• Energy Research

Abstract With respect to channeled liquid cooling thermal management system of electric vehicle battery pack, a thermal model is established for a battery module consisting of 71 18650-type lithium-ion batteries. In this model, thermal-lumped treatment is implemented for each single battery in the module and heat generation of a single battery is determined based on experimental measurements. In particular, heat conduction between neighboring batteries and heat transfer from the battery to the fluid channel outer wall are carefully modeled. We study, by the developed model, the battery module’s thermal behavior, and investigate the effects of discharge/charge C-rate, the liquid flow rate, the heat exchange area between neighboring batteries, and the interfacing area of the battery and the channel outer wall. The simulation results corroborate the effectiveness of the cooling system. It is found from simulation results that: (1) increasing the discharge/charge C-rate leads to higher temperature and worsens the temperature uniformity in the battery module; (2) increasing the liquid flow rate can significantly lower the temperature and improves the temperature uniformity in the battery module; (3) increasing the heat exchange area between neighboring batteries slightly improves the temperature uniformity in the battery module, but only has negligible effect on lowering the temperature of the module; (4) increasing the interfacing area of the battery and the channel outer wall can significantly lower the maximum temperature in the battery module but worsens the temperature uniformity in the module.

Abstract To overcome the inherent poor thermal conductivity of most phase change materials (PCM), inserting highly thermally conductive wire nets with periodic structures into them have been proposed. Numerical simulations have been extensively conducted to determine critical cell size and the effect of cell height and interface gap thickness on the heat transfer within the PCM. In addition, predictive correlations of the effective thermal conductivity were put forward. The simulated results indicate that: for structures with the same porosity, the critical cell size gradually decreases as the thermal conductivity of the wire net (ligament material) increases. For the proposed periodic structure embedded in the considered computational domain with 0.90 porosity, the critical pores per inch (PPI) for copper ligaments is approximately 10 PPI, while for stainless steel, it is approximately 3-5 PPI; a shorter cell height with a lower porosity shortens the melting time, therefore, stacking inexpensive metal wire is considered as an interesting alternative to commercially produced metal foams. Moreover, non-brazed scenarios lead to longer melting times, more than three times, compared to a perfectly brazed case. Furthermore, the effective thermal conductivity of the proposed periodic structure has been numerically calculated, which agrees well with some models available in the literature.

This paper rigorously validates the RANS models against the DNS on predicting turbulent flow and heat transfer of highly buoyant horizontal supercritical fluids. The low-Reynolds number turbulence models of RNG, AKN, V2F and (k−ω) SST that are recommended in literature are selected. Also, the LS model demonstrating good performance in some in-house CFD codes has been reimplemented via User-Defined Functions (UDFs) and examined for supercritical simulations, in particular with strong buoyancy effects. The results indicated that the AKN model works best among the tested models on the reproductions of some bulk parameters that are of interest (such as wall temperature, Nusselt number and skin friction coefficient) and the distortions of the turbulent velocity profile caused by the strong buoyancy, closely followed by the V2F model. The UDFs implemented LS model exhibits much better performances than the originally incorporated version in FLUENT, which is attributed to the more proper model implementation that leads to better treatments on the fluid flow and heat transfer, especially in the near-wall regions. Regarding the reproductions on the turbulence kinetic energy generations under the studied conditions, the RANS models are unable to give satisfactory results, the simulated suppression in the top half is more drastic. Similar to the vertical supercritical fluids, with quite high-strength buoyancy, the heat transfer recovers around the horizontal pipe top wall but the RANS models' response to the “recovery” is poor. The model performance on reproducing the turbulent statistics is closely related to the implementation of the vital structural parameters.

Batteries are the lynchpin of electric vertical takeoff and landing (eVTOL) aircraft, and the high discharge rates pose a critical challenge to the battery thermal management system (BTMS). This work presents a channeled liquid cooling technology-based BTMS for eVTOL aircraft. During the flight, the heat generated from the batteries is partly extracted by circulating liquid coolant within a wavy channel (WC) attached firmly to the battery cells. The heat is then transported into a plate-fin compact heat exchanger (HEX), where all the heat is dissipated into the atmosphere. We report sensitivity analyses of the HEX model to shed light on the impact of the relevant design parameters on the BTMS size, weight, and power. We also examine critical parameters of the coupled WC-HEX BTMS in a one-dimensional off-design analysis. We demonstrate that the liquid cooling system can maintain the battery operating temperature within acceptable levels with a mass of less than 20% of the battery pack mass. Battery degradation using the liquid cooling system is reduced by over three times compared to an air-cooled system for both tilt-wing and lift+cruise eVTOL aircraft.

In this work, melting of a high-temperature inorganic phase change material (PCM) eutectic (with a melting point of 569 °C) within a vertical cylindrical tank has been experimentally investigated. To promote the heat transfer rate, a periodic structure that is constructed by a commercial SS-304 mesh screen has been considered and immersed into the PCM tank. Thermal characteristics of the PCM-periodic structure tank under different initial temperatures (450, 490 and 546 °C) and wall temperatures (620, 640, 660, 680 and 700 °C), are then investigated and reported. The presented experimental data can facilitate practical engineers to find the best operating condition of similar PCM tanks; meanwhile, it can also be employed for the investigation of thermal response of transient heat conduction before melting starts.

