Multi-Objective Optimization and Performance Evaluation of Manifold-Based Cooling Systems for Battery Thermal Management Using RSM and NSGA-II

Document Type

Article

Publication Date

2026

Abstract

Efficient thermal management is critical to the safety, performance, and longevity of lithium-ion battery (LIB) energy storage systems. In this study, a novel manifold cold plate featuring an overflow channel with a triangular ridge at the bottom is proposed for a liquid-cooled Battery Thermal Management System (BTMS). A comprehensive multi-objective optimization framework is developed by integrating Response Surface Methodology (RSM), the Non-dominated Sorting Genetic Algorithm II (NSGA-II), and the Linear Programming Technique for Multidimensional Analysis of Preference (LINMAP) decision-making method to minimize the maximum temperature difference (Delta T-cell) and pressure drop (Delta P) across the cooling plate. The design variables include the manifold channel width ratio (lambda), the height ratio (phi), the inlet velocity (u), and the triangular ridge angle (theta). Second-order polynomial regression models are constructed and validated using Analysis of Variance (ANOVA), yielding high coefficients of determination (R-2 = 0.9926 for Delta T-cell and 0.9600 for Delta P), confirming strong predictive accuracy. Sensitivity analysis reveals that the inlet velocity and channel angle are the primary factors influencing system performance. The LINMAP-based decision-making approach identifies an optimal configuration with lambda= 1.031, phi = 1.47, u = 1.671 m/s, and theta = 29.8 degrees, achieving a Delta T-cell of 12.61 degrees C and a Delta P of 6742.99 Pa, with validation errors below 3%. Transient simulations at 0.5 and 1C discharge rates show that the LINMAP-optimized design reduces the maximum cell temperature by 13.12 degrees C and 11.77 degrees C, respectively, compared to the natural convection baseline, and by 1.42 degrees C and 0.76 degrees C compared to the prototype design, while maintaining comparable hydraulic resistance. This work offers valuable guidance for designing and optimizing liquid-cooled battery thermal management systems with complex manifold structures.

Keywords

Battery thermal management, Response surface methodology, Multi-objective optimization, NSGA-II

Publication Title

Revista Internacional de Métodos Numéricos para Cálculo y Diseño en Ingeniería

ISSN

0213-1315

DOI

10.23967/j.rimni.2025.10.69320

Volume

42

Issue

1

First Page

5

Publisher

Scipedia

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