ACKNOWLEDGEMENT:

I would like to express my heartfelt gratitude to Shazana Infotech for

providing me this opportunity to undergo internship training in Embedded
Systems and Robotics. I sincerely thank my mentor, trainers, and all those who
supported me during this internship program.

I express my sincere gratitude to Shazana Infotech for providing me with

the opportunity to undergo internship training on Embedded System and
Robotics. This internship has given me valuable exposure to practical applications
of embedded systems, IoT, and robotics, which enhanced my technical knowledge
and problem-solving abilities.

I would like to thank my mentors and trainers at Shazana Infotech for their
constant guidance, support, and encouragement throughout the training period.
Their expertise and insightful feedback helped me in successfully completing the
projects and understanding real-world applications.

I also extend my thanks to my faculty, friends, and family members who

supported me during this journey. This internship has been an enriching
experience and has contributed significantly to my professional and personal
growth.
 ABSTRACT

The rapid growth of Electric Vehicles (EVs) has highlighted the

importance of efficient Battery Thermal Management Systems (BTMS) to
ensure safety, performance, and longer battery life. Lithium-ion batteries, which
are widely used in EVs, are highly sensitive to temperature variations.
Overheating can lead to faster degradation, reduced efficiency, and even safety
hazards, while low temperatures adversely affect charging and discharging
capabilities.

This internship at Shazana Infotech focused on exploring, understanding,

and implementing thermal management solutions for EV batteries using
embedded systems and IoT technologies. Various methods such as air cooling,
liquid cooling, and automatic control mechanisms were studied and applied
through hands-on projects. Prototypes were developed using ESP32/Arduino,
DS18B20 temperature sensors, relay modules, cooling fans, and IoT
platforms to monitor and regulate battery temperatures in real time.

The internship experience provided not only technical knowledge of EV

battery systems but also practical exposure to sensor integration,
microcontroller programming, IoT connectivity, and data analysis. This
report presents the technical background, project implementations, outcomes, and
skills acquired during the training program, highlighting the critical role of
BTMS in the future of electric mobility.

2
 TABLE OF CONTENTS

CHAPTER TITLE PAGE

NO. NO.
ABSTRACK 2
1. INTRODUCTION 5
1.1 Current Scenario 5
1.2 Battery System 6
1.3 Role of Battery System 7
1.4 Battery Issues 8
1.5 Battery Thermal Management System 9
1.6 Overview Of The Project 9
2. LITERATURE REVIEW 10
2.1 Introduction 10
2.2 Design and Modelling of Battery Cooling 11
2.3 Cooling System of Battery using Heat pipe 12
2.4 Battery Cell Arrangement Heat Transfer 13

2.7 Battery Useful Life Estimation 17

3. METHODOLOGY 19
3.1 Proposed System 20
3.2 Working Operation 22
3.3 Battery Management System 24
3.4 Mathematical Condition 26
3.5 Battery Thermal Model 28
4. SIMULATION AND RESULTS 32
4.1 Simulation Model of Proposed System 32

3
5. HARDWARE IMPLEMENTATION 35
5.1 Hardware Description 36
5.2 Arduino Controller 36
6. CONCLUSION 44

4
 CHAPTER 1
INTRODUCTION

The global shift towards sustainable transportation has significantly

increased the demand for Electric Vehicles (EVs). At the heart of every EV lies
the battery pack, which serves as the primary source of energy. However, the
efficiency, lifespan, and safety of these batteries are highly dependent on their
operating temperature. Extreme heat can accelerate battery degradation and lead
to safety hazards, while very low temperatures reduce charging efficiency and
overall performance.

To overcome these challenges, a Battery Thermal Management System

(BTMS) is employed. A BTMS ensures that the battery operates within an
optimal temperature range by regulating heating and cooling as required. Various
methods such as air cooling, liquid cooling, phase change materials (PCM), and
advanced active control systems are used to maintain stable conditions.