Abstract Carbon dioxide (CO2) is a natural substance and an environmentally benign, safe and economical refrigerant that can be used for cooling and heating systems. Unlike a traditional reversible heat pump system that only works either in heating or cooling, the air-to-air transcritical CO2 heat pump system reported in this paper is capable of providing simultaneous space heating and cooling through an Air Handling Unit (AHU) at any time. The system with cooling and heating capacities of 210 kW and 110 kW, respectively, was installed in a cinema complex in South Australia, and continuously operated from September to November in 2020. In this paper, the detailed configuration of the CO2 heat pump system with parallel compression is described. A complete system layout, comprising of cooling, heating and shared circuits, is revealed for the first time. A mathematical model based on highly efficient Bitzer compressors has also been developed in this study. The experimental data recorded in an entire heating period of approximately one hour has been utilised for model validation and analysis. Through the validation, the simulated power consumption for the compressors with Variable Speed Drive (VSD) and Fixed Speed Drive (FSD) has been compared to the experimental data with acceptable agreements. The simulated discharge temperatures agree with the actual temperatures measured within 10%. Moreover, the latest system performance from September to November has been evaluated based on the heating and cooling loads and combined COPs. It was found that the combined COP was relatively stable at around 3 regardless of climate conditions.

A numerical study with the aim of upgrading thermal performances of battery pack of electric vehicles is conducted for a full-size-scale battery pack with 22 modules (totally 5664 18650-type lithium-ion batteries contained) cooled by a channeled liquid flow. The heat generation of the battery is modeled based on experimental measurements. Experiments with one typical module (consisting of 180 batteries) of the pack, charging and discharging at different C-rate (2C, 1C or 0.5C) at a specified liquid flow rate, are first carried out. The experimental results in what concerns maximum temperature in the battery module is in good agreement with the corresponding numerical predictions, demonstrating the reliability/fidelity and consequent accuracy of the developed model. The battery thermal management system is then fine-tuned to re-manage the flow distribution among modules for the sake of improving the thermal uniformity across the pack. The effect on the pack thermal performance of different charge/discharge C-rates and flow rates are extensively investigated, and the results indicate that the pack is thermally well-performed during 1C/0.5C discharge/charge operation with a fluid flow rate of 18 L/min; increasing the discharge/charge C-rate worsens the battery pack's thermal characteristics and increasing the coolant flow rate makes the battery pack perform better. (C) 2019 Elsevier Ltd. All rights reserved.

Phase-change materials (PCMs) are widely used in the thermal management of electronic devices by effectively lowering the hot end temperature and increasing the energy conversion efficiency. In this article, numerical studies were performed to understand how temperature instability during the periodic utilization of electronic devices affects the heat-dissipation effectiveness of a phase-change material heat sink embedded in an electronic device. Firstly, three amplitudes of 10 °C, 15 °C, and 20 °C for fixed periods of time, namely, 10 min, 20 min, and 40 min, respectively, were performed to investigate the specific effect of amplitude on the PCM melting rate. Next, the amplitude was fixed, and the impact of the period on heat sink performance was evaluated. The results indicate that under the 40 min time period, the averaged melting rate of PCMs with amplitudes of 20 °C, 15 °C, and 10 °C reaches the highest at 19 min, which saves 14 min, 10 min, and 8 min, respectively, compared with the constant input of the same melting rate. At a fixed amplitude of 20 °C, the PCM with a period of 40 min, 20 min, and 10 min has the highest averaged melting rate at 6 min, 11 min, and 19 min, saving the heat dissipation time of 3 min, 8 min, and 14 min, respectively. Overall, it was observed that under identical amplitude conditions, the peak melting rate remains consistent, with longer periods resulting in a longer promotion of melting. On the other hand, under similar conditions, larger amplitude values result in faster melting rates. This is attributed to the fact that the period increases the heat flux output by extending the temperature rise, while the amplitude affects the heat flux by adjusting the temperature.

Abstract Application of different heat transfer augmentation techniques, including the use of fins or foams, were investigated to enhance the melting rate of a solid phase change material within an annulus where the inner and outer pipes were subjected to constant wall temperature. The carbon fibre fins as well as three commonly-used foams (made of three different materials: nickel, aluminium and copper) were simulated. Firstly, keeping the total fin volume constant, the fin number density effect on the melting rate was investigated. After an optimal fin number density was obtained, three possible strategies (unequal length, uneven intervals and tree-shaped fins) were explored aimed at a more comprehensive understanding of the induced heat transfer enhancement. It was observed that with a fixed fin thickness and volume, the melting time is not a monotonic function of the fin number density and can be optimized. Comparing pure PCM melting, the use of optimized fin number reduced over 60% of melting time, while additional 8% and 4% further time reduction could be achieved by appropriately increasing lengths and decreasing intervals of bottom fins, respectively. The use of tree-like fins resulted in a longer melting time, comparing to that of longitudinal straight fins, which indicates it is not always a good option. Finally, the results, primarily the melting rates, were compared with those obtained through the use of metal foams with different metals. It was observed that the melting time of optimized strategy-1 is rather less than those of Cu and Al foams, and approximately 2200s shorter than that of Ni foams. These results indicate that the fins, if designed properly, can be as efficient as foams.