Holistic battery system design optimization for electric vehicles using a multiphysically coupled lithium-ion battery design tool

Significant challenges appear in the multiphysical engineering process of battery systems for electric vehicles. Thereby, individual standalone simulation models offer essential opportunities to develop components for cellmodule, cooling, mechanics, and electronics. However, in order to address requirements in range, performance, and general installation space shortage for the battery system, interdependencies between the different components have to be considered. This work presents a novel approach to a fully parametrized high voltage battery optimization tool based on coupled simulation models for the battery system's main components. The submodel-concept can both optimize each component individually and perform an overall cost-or weight optimization in which components are designed, considering essential interdependencies. Optimization results illustrate the cause-effect principles between multiple battery system components in great detail. Based on this, integration repercussions for different lithium-ion cell geometries and formats are analyzed from cell-level to system-level. Moreover, further optimizations are performed to identify pareto-optimal results regarding total installation space. Therein, in-depth trade-off relationships between the mechanical battery frame design and its costs to the cooling plate topology as well as the integration capability of the electronics are depicted.