Ahmad Nazari Gazik - Energy Modeling and Sustainable Energy Systems Lab, University of Tehran, Tehran, Iran
Sara Sharifi - Faculty of Material Science and Engineering, Khajeh Nasir Toosi University of Technology, Tehran, Iran
Fatemeh Razi Astaraei - School of Energy Engineering and Sustainable Resources, College of Interdisciplinary Science and Technologies, University of Tehran, Tehran, Iran
Hossein Yousefi - School of Energy Engineering and Sustainable Resources, College of Interdisciplinary Science and Technologies, University of Tehran, Tehran, Iran

Formula SAE is a prestigious student design competition hosted by SAE International. In ۲۰۲۴, the event will take place at the Silverstone Circuit in the UK. FUM Racing team is thrilled to participate in the electric vehicle (EV) class for the first time. To power the proportional system, the vehicle will rely on a battery pack, like most electric cars. This study focuses on designing a thermal management system for the battery pack using numerical models. The team developed a setup using the SST-k model and validated it with analytical results. After careful consideration, they chose a Z-shaped air-based forced convection system for its superior temperature control. To achieve the best design, a three-step process was implemented, all centered around a ۱p۱۰s cylindrical battery pack. The initial design displayed insufficient forced convection in the first air entry, leading to a steady increase in the initial battery's temperature. The second design solved this issue by replacing the sharp edge of the first entry with a curvature and lifting the outlet channel to decrease head loss and increase flow rate in the entry. However, the problem persisted. Further analysis revealed that the primary cause was the separation in the entrance channel. After rectifying this, the final design performed exceptionally well. With a velocity inlet of ۵m/s, the maximum temperature reached ۴۶.۱°C, and the highest temperature difference was ۶.۱°C. This cooling system is expected to enable the car to perform optimally during the competition.

Thermal Management, FSAE, Heat Transfer, Formula Student, Electric Vehicle