1.1 CURRENT SCENARIO

The adoption of Electric Vehicles (EVs) is rapidly increasing worldwide due

to the growing demand for sustainable and eco-friendly transportation.
Governments and industries are investing heavily in EV development to reduce
dependency on fossil fuels and minimize greenhouse gas emissions. However,
one of the most critical challenges faced by EV manufacturers today is the
thermal management of lithium-ion batteries, which are the primary energy
source of these vehicles.

At present, battery packs in EVs operate under varying conditions of load,

climate, and charging cycles. Without an efficient Battery Thermal
Management System (BTMS), these batteries are prone to overheating, reduced
performance, and safety risks such as thermal runaway.
5
 Fig 1: Power Generation 2

In India, the EV market is expanding rapidly under the FAME-II policy and
state-level incentives. However, challenges such as extreme ambient
temperatures, cost constraints, and lack of localized BTMS technologies
remain. This creates an urgent need for research, innovation, and skill development
in the field of EV battery management.

The internship at Shazana Infotech was designed to align with this current
scenario by providing students with practical exposure to BTMS technologies,
enabling them to understand industry trends, tackle real-time challenges, and
develop innovative solutions for the future of electric mobility.

Fig 2: Renewable Energy Scenario

6
1.2 BATTERY SYSTEM
The battery system is the heart of every Electric Vehicle (EV), providing
the electrical energy required to power the motor, auxiliary systems, and
onboard electronics. Among the different energy storage options available,
Lithium-ion (Li-ion) batteries are the most widely used due to their high
energy density, long cycle life, lightweight design, and fast charging
capabilities.
A typical EV battery system consists of:
1. Battery Cells – Small individual Li-ion cells (cylindrical, prismatic, or pouch
type) that store and release energy.
2. Battery Modules – A group of interconnected cells arranged to deliver the
required voltage and capacity.
3. Battery Pack – Several modules combined into a single unit with protective
casing, cooling channels, and monitoring electronics.
4. Battery Management System (BMS) – An electronic control unit that
monitors voltage, current, temperature, and state of charge (SOC) to ensure
safe and efficient operation.
5. Thermal Management System (BTMS) – Maintains the battery within its
optimal temperature range (20°C – 40°C) by using air cooling, liquid cooling,
or phase change materials.

1.3 ROLE OF BATTERY SYSTEM

The battery system plays a central role in the functioning of an Electric Vehicle
(EV). Unlike conventional vehicles that rely on internal combustion engines (ICE),
EVs are completely dependent on the battery as their primary energy storage and
power source. The performance, range, efficiency, and safety of an EV are directly
determined by the quality and design of its battery system.

7
1.4 BATTERY ISSUES
While Lithium-ion batteries have become the most preferred energy source for
Electric Vehicles (EVs) due to their high energy density and efficiency, they face
several technical and operational challenges. These issues directly affect the safety,
lifespan, and performance of EVs and highlight the importance of an efficient
Battery Thermal Management System (BTMS).
🔹 1. Thermal Issues
 Overheating during high current charging/discharging.
 Uneven temperature distribution within cells and modules.
 Risk of thermal runaway, leading to fire or explosion.
🔹 2. Capacity Degradation
 Gradual loss of battery capacity due to repeated charge–discharge cycles.
 Formation of Solid Electrolyte Interphase (SEI) layer reducing efficiency.
 Faster degradation in hot climates or under high load conditions.

1.5 BATTERY THERMAL MANAGEMENT SYSTEM:

The Battery Thermal Management System (BTMS) is one of the most critical
subsystems in an Electric Vehicle (EV). Since lithium-ion batteries are highly
sensitive to temperature, their performance, safety, and lifespan largely depend on
maintaining them within an optimal operating range of 20°C to 40°C. Any
deviation—either overheating or excessive cooling—can lead to capacity loss,
reduced efficiency, and even dangerous thermal runaway.
Functions of BTMS
1. Temperature Regulation – Keeps the battery within a safe and efficient
operating range.
2. Uniform Heat Distribution – Prevents hotspots by ensuring all cells in the pack
are cooled evenly.
3. Safety Protection – Avoids overheating, thermal runaway, and fire hazards.
8
1.6 OVERVIEW OF THE REPORT

This report presents the outcomes of the internship training carried out at Shazana
Infotech, focused on the study and implementation of Battery Thermal Management
Systems (BTMS) for Electric Vehicles (EVs). The internship aimed to provide both
theoretical knowledge and practical skills in embedded systems, IoT integration, and
EV battery technologies.

