the Analysis.

Given:-

A. The Battery Set Geometry: -

The Following are the Parameters for the Battery Set: -

i. The gap between the Batteries(x) = 2mm, 4mm, and 6mm

ii. Inlet Velocity of the System = 3m/sec, 5m/sec, and 10m/sec

iii. The Dimension of Each Battery: 18X65 mm

B. Materials and their Properties: -

Part/Materials	Density $(\frac{k g}{m^{3}})$ $((kg)/m^3)$	Thermal Conductivity $(\frac{W}{m \cdot K})$ $(W/(m*K))$	Specific Heat Coefficient $(\frac{J}{k g \cdot K})$ $(J/(kg*K))$
Battery/Lithium	2700	7.14	900
Battery Cover/Aluminium	2719	202.4	871
Enclosure/Air	1.225	0.242	1006.43

Theories: -

A. Battery Thermal Management System: -

Battery Thermal Management Systems are Methods to improve thermal efficiency while also optimizing the Space between the Batteries. This is a very essential component of any Battery powered System as the System despite having the appropriate energy capacity for the Output can still fail because of thermal failure. The Following are Possible Failure without the BTMS: -

i. Thermal Runaway: Thermal Runaway is when the Heat Released by one Battery gets transferred to the surrounding batteries causing their temperature to rise. This temperature increase in batteries causes an uncontrolled cycle of increase of battery temperature.

ii. Low Performance of Battery output at High Temperature

iii. Reduction of the Life Span of Batteries

The Following are Some BTMS Techniques: -

i. Air Cooling: In this technique, the air is either directly blown over the batteries or air is blown through orifices of the external Surfaces of the Battery so as to cool the battery.

ii. Liquid Cooling: In this technique, the non-reactive liquid with high thermal Capacity is flown over the Batteries or through the External Surfaces of the batteries so as to cool the batteries.

iii. Direct Refrigeration Cooling: In this Technique, the non-reactive refrigerant in a VARS System is flown over the batteries in which evaporator coils in the VARS System is replaced with the battery pack.

iv. Thermo-Electric Module: In this Technique, a Thermo Electric Module is installed over the battery surface such that on the application a of voltage across the Thermo-Electric Module the Battery side gets cool and the Outer side gets hot and over this another method is applied to remove this heat.

Steps to Setup The BTMS of 4X2 Battery: -

A. Setting up the Ansys Workbench: -

Ansys Workbench $\to$ $->$ ToolBox $\to$ $->$ Analysis System $\to$ $->$ $\underset{Selecting \to Holding \to Dragging and Drooping to Project Schematic}{\underset{⏟}{Fluid Flow(Fluent)}}$ $ubrace("Fluid Flow(Fluent)")_("Selecting" -> "Holding" -> "Dragging and Drooping to Project Schematic")$

B. Opening SpaceClaim Geometry and Extracting Volume: -

i. Steps to Open SpaceClaim: -

Ansys Workbench $\to$ $->$ Project Schematic $\to$ $->$ Project $\to$ $->$ Geometry $\to$ $->$ Right-Click $\to$ $->$ Select SpaceClaim Geometry

ii. Steps to Create the Batteries: -

a. Create A Battery: SpaceClaim $\to$ $->$ Select desired Plane by Clickin-on "Select New Sketch Plane" from Graphic Window $\to$ $->$ Click on Sketch Tab $\to$ $->$ Select Circle $\to$ $->$ $\underset{In Our case, Location is Origin and Diameter is 18mm}{\underset{⏟}{Select desired location and desired Circle diameter}}$ $ubrace("Select desired location and desired Circle diameter")_("In Our case, Location is Origin and Diameter is 18mm")$ $\to$ $->$ Enter $\to$ $->$ Select "Return to 3D Mode" from Graphic Window $\to$ $->$ Select the Circle and Pull along Z axis $\to$ $->$ Set the Value to 65 mm $\to$ $->$ Enter

b. Create A Battery Set: SpaceClaim $\to$ $->$ Design $\to$ $->$ Create $\to$ $->$ Linear Pattern $\to$ $->$ Select the Battery $\to$ $->$ Enter $\to$ $->$ Select X direction $\to$ $->$ in General Set Two Dimensional and Set the desired Parameters $\to$ $->$ Enter

c. Create A Battery Set Enclosure: SpaceClaim $\to$ $->$ Prepare $\to$ $->$ Enclosure $\to$ $->$ Select the Batteries $\to$ $->$ Set the desired Parameters $\to$ $->$ Enter

d. Share Topology: SpaceClaim $\to$ $->$ Workbench $\to$ $->$ Share $\to$ $->$ The Common Surfaces and Edges will get auto-detected $\to$ $->$ Enter

