A Digitalized Methodology for Co-Design Structural and Performance Optimization of Battery Modules

In this study, we present an innovative, fully automated, and digitalized methodology to optimize the energy efficiency and cost effectiveness of Li-ion battery modules. Advancing on from today’s optimization schemes that rely on user experience and other limitations, the mechanical and thermal designs are optimized simultaneously in this study by coupling 3D multi-physical behavior models to multi-objective heuristic optimization algorithms. Heat generation at various loading and ambient conditions are estimated with a physics-based, fractional-order battery cell-level model, which is extrapolated to a module that further accounts for the interconnected cells’ heat transfer phenomena. Several key performance indicators such as the surface temperature increase, the temperature variations on the cells, and heat uniformity within the module are recorded. For the air-cooled study case, the proposed coupled framework performs more than 250 module evaluations in a relatively short time for the whole available electro-thermal-mechanical design space, thereby ensuring global optimal results in the final design. The optimal module design proposed by this method is built in this work, and it is experimentally evaluated with a module composed of 12 series-connected Li-ion NMC/C 43Ah prismatic battery cells. The performance is validated at various conditions, which is achieved by accounting the thermal efficiency and pressure drop with regard to power consumption improvements. The validations presented in this study verify the applicability and overall efficiency of the proposed methodology, as well as paves the way toward better energy and cost-efficient battery systems.