The report begins with an Abstract, summarizing the objectives and scope of the
internship. The Introduction highlights the importance of EVs and the need for
effective thermal management of battery systems. The Technical Background section
provides insights into the fundamentals of EV batteries, their thermal challenges, and
the role of BTMS in ensuring safety and performance.

CHAPTER 2

LITERATURE SURVEY

Research on Battery Thermal Management Systems (BTMS) for EVs spans

battery electrochemistry, heat generation/transfer, pack design, control, and safety. The
key themes and findings from prior work are summarized below.

1) Heat generation & temperature effects

 Classic studies explain how ohmic losses and entropic heat drive temperature rise
during charge/discharge; elevated temperatures accelerate aging, while low
temperatures increase internal resistance and reduce power.

 Seminal reviews highlight the tight coupling between temperature, degradation,

power capability, and safety in Li-ion cells.

9
2) Thermal runaway & safety

 Abuse and failure analyses show that overcharge, internal shorts, and high
temperatures can trigger thermal runaway, propagating between cells if packs
lack adequate thermal barriers and venting.

 Safety frameworks emphasize detection, containment, and propagation

mitigation.

2.1 INTRODUCTION

The global transition toward Electric Vehicles (EVs) is driven by the need for
sustainable transportation, reduction of greenhouse gas emissions, and decreasing
dependency on fossil fuels. At the core of every EV lies the battery system, which acts
as the primary energy source. Among available technologies, lithium-ion batteries
dominate due to their high energy density, long cycle life, and lightweight nature.
However, these batteries are highly sensitive to temperature fluctuations, which
directly influence their performance, safety, and lifespan.

2.2 DESIGN AND MODELING SYSTEM OF BATTERY COOLING

A well-designed battery cooling system must remove the heat generated during
charge/discharge and keep all cells within the target temperature band to maximize
performance, life, and safety. The design process combines electro-thermal
characterization, thermal modeling, fluid/air flow design, control strategy, and
testing/validation.

1. Design objectives & constraints

 Maintain cell temperature within the optimal range (typically 20–40°C,

application dependent).

 Limit maximum temperature gradient across cells (target ≤ 2–5°C).

10
  Minimise parasitic power consumption (fans/pumps).

 Meet packaging, weight, cost and safety constraints.

2. Sensor placement & diagnostics

 Place sensors at hotspots, module center and edge to capture gradients.

 Add redundancy: at least 2 sensors per module or per string for fault tolerance.

2.3 COOLING SYSTEM FOR BATTERY USING HEAT PIPES

1. Overview — What is a heat-pipe cooling system?

A heat pipe is a passive two-phase heat-transfer device that transports large

amounts of heat with very small temperature drop. Inside a sealed pipe, a working fluid
evaporates at the hot end, travels as vapor to the cold end, condenses, and returns by
capillary action (wick) to repeat the cycle. For EV battery packs, heat pipes are used to
move heat away from hot cells to cooling headers, cold plates, or radiators—improving
temperature uniformity and reducing hotspots.

2. Why use heat pipes in BTMS?

 Very high effective thermal conductivity (orders of magnitude higher than

metals).

 Passive operation — no moving parts, silent and reliable.

 Good for lateral heat spreading (taking heat from cell center to edge/cold-plate).

 Useful in constrained mechanical layouts where direct coolant channels are hard
to place.

 Can be combined with liquid cold plates or air-cooled radiators as hybrid

systems.

3. Typical architectures

1. Heat-pipe-assisted cold plate

11
 o Heat pipes embedded in a cold plate spread cell heat to coolant channels.

