Thermal Management of Electric Vehicle Rapid Charging

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dc.contributor.authorBarani, Amirhossein
dc.contributor.departmentChalmers tekniska högskola / Institutionen för mekanik och maritima vetenskapersv
dc.contributor.departmentChalmers University of Technology / Department of Mechanics and Maritime Sciencesen
dc.contributor.examinerVdovin, Alexey
dc.contributor.supervisorJahnen, Tim
dc.date.accessioned2024-09-06T09:38:33Z
dc.date.available2024-09-06T09:38:33Z
dc.date.issued2024
dc.date.submitted
dc.description.abstractOne 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.
dc.identifier.coursecodeMMSX30
dc.identifier.urihttp://hdl.handle.net/20.500.12380/308531
dc.language.isoeng
dc.setspec.uppsokTechnology
dc.subjectMegawatt Charging System (MCS)
dc.subjectElectric Vehicle Fast
dc.subjectCharging
dc.subjectThermal Management
dc.subjectLiquid-Cooled Cable
dc.subjectPower Module Cooling
dc.subjectEV
dc.subjectBEV
dc.subjectHeavy Duty
dc.subjectTrucks
dc.subjectRapid Charging
dc.subjectCharging
dc.titleThermal Management of Electric Vehicle Rapid Charging
dc.type.degreeExamensarbete för masterexamensv
dc.type.degreeMaster's Thesisen
dc.type.uppsokH
local.programmeSustainable energy systems (MPSES), MSc
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