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<p>This study presents a hybrid battery cooling system that integrates thermoelectric Peltier modules with a conventional radiator, enhanced by an intelligent solenoid-controlled bypass mechanism. The system enables selective activation of four 30&#xa0;W Peltier modules only during critical thermal events, such as high-rate battery charging or discharging, significantly reducing energy consumption. Unlike conventional systems where TECs run continuously, the proposed configuration operates the modules for just 10–15&#xa0;min in a 60-minute cycle. Combined with a 100&#xa0;W radiator fan operating continuously, the system’s total energy consumption is limited to approximately 100 Wh substantially lower than comparable hybrid systems that consume 200–300 Wh per hour. A modified copper block provides coolant below ambient temperature, enhancing thermal efficiency beyond conventional architectures. To evaluate and optimize system performance, Response Surface Methodology (RSM) with a Central Composite Design (CCD) was employed, analyzing the effects of coolant flow rate, coolant ratio, and radiator fan speed on key thermal performance parameters. Second-order polynomial regression models were developed with high predictive accuracy R² = 0.9372 to 0.9996. Experimental validation showed deviations between predicted and observed responses remained below 1.78%. A machine learning-based Pearson correlation heatmap confirmed the strong influence of coolant flow rate and ratio on heat energy (0.98), convective heat transfer (0.77), hybrid temperature difference (0.90), and overall heat transfer coefficient (0.95), while fan speed had negligible impact. These results demonstrate the system’s low-energy, high-performance potential and its viability as an advanced thermal management solution for hybrid and electric vehicles.</p>

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Optimization and Thermal Performance Parameters of Novel Hybrid Automotive Cooling System Designed for Modern Hybrid Electric Vehicles

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Himanshu Sharma,
  • Gaurav Saxena,
  • Ravindra Randa,
  • R. S. Rajput

摘要

This study presents a hybrid battery cooling system that integrates thermoelectric Peltier modules with a conventional radiator, enhanced by an intelligent solenoid-controlled bypass mechanism. The system enables selective activation of four 30 W Peltier modules only during critical thermal events, such as high-rate battery charging or discharging, significantly reducing energy consumption. Unlike conventional systems where TECs run continuously, the proposed configuration operates the modules for just 10–15 min in a 60-minute cycle. Combined with a 100 W radiator fan operating continuously, the system’s total energy consumption is limited to approximately 100 Wh substantially lower than comparable hybrid systems that consume 200–300 Wh per hour. A modified copper block provides coolant below ambient temperature, enhancing thermal efficiency beyond conventional architectures. To evaluate and optimize system performance, Response Surface Methodology (RSM) with a Central Composite Design (CCD) was employed, analyzing the effects of coolant flow rate, coolant ratio, and radiator fan speed on key thermal performance parameters. Second-order polynomial regression models were developed with high predictive accuracy R² = 0.9372 to 0.9996. Experimental validation showed deviations between predicted and observed responses remained below 1.78%. A machine learning-based Pearson correlation heatmap confirmed the strong influence of coolant flow rate and ratio on heat energy (0.98), convective heat transfer (0.77), hybrid temperature difference (0.90), and overall heat transfer coefficient (0.95), while fan speed had negligible impact. These results demonstrate the system’s low-energy, high-performance potential and its viability as an advanced thermal management solution for hybrid and electric vehicles.