2. Heat-pipe thermal spreader + air duct

o Heat pipes move heat from cell center to edge where fans/external fins
dissipate it.

2.4 BATTERY CELL ARRANGEMENT AND DESIGNING OF LIQUID

COOLING SYSTEM

1. Battery Cell Arrangement (Pack Architecture)

A correct cell arrangement is the first step because cooling paths and thermal behaviour
depend on how cells are grouped and connected.

1.1 Cell → Module → Pack hierarchy

 Cell: smallest unit (cylindrical / prismatic / pouch).

 Module: group of cells connected electrically and packaged together.

 Pack: several modules assembled with mechanical structure, busbars, BMS,

BTMS.

1.2 Electrical arrangement

 Series (S) to increase voltage: cells in series add voltages.

 Parallel (P) to increase capacity/current: parallel strings increase capacity and

reduce effective internal resistance.

 Packs are specified as S × P (e.g., 96S2P).

1.3 Thermal implications of arrangement

 Series strings: voltage increases but thermal gradients can appear across module
length.

 Parallel strings: better current sharing but more cells to cool in a compact
region.

12
  Module spacing & orientation: provide channels or contact areas for cooling
plates.

 Hotspot risk: cell-to-cell heat spreading must be designed so local hotspots do

not form — use TIM, spreaders or heat pipes in addition to liquid channels.

2.7 ESTIMATION AND CALCULATION OF REMAINING USEFUL

LIFE FOR BATTERY

1. Introduction to RUL

The Remaining Useful Life (RUL) of a battery refers to the predicted time or
number of cycles the battery can continue to operate safely and efficiently before
reaching its end of life (EOL).

 End of Life (EOL) is generally defined when the battery’s capacity drops to 70–
80% of its rated capacity or when internal resistance increases beyond a safe
limit.

 RUL is therefore a critical parameter for Electric Vehicles (EVs) as it directly

impacts range prediction, maintenance planning, and safety assurance.

2. Importance of RUL Estimation

 Enables predictive maintenance and timely replacement of battery packs.

 Helps in warranty management for EV manufacturers.

 Reduces risk of unexpected battery failure.

 Supports second-life applications (reuse of EV batteries in stationary storage).

 Enhances thermal and safety management in BMS.

3. Methods for RUL Estimation

(a) Capacity Fade Based Estimation

13
  RUL is calculated by tracking the decrease in usable capacity over cycles.

 Formula:

RUL=Ccurrent−CEOLΔCper cycleRUL = \frac{C_{current} - C_{EOL}}{\Delta

C_{per\ cycle}}RUL=ΔCper cycleCcurrent−CEOL

Where:

 CcurrentC_{current}Ccurrent = Current capacity

 CEOLC_{EOL}CEOL = Capacity at end of life (e.g., 80% of rated)

(b) Internal Resistance Growth Method

 Since internal resistance increases with aging, RUL is predicted by modeling the
resistance growth curve.

 Works well for online monitoring but must be corrected for temperature effects.

(c) Model-Based Prediction

 Uses Equivalent Circuit Models (ECM) or electrochemical models combined

with degradation equations.

 Extended Kalman Filters (EKF), Particle Filters (PF) and Prognostics-based

models are widely used.

14
 CHAPTER 3

METHODOLOGY

The methodology adopted for the development and study of a Battery Thermal
Management System (BTMS) for Electric Vehicles (EVs) involves a systematic
combination of literature review, system design, modeling, experimental validation, and
performance evaluation. The following structured approach was followed:

1. Literature Review & Problem Identification

 Conducted an extensive literature survey on battery performance, thermal

behavior, and existing cooling technologies.

 Identified major challenges such as temperature rise, uneven cell heating, thermal
runaway risk, and reduced lifespan.

 Defined the research gap: the need for an efficient, cost-effective, and reliable
BTMS that ensures safety and longer battery life.

