Optimization of air-cooling strategies for an electric formula varsity battery pack

Aswandi, Arman Kushairy (2024) Optimization of air-cooling strategies for an electric formula varsity battery pack. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This project report delves into the fascinating world of electric vehicles technology, focusing specifically on the optimization of air-cooling strategies for an electric Formula Varsity battery pack. The main objective of this research is to thoroughly investigate and optimize various strategies for air-cooling to be applied for the Formula Varsity battery pack, with the aim of enhancing its thermal management system. This project involves designing an air-cooling system for the electric Formula Varsity battery pack. The incorporation of external airflow is designed to enhance the heat transfer through the air, expediting the cooling process. In this project, Arduino acting as both circuit controller and temperature monitor for the battery pack to serve as a temperature monitoring system, utilizing a sensor to measure ambient temperature. The final product that has been fabricated consists of an axial fan, air ducting and a steel plate to replace the current ai cooling strategies system. Steel plate was cut to fit perfectly onto the gap of the body chassis and the measurements were taken based on the current air-cooling system battery pack cover. After the steel plate is perfectly fit, holes are drilled onto the battery pack cover to allow the fan to be mounted and also holes to hold down the plastic part that has been sealed with the ducting. The plastic part and ducting were then connected to the side part of the Formula Varsity to allow only clean fresh air to enter the battery pack. The experimental was simulated in three conditions which is the time taken to cooldown the battery pack of the Formula Varsity from 60°C to 30°C. The result of testing reveals that the application of innovative cooling tactics significantly reduces cooldown time. When a low-speed fan is placed at the front of the vehicle to mimic airflow during motion, the cooldown time decreases from 690 seconds (current method) to 210 seconds. Further when a high-speed fan is employed, the cooldown time is reduced to 120 seconds. Other than that, the results show the current air-cooling strategies took 750 seconds to cooldown the battery pack when in static, while the new air-cooling strategies manage to cut down the time by half which is approximately 330 seconds. Next is the ability to keep the battery pack working in its optimal working temperature (continuous heat supply to simulate the heat rejection from battery when light usage of battery such as vehicle electrical appliances and slow speed driving). The data obtained revealed that the application of newly developed cooling strategies managed to maintain the battery pack in optimal working temperature. However, the current air￾cooling strategy failed to maintain the battery pack in its optimal working temperature (35°C to 45°C) when continuous heat applied to the battery pack, thus the heat supply has been forced to shut to make sure that the battery won’t suffer any damage. The last condition is the ability to keep the battery pack working in its optimal working temperature (continuous heat supply to simulate the heat rejection from battery when heavy usage such in Formula Varsity race) respectively. The results show only new air-cooling strategies which applied with high-speed fans at the front of the vehicle were managed to achieve a successful test. Results demonstrate the efficiency of the new air-cooling strategy compared to current air-cooling strategies. In conclusion, the inquiry of optimizing air￾cooling plan for Electric Formula Varsity battery pack where extensive testing and inventive initiatives enhanced the cooling system’s efficiency, addressing significant battery temperature concerns. Models from experiments shed light on procedures and the battery’s capacity to sustain ideal temperatures.

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