Abstract: Air-cooled thermal management technology has been widely employed for regulating the temperature of lithium-ion batteries in electric vehicles due to its simplicity, cost-effectiveness, and low energy consumption. However, conventional air-cooled systems suffer limitations such as inadequate cooling capacity and uneven temperature distribution within battery packs. This work made an effort in designing a novel Π-type air-cooled battery thermal management system (BTMS) and comparing its cooling performance with the conventional Z-type system through numerical simulations. Results indicated that the Π-type BTMS could achieve a more uniform internal airflow, thereby reducing both the maximum temperature and temperature differentials across the battery pack compared to the Z-type system. Furthermore it entailed an investigation on the inf-luence of structural parameters such as inlet height, inlet width, and outlet position on the Π-type BTMS performance. Functional relationships between these parameters and key thermal metrics were established. Leveraging the multi-objective particle swarm optimization (MOPSO) algorithm, all the relevant parameters were optimized, and the optimal solution was selected by innovatively using the Critic weight method, addressing subjective biases inherent in previous studies. The optimized structural parameters notably enhanced the Π-type BTMS cooling performance, including the reductions in maximum battery pack temperature, temperature differentials, and average temperature by 11.11%, 50.74%, and 7.41%, respectively.
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2026, Vol. 40 