2. Battery System Analysis

 Studied different battery chemistries (Li-ion, NMC, LFP) and their thermal
characteristics.

 Examined cell arrangement and module design to determine hot-spot formation.

 Selected an appropriate battery module configuration for modeling and testing.

15
3. Selection of Cooling Method

 Compared various cooling techniques: air cooling, liquid cooling, PCM-based

cooling, and heat-pipe systems.

 Selected liquid cooling with integrated heat-pipe assistance for efficient heat
transfer and temperature uniformity.

3.1 PROPOSED SYSTEM

The proposed system is a Hybrid Battery Thermal Management System

(BTMS) designed to maintain safe operating temperature and improve the
performance, safety, and lifespan of EV battery packs. It combines liquid cooling
channels with heat pipes, supported by an intelligent Battery Management System
(BMS) for real-time monitoring of SOC, SOH, and RUL.

1. Key Features of the Proposed System

 Hybrid Cooling Approach: Integration of liquid cooling (for bulk heat removal)
and heat pipes (for localized hotspot suppression).

 Real-Time Monitoring: Continuous measurement of temperature, voltage,

current, SOC, SOH, and RUL.

 Adaptive Control: ESP32-based controller adjusts coolant flow rate and fan
speed based on battery thermal load.

 Uniform Temperature Distribution: Heat pipes redistribute heat, minimizing

cell-to-cell temperature differences.

 Smart Estimation Algorithms:

o SOC via Coulomb Counting + Kalman Filter

o SOH via capacity fade and impedance measurement

16
 o RUL using hybrid model-based and data-driven techniques

 Safety Mechanisms: Protection against over-temperature, over-charge, over-

discharge, and thermal runaway.

2. System Architecture

The proposed BTMS consists of the following components:

1. Battery Pack – Lithium-ion cells arranged in series-parallel modules.

2. Liquid Cooling Plate – Channels for coolant circulation, placed beneath the
battery modules.

3. Heat Pipes – Embedded across cell arrays for quick lateral heat transfer.

4. Coolant Pump & Radiator/Fan – Actively removes heat from coolant loop.

5. Sensors –

o Temperature sensors (DS18B20 / thermocouples)

o Current sensor (Hall-effect sensor)

o Voltage monitoring circuits

6. Microcontroller (ESP32 / BMS Controller) –

o Processes sensor data

o Estimates SOC, SOH, RUL

o Controls coolant pump and fan

7. IoT Integration – Data logging and visualization for predictive maintenance.

17
 Fig 3: Battery thermal management system block diagram

3.2 WORKING OPERATION

The proposed Hybrid Battery Thermal Management System (BTMS) operates

by continuously monitoring, controlling, and stabilizing the temperature of EV
battery cells during charging, discharging, and idle states. The operation can be
explained step by step:

1. Sensing & Data Acquisition

 Multiple sensors (voltage, current, and temperature) are placed across the battery
modules.

 These sensors measure:

o Cell voltage & pack voltage

o Charging/discharging current

o Cell surface and coolant temperatures

 Data is fed into the BMS controller (ESP32 / MCU) in real time.

2. Battery State Estimation

 The controller estimates:

o State of Charge (SOC) – Remaining capacity using Coulomb Counting +

Kalman Filter.

18
 o State of Health (SOH) – Based on capacity fade and internal resistance
growth.

o Remaining Useful Life (RUL) – Predicted from degradation models and

historical data.

 This information is used to optimize cooling and safety strategies.

3. Cooling Activation

 If battery temperature rises above a set threshold (e.g., 40°C):

o The liquid coolant pump is activated, circulating coolant through channels

beneath the cells.

o Heat pipes transfer heat from local hotspots to the coolant plate.

4. Temperature Equalization

 The heat pipes ensure lateral spreading of heat across cells, preventing hotspots.

 The liquid cooling system provides uniform removal of thermal energy.

 This maintains temperature uniformity (ΔT ≤ 3°C) across the battery pack.

