Development and validation of a thermal management system for a twin battery through Hardware-in-the-Loop simulation

In the last few years, the automotive industry has undergone a significant transformation by shifting from conventional internal combustion engines to electric motors. This change has been highly driven by the implementation of stringent environmental regulations aimed at reducing the amount of air pollution and greenhouse gas emissions. Countries around the world, particularly in Europe, have introduced policies that incentivize the production and adoption of electric vehicles (EVs), setting ambitious targets for emission reductions and promoting low-emission technologies. As a result, the electrification of vehicles has been accelerated, with many vehicle manufacturers investing in research and development to enhance battery performance, energy efficiency and the overall sustainability of EVs. This transformation reflects not only a response to regulatory compliance, but it comes from the general push toward a more sustainable future, using fewer fossil fuels. This research focuses precisely on finding more sustainable and advanced technologies, trying to offer solutions different from those already on the market. It explores an automotive dual battery pack with two major innovations: the use of sodium as an active material for one of the two batteries and the implementation of an immersion cooling technique. Most automotive batteries today are lithium-ion based, but sodium could represent a new revolutionary solution regarding cost reduction and environmental friendliness. This project mainly investigates a distinct method for managing battery temperature by implementing an immersive cooling system. In contrast to conventional cooling techniques that use serpentine or external systems, the batteries are fully submerged in a dielectric fluid, providing better thermal conductivity and more effective heat dispersal. In electric vehicles, it is crucial to have effective thermal management to address high power demands that can result in significant temperature rises affecting battery lifespan, performance, and safety. The main goal of this study is to examine the thermal behaviour of the dual battery system, considering both the heating and cooling procedures. To accomplish this, the study uses a Hardware-in-the-loop (HIL) simulation method to mimic real-life operating conditions by simulating the power requirements of the battery system. This technique permits close monitoring of factors, facilitating a precise evaluation of the impact of various load situations on the system's temperature. Using this technique, the battery pack will be emulated directly by “Speed Goat”, hardware that enables the simulation of the operation of physical components. The study's findings are anticipated to provide crucial information that will help improve the efficiency and reliability of this battery system, assisting the study that will be conducted shortly to arrive at the production of a prototype.