Review Paper on Design and Development of an Air-Cooled Cooling System in EV Battery

The performance, safety, and lifespan of electric vehicle (EV) batteries are highly dependent on effective thermal management. Excessive heat generation during charging and discharging cycles can lead to reduced efficiency, accelerated degradation, and potential safety hazards. This project focuses on the design and development of an air-cooled thermal management system for EV battery packs. The proposed system utilizes forced air convection to maintain optimal battery operating temperatures within a safe range. A detailed study of heat generation mechanisms in lithium-ion batteries is conducted to determine cooling requirements. Computational Fluid Dynamics (CFD) simulations and thermal modeling are employed to optimize airflow distribution, fin geometry, and fan placement for maximum cooling efficiency with minimal power consumption. A prototype air-cooled system is developed and tested under varying load conditions to evaluate its performance in terms of temperature uniformity, response time, and energy efficiency. Results demonstrate that the designed air-cooled system effectively regulates battery temperature, ensuring improved performance and extended battery life while maintaining cost effectiveness and structural simplicity compared to liquid cooling systems.