Direct Cooling Battery Thermal Management System Prevents Overheat Risks and Extends EV Battery Life

The Hidden Danger Inside Every EV Battery Pack

Electric vehicle power batteries generate significant heat during operation. Excessive temperatures directly impact battery performance and lifespan, and can lead to serious safety incidents including overheating, electrolyte leakage, fire, and even explosion. While conventional cooling systems help manage temperature, batteries remain vulnerable to uncontrollable events such as collisions or internal short circuits that can trigger thermal runaway.

To ensure safe battery operation, continuous temperature monitoring and rapid cooling measures are essential. Addressing this critical need, the Tenglong Automotive engineering team has developed a direct cooling-based battery thermal management system that integrates battery cooling with vehicle climate control for comprehensive thermal protection.

Engineering Excellence: Dual-Mode Cooling with Intelligent Control

This project introduces a sophisticated thermal management system featuring multiple protective layers:

Dual Airflow Design with Filtration: Air vents are positioned at both the bottom and top of the protective housing, each equipped with dust screens and dampers. Multiple blowers are installed between the dust screens and dampers, delivering forced airflow across the battery assembly.

Real-Time Temperature Monitoring: Temperature sensors are strategically placed inside the protective housing and within the cooling water tank. Heat dissipation fins are evenly spaced on the outer wall of the housing to enhance passive cooling.

PID Compressor Control: The system compressor speed is regulated by a PID controller. The input is the temperature difference between the actual measured temperature at the cabin evaporator air side outlet and the target temperature. The output is a PWM signal used for precise compressor speed control.

Integrated Vehicle Thermal Management: The system integrates the vehicle powertrain cooling circuit with the battery pack cooling system and the automotive air conditioning system. All components are connected through a vehicle-level logic relationship, establishing coordinated thermal management across the entire vehicle.

Key Innovations for Battery Safety

Dual-Mode Cooling Protection: Real-time temperature monitoring triggers either fan-based air cooling or water pump-based liquid cooling depending on the severity of temperature rise. This dual-approach strategy significantly improves safety margins.

High Efficiency with Low Weight: The direct cooling architecture delivers superior cooling efficiency while minimizing system weight and cost, directly contributing to improved battery lifespan, safe battery pack operation, and enhanced overall battery efficiency.

Variable Frequency Energy Savings: The system adapts fan and water pump power based on detected temperature levels, reducing energy consumption during lower-temperature operation.

Proven Results and Intellectual Property

The project represents the successful implementation of a national invention patent: "A Battery Cooling System for New Energy Vehicles" (Patent No. ZL201810502762.X). The patented design features a protective housing, strategically positioned air vents with dust screens and dampers, blowers for forced convection, thermal conductive plates mounted perpendicular to the housing walls, and integrated temperature sensors for real-time monitoring.

The final evaluation committee confirmed that the system has been successfully applied to the company's spraying vehicle product line, where it has effectively extended battery service life, ensured safe battery pack operation, and improved battery efficiency. The product has achieved commercial sales, delivering positive economic returns.

Commitment to Comprehensive Thermal Safety

This project reinforces Xiangyang Tenglong Automotive's dedication to proactive battery safety. By integrating this direct cooling thermal management system into our vehicle lineup—including spraying vehicles, buses, and logistics vehicles—we ensure that our customers benefit from extended battery life, safe and reliable battery operation, and enhanced vehicle safety under all operating conditions.

RD12 Project Proposal for Design of a Direct Cooling-Based Power Battery Thermal Management System for New Energy Vehicles