5. Intelligent Control

 The BMS controller dynamically adjusts pump speed and fan operation
depending on load conditions:

o Light Load / Idle → Minimal cooling (energy saving).

o High Load / Fast Charging → Maximum cooling for safe operation.

 If abnormal rise is detected (thermal runaway initiation), the system triggers

emergency shutdown and alerts.

6. IoT Data Monitoring

19
  All operating parameters (SOC, SOH, RUL, temperature, coolant flow) are
transmitted to a cloud dashboard.

 Users and engineers can monitor battery performance remotely, enabling

predictive maintenance.

3.3 BATTERY MANAGEMENT SYSTEM

A Battery Management System (BMS) is the intelligent control unit that

monitors, regulates, and ensures the safe and efficient operation of the battery pack in
Electric Vehicles (EVs). Since Lithium-ion batteries are highly sensitive to
temperature, voltage, and current fluctuations, a BMS is essential to protect the
battery, optimize performance, and extend lifespan.

1. Functions of BMS

The major functions of a BMS are:

 Monitoring

o Tracks voltage, current, and temperature of each cell.

o Ensures all cells are within safe operating ranges.

 State Estimation

o State of Charge (SOC): Measures available capacity.

o State of Health (SOH): Determines battery degradation.

o Remaining Useful Life (RUL): Predicts how long the battery can function
reliably.

 Thermal Management

o Works in coordination with the Battery Thermal Management System

(BTMS).

o Activates cooling/heating mechanisms to maintain optimal temperature.

 Cell Balancing

20
 o Prevents overcharging/over-discharging by balancing charge across all
cells.

o Uses active or passive balancing techniques.

 Protection Features

o Over-voltage / under-voltage protection

o Over-current / short-circuit protection

o Over-temperature protection

2. BMS Architecture

A typical BMS consists of the following modules:

 Sensing Unit – Voltage, current, and temperature sensors.

 Control Unit (MCU/ESP32/DSP) – Processes data and runs algorithms for

SOC, SOH, RUL estimation.

 Balancing Circuit – Manages charge distribution among cells.

 Power Electronics – Controls charging/discharging paths.

3. Role in Thermal Management

 The BMS continuously monitors cell temperatures and decides when to

activate the cooling system (liquid cooling, heat pipes, fans, etc.).

 Ensures temperature uniformity within the pack to prevent hotspots.

 Maintains battery temperature in the safe zone (20°C–40°C) for best

performance and longevity.

4. Advantages of BMS in EV Applications

 Enhances battery safety by preventing overheating and overcharging.

 Increases battery lifespan through proper monitoring and balancing.

 Improves EV driving range by efficient utilization of available energy.

21
3.4 MATHEMATICAL CONDITIONS

The design and operation of a Battery Thermal Management System (BTMS)

depend on several mathematical models that describe the electrical, thermal, and
degradation characteristics of the battery. These conditions are essential for accurate
prediction of battery performance, safety, and life cycle.

1. Heat Generation in Battery Cells

During charging and discharging, the battery generates heat due to internal
resistance and electrochemical reactions. The total heat generated (Qgen) is:

Qgen=I2Rint+I⋅(Eocv−V)Q_{gen} = I^2R_{int} + I \cdot (E_{ocv} - V)Qgen=I2Rint

+I⋅(Eocv−V)

2. Heat Transfer Equation (Cooling Requirement)

The cooling system must remove the generated heat to maintain safe battery
operation. The heat transfer rate is given by:

Q=m⋅Cp⋅ΔTQ = m \cdot C_p \cdot \Delta TQ=m⋅Cp⋅ΔT

3. State of Charge (SOC) Estimation

SOC is the measure of available energy in the battery relative to its capacity.
Using Coulomb counting:

SOC(t)=SOC(t0)−1Cn∫t0tI(τ) dτSOC(t) = SOC(t_0) - \frac{1}{C_n} \

int_{t_0}^{t} I(\tau) \, d\tauSOC(t)=SOC(t0)−Cn1∫t0tI(τ)dτ

4. State of Health (SOH) Estimation

SOH represents the aging and degradation of the battery.

