Optimization design of liquid-cooled battery thermal management system based on wavy tube

There are two cooling tube arrangements were designed, and it was found that the double-tube sandwich structure had better cooling effect than the single-tube structure. In order to analyze the effects of three parameters on the cooling efficiency of a liquid-cooled battery thermal management system, 16 models were designed using L₁₆ (4³) orthogonal test, and the major and minor factors in the models were analyzed. The results show that among the three parameters, the coolant mass flow rate has the most significant impact on the maximum temperature of the battery module, followed by the inlet coolant temperature, and the coolant thermal conductivity has the least effect. In terms of temperature uniformity, the effects of all three factors on module temperature differences are very remarkable, with coolant mass flow rate and inlet temperature having particularly significant effects. The double-tube structure achieved a maximum temperature reduction of 6.7 °C and improved temperature uniformity with a maximum temperature difference reduction of 2.4 °C. Based on a comprehensive balancing method, parameter optimization was performed to determine the optimal combination of factors, further enhancing the cooling performance of the battery module.