C. Opening Mechanical(Meshing) and Meshing the Geometry: -

i. Steps to Open Meshing: -

Ansys Workbench $\to$ $->$ Project Schematic $\to$ $->$ Project $\to$ $->$ Mesh $\to$ $->$ Right-Click $\to$ $->$ Edit

ii. Steps to Name the Boundary: -

Mechanical(Meshing) $\to$ $->$ Model Working Window $\to$ $->$ Select the Boundary $\to$ $->$ Click N $\to$ $->$ Give the desired Name $\to$ $->$ Enter

iii. Steps to Create the Mesh: -

a. Setting Base Mesh Size: Outline Window $\to$ $->$ Select Mesh $\to$ $->$ Details of Mesh Window $\to$ $->$ Defaults $\to$ $->$ Element Size is set to the desired size

b. Setting Inflation Layer: Select Mesh $\to$ $->$ Right-Click $\to$ $->$ Select "Inflation" from Insert $\to$ $->$ $\underset{In our case, Select geometry and Edge and Inflation Type as First Layer to desired value with 5 layers}{\underset{⏟}{Set the desired Parameters}}$ $ubrace("Set the desired Parameters")_("In our case, Select geometry and Edge and Inflation Type as First Layer to desired value with 5 layers")$


Meshed Geometry	Inflation Layers

D. Setuping the Physics and Boundary Conditions: -

i. Steps to Open Ansys Fluent: -

Ansys Workbench $\to$ $->$ Project Schematic $\to$ $->$ Project $\to$ $->$ Setup $\to$ $->$ Right-Click $\to$ $->$ Edit

ii. Steps to Check Mesh: -

Fluent $\to$ $->$ Outline View Window $\to$ $->$ Setup $\to$ $->$ General $\to$ $->$ Mesh $\to$ $->$ Check

iii. Steps to Set up the Physics: -

a. Setting Viscous Model: Fluent $\to$ $->$ Physics $\to$ $->$ Models $\to$ $->$ Energy

b. Setting Viscous Model: Fluent $\to$ $->$ Physics $\to$ $->$ Models $\to$ $->$ Viscous $\to$ $->$ $\underset{In our case Select K-Omega Standard}{\underset{⏟}{Select Desired Viscous Model}}$ $ubrace("Select Desired Viscous Model")_("In our case Select K-Omega Standard")$

c. Creating desired Materials: Fluent $\to$ $->$ Physics $\to$ $->$ Materials $\to$ $->$ Create/Edit... $\to$ $->$ $\underset{In our case, Create Lithium Material}{\underset{⏟}{Select/Create the desired Fluid}}$ $ubrace("Select/Create the desired Fluid")_("In our case, Create Lithium Material")$ $\to$ $->$ Enter

d. Setting Cell Zones: Fluent $\to$ $->$ Physics $\to$ $->$ Zones $\to$ $->$ Cell Zone $\to$ $->$ $\underset{In our case, Selected All the batteries}{\underset{⏟}{Select the desired Zone}}$ $ubrace("Select the desired Zone")_("In our case, Selected All the batteries")$ $\to$ $->$ $\underset{Set the Type to Solid}{\underset{⏟}{Set the Desired Type}}$ $ubrace("Set the Desired Type")_("Set the Type to Solid")$ $\to$ $->$ Edit $\to$ $->$ Set Desired Material to Lithium $\to$ $->$ Apply

iv. Steps to Set Boundary Conditions: -

Fluent $\to$ $->$ Physics $\to$ $->$ Zone $\to$ $->$ Boundaries $\to$ $->$ Select the desired Component $\to$ $->$ Select the Desired Type for that Component $\to$ $->$ Edit $\to$ $->$ Add the Values for the Component $\to$ $->$ Apply & Close

v. Steps to Initialize and Set Desired Graphical Views: -

a. Initializing: Fluent $\to$ $->$ Solution $\to$ $->$ Initialization $\to$ $->$ Initialize

b. Setting the desired Contour: Fluent $\to$ $->$ Results $\to$ $->$ Graphics $\to$ $->$ Contours $\to$ $->$ New $\to$ $->$ Rename $\to$ $->$ Select Variable for Contour of $\to$ $->$ Select Surface $\to$ $->$ Save/Display

Ch10 BTMS Setup Battery Temperature Contour

Steps to Analyse the Gate Valve: -

A. Performing Calculations and Developing Results: -

i. Steps to Open Fluent: -

Ansys Workbench $\to$ $->$ Project Schematic $\to$ $->$ Project $\to$ $->$ Setup $\to$ $->$ Right-Click $\to$ $->$ Edit

ii. Steps to Run Calculations: -

a. Setting No. of Iterations: Fluent $\to$ $->$ Solution $\to$ $->$ Run Calculations $\to$ $->$ $\underset{In Our Case, No. of Iterations is set to 200}{\underset{⏟}{Setting Desired Iterations in No. of Iterations}}$ $ubrace("Setting Desired Iterations in No. of Iterations")_("In Our Case, No. of Iterations is set to 200")$

b. Running Calculations: Fluent $\to$ $->$ Solution $\to$ $->$ Run Calculations $\to$ $->$ Calculate

