电池热管理散热器流动换热特性实验与数值仿真研究

刘杙; 杜毅; 万红牛; 马科帅; 冀文涛

doi:10.12465/issn.0253-4339.20241105002

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电池热管理散热器流动换热特性实验与数值仿真研究

更新时间：2025-09-28

- 电池热管理散热器流动换热特性实验与数值仿真研究
- Experimental Investigation on Thermo-Hydraulic Performance of a Fin and Tube Heat Exchanger for Battery Thermal Management
- 制冷学报 2025年页码：1-11
- 作者机构：
  
  1.西安交通大学能源与动力工程学院热流科学与工程教育部重点实验室西安 710049
  2. 青岛求是工业技术研究院青岛 266427
- 作者简介：
  
  冀文涛，男，教授，西安交通大学能源与动力工程学院，029-82665445，E-mail：wentaoji@xjtu.edu.cn。研究方向：制冷工质沸腾与凝结相变换热，高效换热器设计，热泵干燥等。
- 基金信息：
  
  本文受陕西省秦创原“科学家+工程师”队伍建设项目(2022KXJ-001);青岛市自然科学基金项目(23-2-1-215-zyyd-jch┫。(The project was supported by Shaanxi Province Qin Chuangyuan "Scientist + Engineer" Team Construction Project ┣2022KXJ-001┫┣23-2-1-215-zyyd-jch)
- DOI：10.12465/issn.0253-4339.20241105002
  中图分类号： TB61⁺1;TB657.5
- CSTR：XXXXX.XX.XXX.20241105002
- 收稿：2024-11-05，
  
  修回：2024-12-04，
  
  录用：2024-12-06，
  
  网络出版：2025-09-28，
- 稿件说明：
移动端阅览
刘杙,杜毅,万红牛等.电池热管理散热器流动换热特性实验与数值仿真研究[J].制冷学报,

Liu Yi,Du Yi,Wan Hongniu,et al.Experimental Investigation on Thermo-Hydraulic Performance of a Fin and Tube Heat Exchanger for Battery Thermal Management[J].Journal of Refrigeration,
刘杙,杜毅,万红牛等.电池热管理散热器流动换热特性实验与数值仿真研究[J].制冷学报, DOI：10.12465/issn.0253-4339.20241105002. CSTR： XXXXX.XX.XXX.20241105002.

Liu Yi,Du Yi,Wan Hongniu,et al.Experimental Investigation on Thermo-Hydraulic Performance of a Fin and Tube Heat Exchanger for Battery Thermal Management[J].Journal of Refrigeration, DOI：10.12465/issn.0253-4339.20241105002. CSTR： XXXXX.XX.XXX.20241105002.

摘要

基于空气直接冷却的电池热管理因成本低、结构简单等优点被广泛应用。然而，随着风速的提高，噪声和功耗也会增加。针对一典型平直翅片电池热管理用管翅式散热器，采用实验和数值模拟方法研究了风速为2.1~6.1 m/s，冷却工质入口与空气进口温差为20~40℃，冷却工质质量流量为0.35~0.55 kg/s时的流动换热特性。研究结果表明：这3个参数对平直翅片散热器的换热性能均存在显著影响。随着风速的增加，空气侧表面对

流传热系数最大提高了102.1%；随着水入口与空气进口温差Δ

w-a

的增加，表面对流传热系数提高了19.1%~28.9%，并与Δ

w-a

变化接近线性关系；冷却工质质量流量增加增强了换热，表面对流传热系数随之增加，且表面对流传热系数在相同流量增幅下增加的程度接近。为了更深入地研究散热器内部的流动状态，根据相同实验条件进行了数值模拟。研究了不同管径、管束列间距等参数变化对换热器换热性能的影响，分析了不同参数对散热器流动换热的影响，获得了相同结构和材料相对较优的换热器几何参数。

Abstract

Objective

Battery thermal management is crucial for ensuring the performance， safety， and longevity of batteries， particularly in electric vehicles and energy-storage systems. Direct air-cooling systems are widely used because of their simplicity， cost-effectiveness， and reliability. However， while increasing the air velocity leads to a higher heat-dissipation efficiency， it also leads to higher power consumption and noise. This study aims to experimentally and numerically analyze the flow and heat transfer characteristics of a typical flat fin-and-tube heat exchanger used in battery thermal management. This research focuses on investigating the effects of operational parameters， including air velocity， temperature difference between the coolant and air， and coolant mass flow rate， on the heat transfer performance.

Methods

Both experimental and numerical approaches were employed to evaluate the heat transfer performance of the heat exchanger. The experimental setup featured a copper-fin and 316L stainless steel tube unit with two fans to enhance forced convection， and tests were conducted across air velocities of 2.1-6.1 m/s， coolant-to-air temperature differences of 20-40 ℃， and coolant mass flow rates of 0.35-0.55 kg/s. The performance was evaluated using the heat transfer coefficients， pressure drops， and overall heat dissipation rate， with an uncertainty of 6.5% and repeatability within 2.2%. A three-dimensional steady-state CFD model of a unit was developed by adopting no-slip wall conditions， symmetry/periodic boundaries， and wall contact resistance with the corresponding boundary conditions. Mesh independence was achieved with approximately 1.41 million cells， solver residuals established at 10⁻⁷， and parametric analysis was conducted for tube outer diameters ranging from 3 mm to 6 mm and bundle spacings from 7 mm to 11 mm.

Results and Discussions

The results illustrate the effects of air velocity， temperature difference， and coolant mass flow rate on the thermohydraulic performance of the heat exchanger. As the air velocity increases， the airside heat transfer coefficient improves owing to the enhanced convective heat transfer， with a maximum increase of 102.1% in the 2.1-6.1 m/s velocity range. Similarly， increasing the temperature difference from 20 ℃ to 40 ℃ leads to a rise in the heat transfer coefficient by 19.1% to 28.9%， showing a nearly linear relationship. A higher coolant mass flow rate enhances the heat transfer rate， leading to a proportional increase in the heat transfer coefficient. Numerical simulations confirm these trends and provide insights into the flow behaviors， including the formation of cross-flow vortices that enhance heat transfer， particularly at higher air velocities. The simulations also reveal that transverse vortices form in the fin gaps， which shrink with increasing air velocity. Furthermore， the simulation results indicate that the optimal pipe diameter for maximizing heat transfer performance is 6 mm， with a tube bundle pitch of 9 mm.

Conclusions

This study concludes that the air velocity， coolant temperature difference， and coolant mass flow rate are the primary factors influencing the heat transfer performance of flat fin-and-tube heat exchangers for battery thermal management. Both the experimental and numerical results indicate that increasing the air velocity and coolant mass flow rate significantly enhances the heat transfer. Furthermore， the temperature difference between the coolant and air directly affects the heat transfer coefficient. Based on these findings， the optimal heat exchanger design should have a pipe diameter of 6 mm and tube bundle pitch of 9 mm. This configuration provides the optimum heat transfer performance and is recommended for improving the efficiency of air-cooled thermal management systems for high-performance battery applications.

关键词

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