Deformation modeling of cylindrical cells and wireless management system for direct cooled battery packs

The following thesis project is aimed at the study of the thermal behavior of a 3s3p Li-Ion battery pack and at proposing an innovative solution of communication between cell boards and BMS, based on the wireless Bluetooth 5.0 LE technology. In the first part of the project, the entire battery pack, including casing, bus bar mount and fluid dividers, have been designed on CAD environment, and then through CFD simulations have been refined so to avoid generation of turbulences and points of stagnation which could deteriorate the effectiveness of the cooling. Then, after have printed the components and connected the cells so to generate a 3s3p battery, the pack has been created and subjected to tests with forced air cooling, so to compare the results obtained through CFD simulations. The data of the test have been collected first with a classical daisy chain of cell boards and BMS, communicating with each other through a wired serial communication system. Then, such system has been converted in wireless, based on BLE 5.0 technology, connecting the cell boards to a Bluetooth chip. The goal of such conversion is to allow a reduction of total weight and complexity of the battery pack, improving also its modularity.