SOH=CactualCrated×100%SOH = \frac{C_{actual}}{C_{rated}} \times

100\%SOH=CratedCactual×100%

5. Remaining Useful Life (RUL) Estimation

RUL is calculated based on degradation rate:

22
RUL=CEOL−CcurrentdC/dtRUL = \frac{C_{EOL} -
C_{current}}{dC/dt}RUL=dC/dtCEOL−Ccurrent

3.5 BATTERY THERMAL MODEL

The Battery Thermal Model describes the heat generation and dissipation
processes within the battery pack. Since Lithium-ion batteries are sensitive to
temperature variations, accurate thermal modeling is essential to design an effective
Battery Thermal Management System (BTMS).

1. Heat Generation in Battery Cell

The main sources of heat inside a battery cell are:

 Ohmic (resistive) heating due to internal resistance.

 Reaction heat due to electrochemical polarization.

The total heat generation rate is:

Qgen=I2Rint+I⋅(Eocv−V)Q_{gen} = I^2R_{int} + I \cdot (E_{ocv} - V)Qgen=I2Rint

+I⋅(Eocv−V)

2. Energy Balance Equation

The thermal behavior of a battery cell can be expressed using an energy balance:

m⋅Cp⋅dTdt=Qgen−Qdissm \cdot C_p \cdot \frac{dT}{dt} = Q_{gen} - Q_{diss}m⋅Cp

⋅dtdT=Qgen−Qdiss

23
 Fig 5: Battery thermal model

5. Multi-Cell Pack Model

In a battery pack with many cells, temperature distribution must be considered. The
thermal model extends to:

miCp,idTidt=Qgen,i−∑Qdiss,im_i C_{p,i} \frac{dT_i}{dt} = Q_{gen,i} - \sum

Q_{diss,i}miCp,idtdTi=Qgen,i−∑Qdiss,i

Where each cell iii interacts thermally with neighboring cells through conduction and
convection.

6. Importance of Thermal Model

 Prevents hotspot formation inside modules.

 Ensures uniform temperature distribution (ΔT ≤ 3–5°C).

 Helps optimize cooling system design (liquid flow rate, pipe dimensions, fan
speed).

 Enhances battery safety, life, and performance.

CHAPTER 4

SIMULATION AND RESULTS

To evaluate the effectiveness of the proposed Battery Thermal Management

System (BTMS), a simulation model was developed using MATLAB/Simulink. The
model incorporated the battery pack, thermal behavior equations, liquid cooling
channels, motor pump control, and temperature feedback from sensors. Different
operating scenarios such as fast charging, high current discharge, and ambient
temperature variations were simulated to analyze the system performance.

The results showed that without thermal management, the battery temperature
could rise beyond 60°C during continuous operation, leading to performance
24
degradation and safety risks. However, with the proposed BTMS, the liquid cooling
system successfully maintained the battery temperature within the safe range of 25°C–
40°C, even under high load conditions. The motor pump activation was observed to
respond dynamically to sensor inputs, ensuring efficient coolant circulation.4.1
SIMULATION MODEL OF PROPOSED SYSTEM

Fig 7: Simulation Model of Proposed System.

5. Simulation Options

1. MATLAB ODE (ode45) — quick for lumped models and control logic (code
provided below).

2. Simulink — visual block implementation, easy to expand to multiple nodes and

add coolant dynamics.

o Use Integrator, Sum, Gain, Switch / Relay blocks, Lookup Table for Q_gen
profile, PID for pump PWM if needed.

25
 CHAPTER 5

HARDWARE IMPLEMENTATION

(Battery Thermal Management System for EVs — Shazana Infotech)

Below is a complete, practical guide to implement the proposed hybrid BTMS

(liquid cooling + heat pipes) prototype using embedded hardware (ESP32), sensors,
pumps/fans, cold-plate/heat-pipe assembly, power electronics and IoT connectivity.
Follow step-by-step: BOM → mechanical integration → electrical wiring →
PCB/connector notes → software hooks → testing & safety.

