Coupled Electro-Thermal Simulation of Battery Modules Using ANSYS<br />Dr. Firas Thair Al-Maliky<br /><br />The increasing adoption of lithium-ion battery modules in electric vehicles and renewable energy storage systems demands improved reliability, safety, and performance. A critical aspect affecting these parameters is the complex interaction between electrical and thermal behaviors within the battery cells during charge and discharge cycles. Excessive heat generation can degrade battery life and pose safety hazards, making accurate thermal management essential.<br /><br />This study presents a coupled electro-thermal simulation approach for battery modules using ANSYS software, integrating electrochemical and thermal physics to predict temperature distribution and electrical performance simultaneously. The simulation combines the electrical current flow, heat generation through Joule heating, and heat dissipation via conduction and convection mechanisms within the battery pack.<br /><br />The electrochemical model calculates the voltage, current, and state-of-charge dynamics based on the battery’s electrochemical properties and usage conditions. Simultaneously, the thermal model solves transient heat transfer equations to estimate temperature profiles inside the battery cells and across the module. Coupling these models enables realistic assessment of temperature rise due to internal resistances and chemical reactions.<br /><br />Simulations were performed on a typical lithium-ion battery module subjected to various charge-discharge rates and ambient temperatures. Results demonstrate that higher discharge rates significantly increase internal temperatures, which, if not properly managed, may lead to thermal runaway or reduced battery lifespan. The thermal gradients identified highlight the importance of efficient cooling system designs, such as liquid or air cooling channels integrated within the module.<br /><br />Moreover, the model allows evaluation of different battery configurations and cooling strategies to optimize thermal uniformity and electrical efficiency. Sensitivity analyses on material thermal conductivities and convective heat transfer coefficients provide valuable insights into critical design parameters.<br /><br />In conclusion, the coupled electro-thermal simulation using ANSYS offers a powerful tool for battery engineers to predict complex thermal-electrical interactions and design safer, more efficient battery systems. Incorporating such detailed multiphysics modeling into the development cycle can accelerate innovation in energy storage technologies, supporting sustainable energy goals and cleaner transportation solutions.<br /><br />Al-Mustaqbal University – The No. 1 Private University in Iraq