Design and Development of Test Rig for Thermal Performance Analysis of Lithium-Ion Battery

Abstract

The use of lithium-ion batteries in vehicles and large energy storage systems requires good thermal management to ensure safety, performance and longevity. This report describes the design and application of a low-cost test rig based on Arduino. The test rig monitors the performance of a lithium-ion battery pack in a 5S1P configuration. The main reason for this work is that battery health depends on its operating temperature. The temperature must be between 20°C and 40°C to prevent degradation and the risk of thermal runaway. The system uses sensors to collect real-time data on key parameters. These parameters include cell surface temperatures, total pack voltage and discharge current. An Arduino Uno microcontroller is the central data collection unit. It interfaces with five digital temperature sensors, an ACS712 current sensor and a custom voltage divider circuit. Data is sent to a computer for analysis. The test rig is designed to compare two cooling systems. These are a Simple Air-Cooling System (SACS) and a Hybrid Cooling System under Dry-out Conditions (HCSDC). The comparison is done at discharge rates (1C, 3C and 5C). This project provides an open-source platform for analysis. It aims to help validate battery models and offer a tool for research, education and evaluating new battery cooling technologies. The lithium-ion battery pack and its thermal management are crucial for vehicles and energy storage. Lithium-ion batteries require temperature control to work safely and efficiently. The test rig helps to ensure that lithium-ion batteries operate within a temperature range. This is important, for preventing damage and ensuring the longevity of lithium-ion batteries.