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Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES

Thermal management design for electric vehicles (EV) is very important in order to manage the thermal dissipated by operating components. This research aims at performing design optimization of a thermal management system for battery modules, controller and electric motor in EV. A combination of pas...

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Main Authors: tamaldin, noreffendy, Mat Yamin, Ahmad Kamal, Abdollah, Mohd Fadzli bin, Amiruddin, Hilmi, ABDULLAH, Mohd Azman
Format: Article
Language:English
Published: Elsevier 2013
Subjects:
TJ Mechanical engineering and machinery
Online Access:http://eprints.utem.edu.my/id/eprint/12149/1/Tamaldin_et_al._-_2013_-_Design_Optimization_of_Thermal_Management_System_for_Electric_VehicleUtilizing_CFD_Analysis%2C_DFMEA_and_CES.pdf
http://eprints.utem.edu.my/id/eprint/12149/
http://dx.doi.org/10.1016/j.proeng.2013.12.184
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spelling my.utem.eprints.121492015-05-28T04:22:43Z http://eprints.utem.edu.my/id/eprint/12149/ Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES tamaldin, noreffendy Mat Yamin, Ahmad Kamal Abdollah, Mohd Fadzli bin Amiruddin, Hilmi ABDULLAH, Mohd Azman TJ Mechanical engineering and machinery Thermal management design for electric vehicles (EV) is very important in order to manage the thermal dissipated by operating components. This research aims at performing design optimization of a thermal management system for battery modules, controller and electric motor in EV. A combination of passive and active cooling systems is proposed where air cooled is used in battery modules, water cooling for controller and water jacket for electric motor. Design Failure Mode and Effect Analysis (DFMEA) method is deployed to identify the potential failure modes and causes so that improvements can be made for battery modules, controller and electric motor. The design for all of the components and the thermal management system were done with CATIA V5. The material selections process for the designs was based on the analysis using Cambridge Engineering Selector (CES EduPack). Final design was utilizing water cooled for electric motor and controller while using air cooled for battery modules. It was found that best material for electric motor and controller water jacket is with aluminum alloy 6060 while air cooled ducting using High Density Poly Ethylene (HDPE) and battery housing using Polycyclohexylenedimethylene Terephthalate (PCT). The thermal management system for battery modules is simulated using ANSYS CFD software. Results from simulation were validated with manual calculation and have shown good agreement based on the data collected at various vehicle speeds. Elsevier 2013-12-31 Article PeerReviewed application/pdf en http://eprints.utem.edu.my/id/eprint/12149/1/Tamaldin_et_al._-_2013_-_Design_Optimization_of_Thermal_Management_System_for_Electric_VehicleUtilizing_CFD_Analysis%2C_DFMEA_and_CES.pdf tamaldin, noreffendy and Mat Yamin, Ahmad Kamal and Abdollah, Mohd Fadzli bin and Amiruddin, Hilmi and ABDULLAH, Mohd Azman (2013) Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES. Procedia Engineering , 68. pp. 305-312. ISSN 1877-7058 http://dx.doi.org/10.1016/j.proeng.2013.12.184
institution Universiti Teknikal Malaysia Melaka
building UTEM Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Teknikal Malaysia Melaka
content_source UTEM Institutional Repository
url_provider http://eprints.utem.edu.my/
language English
topic TJ Mechanical engineering and machinery
spellingShingle TJ Mechanical engineering and machinery
tamaldin, noreffendy
Mat Yamin, Ahmad Kamal
Abdollah, Mohd Fadzli bin
Amiruddin, Hilmi
ABDULLAH, Mohd Azman
Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES
description Thermal management design for electric vehicles (EV) is very important in order to manage the thermal dissipated by operating components. This research aims at performing design optimization of a thermal management system for battery modules, controller and electric motor in EV. A combination of passive and active cooling systems is proposed where air cooled is used in battery modules, water cooling for controller and water jacket for electric motor. Design Failure Mode and Effect Analysis (DFMEA) method is deployed to identify the potential failure modes and causes so that improvements can be made for battery modules, controller and electric motor. The design for all of the components and the thermal management system were done with CATIA V5. The material selections process for the designs was based on the analysis using Cambridge Engineering Selector (CES EduPack). Final design was utilizing water cooled for electric motor and controller while using air cooled for battery modules. It was found that best material for electric motor and controller water jacket is with aluminum alloy 6060 while air cooled ducting using High Density Poly Ethylene (HDPE) and battery housing using Polycyclohexylenedimethylene Terephthalate (PCT). The thermal management system for battery modules is simulated using ANSYS CFD software. Results from simulation were validated with manual calculation and have shown good agreement based on the data collected at various vehicle speeds.
format Article
author tamaldin, noreffendy
Mat Yamin, Ahmad Kamal
Abdollah, Mohd Fadzli bin
Amiruddin, Hilmi
ABDULLAH, Mohd Azman
author_facet tamaldin, noreffendy
Mat Yamin, Ahmad Kamal
Abdollah, Mohd Fadzli bin
Amiruddin, Hilmi
ABDULLAH, Mohd Azman
author_sort tamaldin, noreffendy
title Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES
title_short Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES
title_full Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES
title_fullStr Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES
title_full_unstemmed Design Optimization of Thermal Management System for Electric Vehicle Utilizing CFD Analysis, DFMEA and CES
title_sort design optimization of thermal management system for electric vehicle utilizing cfd analysis, dfmea and ces
publisher Elsevier
publishDate 2013
url http://eprints.utem.edu.my/id/eprint/12149/1/Tamaldin_et_al._-_2013_-_Design_Optimization_of_Thermal_Management_System_for_Electric_VehicleUtilizing_CFD_Analysis%2C_DFMEA_and_CES.pdf
http://eprints.utem.edu.my/id/eprint/12149/
http://dx.doi.org/10.1016/j.proeng.2013.12.184
_version_ 1665905488576905216
score 13.211869

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