Development of an Automated 3D-CFD Methodology for Battery Cooling Plate Parametric Optimization in Electric Mobility

Theautomotive industry is currently undergoing a significant transition from non-renewable energy sources, primarily fossil fuels derived from crude oil, towards more sustainable al ternatives such as fuel cells, synthetic fuels, and electric power. Among these, electric energy is playing a central role, with BEVs and HEVs emerging as the most widespread solutions for passenger transportation. Despite their increasing market penetration over the past decade, these technologies still face several challenges that hinder full consumer acceptance, particularly when compared to traditional Internal Combustion Engine (ICE) vehicles. One of the primary limitations remains the reduced driving range. In this context, the research work focuses on enhancing battery systems to align with the performance expectations of modern users. A key factor in this challenge is an effective cooling system, as temperature control has a direct influence on performance, durability, and operational safety. Proper cooling ensures the battery operates within the optimal temperature range, thereby preserving reliability, minimizing the risk of critical failures, and mitigating battery degradation. This thesis, developed in collaboration with GammaTech Engineering, Politecnico di Torino, and Cornaglia, aims to establish a semi-automated 3D-CFD methodology based on Conjugate Heat Transfer (CHT) simulations using Siemens Star-CCM+. The objective is to optimize battery cooling plate designs by simulating various geometric configurations, ultimately reducing development time and cutting costs for Original Equipment Manufac turers (OEMs) while ensuring performance targets are met. The methodology is designed to be general-purpose and applicable to any parametric CAD model imported into the simulation environment. More in detail, the first phase of the work focused on developing the simulation frame work using a simplified prototype geometry, in order to reduce computational time and complexity. The objective was to create a tool capable of identifying the optimal plate de sign by varying the heights of the coolant channels to meet thermal and flow performance requirements. In the second phase, the validated methodology was applied to a real-size battery cooling plate, under realistic operating boundary conditions, to determine the most effective configuration. To conclude, a quasi-fully automated design procedure for battery cooling plates has been developed and successfully validated on both a scaled prototype and a real-size model. The approach supports parametric geometry optimization and offers adaptability to a wide range of application contexts.