iii. Steps to Generate Desired Contours in CFD-Post(Results): -

a. Opening CFD-Post: Ansys Workbench $\to$ $->$ Project Schematic $\to$ $->$ Project $\to$ $->$ Results $\to$ $->$ Right-Click $\to$ $->$ Edit

b. Setting Desired Results on Fluid Boundaries: CFD-Post $\to$ $->$ Outline $\to$ $->$ FFF $\to$ $->$ Select Desired Boundary $\to$ $->$ Colour $\to$ $->$ Mode $\to$ $->$ Constants/Variables $\to$ $->$ Apply

c. Setting Desired Results on Volume: CFD-Post $\to$ $->$ Outline $\to$ $->$ User Loactions and Plot $\to$ $->$ Right-Click $\to$ $->$ Insert $\to$ $->$ Select Desired Method

iv. Steps to Perform Calculations from Parameters: -

Ansys Workbench $\to$ $->$ Project Schematic $\to$ $->$ Parameter Set $\to$ $->$ Set the desired Conditions $\to$ $->$ Right-Click on any new Set Condition $\to$ $->$ Update Selected Design Points

Generated Results/Plots: -

A. Temperature of Battery for different inlet velocities and Gaps: -

Gap Between Batteries(mm)	Inlet Velocity(m/sec)	1st Row Battery Temperature(K)	2nd Row Battery Temperature(K)	3rd Row Battery Temperature(K)	4th Row Battery Temperature(K)	Heat Transfer Coefficient(W/m^2K)
2mm	3	335.68	348.27	358.37	364.21	39.46
2mm	5	324.38	332.64	338.87	344.1	53.35
2mm	10	314.6	319.17	322.3	325.39	78.18
4mm	3	336.78	345.64	347.49	350.29	42.87
4mm	5	324.84	331.15	332.7	334.91	57.18
4mm	10	314.78	318.63	319.22	320.13	81.23
6mm	3	337.94	347.42	347.79	348.28	42.41
6mm	5	325.7	332.35	332.42	332.1	57.06
6mm	10	315.31	319.45	319.46	318.52	81.23

B. Results Developed For 2mm gap and Inlet Velocity of 3 m/sec: -


Steady State Batteries Temperature	Steady State Temperature on XZ Plane

Steady State Temperature on XY Plane	Steady State Battery Temperature on XZ Plane with Velocity Vectors

C. Results Developed For 4mm gap and Inlet Velocity of 3 m/sec: -


Steady State Batteries Temperature	Steady State Temperature on XZ Plane

Steady State Temperature on XY Plane	Steady State Battery Temperature on XZ Plane with Velocity Vectors

D. Results Developed For 4mm gap and Inlet Velocity of 3 m/sec: -


Steady State Batteries Temperature	Steady State Temperature on XZ Plane

Steady State Temperature on XY Plane	Steady State Battery Temperature on XZ Plane with Velocity Vectors

E. Simulation Animation developed for 6mm: -


Steady State Simulation for Gap at 6mm	Un-Steady State Simulation for Gap at 6mm

Observation and their Reasons: -

A. Temperature comparison between all the Rows for a specific Gap: -

It can be understood that the Temperature of batteries in the 1st Row will be lowest and the batteries in the 4th Row will be highest and for inlet velocity of 3 m/sec this holds but if we observe the batterie temperature of 6mm for 5 m/sed and 10m/sec the temperature of 4th Row is lower than the 3rd Row This is because at these velocities the turbulent behaviour starts to become dominant and due to un-interepted Flow beyond the 4th Row(which causes a low-pressure Region) the Air from around starts to converge around it causing the Temperature for 4th Row of 6mm Gap to drop.

The Pressure Comparison between 2nd, 3rd and 4th Row for 6mm Gap is given below

Ch10 BTMS 6mm Solution Pressure Contour Comparison

B. Effect of Change in Velocity compared to Change in Gap: -

i. Inlet Velocity: It can be observed from the Generated Results that the Average temperature of the Battery Set Decreases Significantly by increasing Inlet Velocities this is because the mass flow rate $(\dot{m})$ $(dot(m))$ and the Coefficient of heat transfer(h) both increases with the increase of Inlet Velocity causing a significant drop in temperature.

ii. Batteries Gaps: It can be observed that the Change in Gap Causes the Temperature of the Rows of Batteries behind the 1st to lower significantly this is because the lower Gap causes obstruction of airflow to batteries behind 1st Row Batteries and as the Gap is increased the airflow to the batteries is increased causing appropriate cooling.

From the above Simulation for any given Velocity, the temperature profile of 4mm vs 6mm is fairly close and 4mm vs 2mm is significantly better for 4mm, and the higher the Velocity the better the cooling. Hence, it can be seen that the 4mm Gap with a 10 m/sec inlet velocity has a good Temperature as well as space-saving efficiency taken together.