Thermal-electrochemistry simulations improve on overall battery performance, safety and life
The global rise in gasoline prices, combined with ever-increasing pollution from vehicles with IC engines, have given rise to the tremendous interest in electric and hybrid vehicles, in turn pushing battery science forward.
  • Temperature distribution analysis of an ASCS battery module of 84 cells: 42 cells are connected in series, and each row is connected in parallel. The liquid-cooled plates are lateraly postionned on each side of those rows (Model courtesy of ASCS, Stuttgart and Behr).
  • Shown here is the screen representation of a battery pack cooling simulation in STAR-CCM+. The battery pack was designed in BDS and the flow and thermal simulation conducted in STAR-CCM+ using the Battery Simulation Module (BSM).
  • Through our long term collaboration with Battery Design LLC, a leader in electrochemical model development, CD-adapco is able to offer an expansive solution for coupled thermal-electrochemical simulations. Shown is a scalar plot of Specific Ohmic Heat Source on battery connectors.

The ability to deploy and accept large amounts of electrical energy in a robust, light weight package is a key enabler for the electrification of vehicles. The interest of the global vehicle manufacturers dovetails well with a long term, more wide spread trend demanding ever greater time between recharges for consumer and hand held devices and other applications using batteries. Such widespread focus on this enabling technology has driven CD-adapco to create a specific workflow and tools aimed squarely at providing simulation insight in to coupled thermal-electrochemical problems found in electrochemical devices

Having been computing coupled thermal-electrochemical simulations for a number of years and through our long term collaboration with Battery Design Llc, a leader in electrochemical model development, CD-adapco is able to offer an expansive solution for such modelling. This page offers an introduction in to our solutions and the surrounding documents should provide a further resource for advanced reading. To discuss particular technical problems or simulation issues with our experts please contact your local support office.

The core concept of CD-adapco's battery modelling technology is the reuse of underlying electrochemistry code in both our battery cell level tool, Battery Design Studio, and our battery pack level tool, STAR-CCM+ Battery Simulation Module. By using the same code implementation across these two products an electrochemist can pass on a model of a battery's electrochemistry, created in Battery Design Studio, which can be used by a thermal engineer to capture the response of a number of battery cells once they are stacked together in a pack. This leverage of each others work allows for a higher level of confidence in the final results and also a more complete representation of the physics modelled within the simulation. This core advantage is complimented by sophisticated, contemporary electrochemistry models which capture the details of a cell's electrodes and tabbing design even when running mutli-cell simulations. The tabbing effect on a cell's performance can be significant and they can contribute to the overall thermal-electrochemical problem, only by considering these details can a 'correct' simulation by arrived at. Further details on the methods we use and examples of these electrode effects can be found on the right side of this page.

Particle level analysis - STAR-CCM+ has a revolutionary solver, called 3D MicroStructure Electro-chemistry, which enables material designers to explore the impact of changes in material design on the performance of lithium ion chemistry electrodes. As more design is applied to the formulation of a cell's electrodes so this tool will enable electro-chemists to simulate the performance of different designs hence avoiding expensive testing and providing insight not possible from alternative methods

Cell Level analysis - Battery Design Studio® is a unique tool that allows engineers to design battery cells, simulate performance, and analyse data from both simulation and test work. The tools contains many utilities and function specific to the battery industry using familiar language and concepts for cell engineers

Pack Level analysis - STAR-CCM+ Battery Simulation Module allows cell level models, created in Battery Design Studio, to be used in a complex 3 dimensional representation of a battery pack. The cell can be replicated along with connecting parts and straps many times to create the pack design, all create using automatic tools within Battery Simulation Module. Within this model all forms of heat transfer (conduction, convection & radiation) can be included and an arbitrary number of material included. Hence both air and liquid cooling can be simulated with one model as well as the many thermally or electrically conducting components surrounding these operating battery cells.

This unique methodology is a collaboration of two industry-leading products to offer a single, integrated solution using CD-adapco’s STAR-CCM+, it's Battery Simulation Module and Battery Design Studio
The ability to analyze all characteristics of a battery pack/module within a single environment and ensure the correct overall performance is a key driver in reducing prototype/testing cost and ensuring reliability of batteries in the industry. CD-adapco has partnered with a number of battery industry and research institutions, such as ASCS (Automotive Simulation Center Stuttgart) and the US National Renewable Energy Laboratory (NREL) to validate the simulation process in an industrial environment under very rigorous situations, thereby ensuring this unique methodology remains state-of-the-art.

High capacity electrochemical devices are a revolutionary technology and in keeping with the times, the use of unique, state-of-the-art tools such as numerical simulation are critical in ensuring the success of tomorrow’s technology being designed today

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