1) Goals of hardware build

 Measure cell/module temperatures, current & voltages.

 Actively control coolant pump & radiator fan(s).

 Use heat pipes + cold-plate for heat spreading and coolant removal.

 Provide IoT telemetry (ESP32 → Thingspeak / Blynk / Firebase).

 Make a safe, testable prototype for lab validation.

2) Bill of Materials (BOM — prototype level)

Electronics

 ESP32 Dev Board (WROOM/WROOM32) ×1

 DS18B20 digital temperature sensors (waterproof) × 6–12 (or more per node)

 NTC thermistors or K-type thermocouples (optional) ×2–4

 Current sensor: INA219 (I2C, high-side) or ACS712 (hall) ×1

26
  Voltage sensing divider (for pack sense) or dedicated ADC module ×1

 Relay module (5V/12V, opto-isolated) × 1–2 or high-side MOSFET driver (e.g.,

IRLZ44N or logic MOSFET + gate driver) ×2

Fig 9: Hardware Block

5.1 HARDWARE DESCRIPTIONS

The various components area used in this battery thermal management

system. They are as follows:

 Battery -12V, 7.5Ah

 Arduino Uno

 Current Sensor – Hall Effect Sensor

 Temperature Sensor – LM35

 Motor Pump - 12V DC30

5.2 ARDUINO CONTROLLER:

The Arduino (ATmega328 microcontroller) is used as the central controller for

monitoring and controlling the Battery Thermal Management System. The block
diagram illustrates how the microcontroller integrates sensors, the cooling system, and a
display unit.

Working Principle

1. Battery Temperature Sensing

27
 o Two batteries (Battery 1 and Battery 2) are monitored using LM35
temperature sensors.

o The LM35 outputs an analog voltage proportional to temperature (10

mV/°C).

2. Microcontroller Processing

o The ATmega328 Arduino continuously reads the temperature data.

o Pre-programmed threshold values decide whether the cooling system

should be activated.

o The controller ensures both batteries are maintained within safe operating
limits.

COMMUNICATION

(Battery Thermal Management System for EVs – Shazana Infotech)

Efficient communication between hardware modules is essential for the safe and
reliable operation of the Battery Thermal Management System (BTMS). The
communication framework consists of sensor-to-controller communication,
controller-to-actuator communication, and controller-to-user/cloud
communication.

1. Sensor-to-Controller Communication

 Temperature Sensors (LM35 / DS18B20):

o LM35 uses analog voltage output to communicate with the

Arduino/ATmega328.

o DS18B20 uses the One-Wire digital protocol, reducing wiring

complexity.

 Current and Voltage Sensors:

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 o Modules like INA219 use the I²C protocol (two-wire communication:
SDA & SCL).

o Voltage dividers directly provide analog signals to the ADC pins of the
controller.

2. Controller-to-Actuator Communication

 The ATmega328/Arduino processes sensor inputs and generates control signals

for the cooling system (pump and fan).

 Relay Modules / MOSFET Drivers:

Fig 10: Arduino Uno 31

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 CHAPTER 6

CONCLUSION

The development of a Battery Thermal Management System (BTMS) is

essential for enhancing the safety, performance, and durability of electric vehicle
batteries. Effective thermal regulation ensures that battery cells operate within their
optimal temperature range, thereby preventing overheating, thermal runaway, and
efficiency losses. Through the integration of temperature sensors, Hall effect current
sensors, motor pumps, and control systems such as Arduino-based controllers, the
proposed BTMS provides a reliable solution for real-time monitoring and active
cooling.

The study also highlights various design aspects, including liquid cooling
systems, heat pipe integration, and state estimation methods for charge, health, and
remaining useful life of the battery. By implementing such a system, EVs can achieve
improved charging efficiency, longer battery lifespan, and safer operation under
diverse environmental and load conditions. Overall, the BTMS represents a critical step
toward advancing sustainable and reliable electric mobility.

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