Thermal Management of Electric Vehicle Rapid Charging
Typ
Examensarbete för masterexamen
Master's Thesis
Master's Thesis
Program
Sustainable energy systems (MPSES), MSc
Publicerad
2024
Författare
Barani, Amirhossein
Modellbyggare
Tidskriftstitel
ISSN
Volymtitel
Utgivare
Sammanfattning
One of the main barriers to rapid charging of electric vehicles is the thermal management of batteries and charging equipment. Current charging patterns are designed
to maintain battery health and safety while avoiding thermal events. Additionally,
protection systems monitor the temperature of charging components and, if it exceeds safe limits, reduce power intake to mitigate risks. This increases charging time
and impacts the reliability of rapid charging systems. An efficient thermal management system plays a key role in increasing charging stability and enabling faster
charging at higher capacities.
This study investigates the thermal management of charging cables and power modules in a Megawatt Charging System (MCS) suitable for heavy-duty vehicles. The
research is divided into two parts. First, 3D CFD simulations are conducted for
three liquid-cooled cable structures to compare their performance and determine
their energy loss and cooling demand. Based on these results, in the second part,
four cooling systems (heatsink, heatsink+PCM, liquid cooling, and immersion coolng) are designed for the power modules, and their performance is studied through
1D simulations. The findings provide a holistic view of the capabilities of various
thermal management strategies and determine their efficiency in various scenarios.
Considering the oil-cooled charging cable model and the liquid cooling system as the
reference, the results demonstrate that charging a heavy-duty EV with a 1 MW MCS
under a constant current-constant voltage (CC-CV) charging method for 45 minutes
transfers 370 kWh of energy to the battery. The total system efficiency, including
power modules and cables, is 97.3%. Of the input energy, 9.12 kWh ( 2.4%) is lost in
the power modules, 0.41 kWh ( 0.1%) in the charging cable and its cooling system,
and 0.34 kWh ( 0.1%) in the power module cooling system.
Beskrivning
Ämne/nyckelord
Megawatt Charging System (MCS) , Electric Vehicle Fast , Charging , Thermal Management , Liquid-Cooled Cable , Power Module Cooling , EV , BEV , Heavy Duty , Trucks , Rapid Charging , Charging