A multi-scale modeling approach for predicting and mitigating thermal runaway in electric vehicle batteries

This study presents a unique multi-scale modelling technique for electric vehicle (EV) battery thermal runaway prediction models using electrochemical, thermal, and machine learning approaches. This modelling framework has illuminated the thermal runaway’s physical process and the race between heat production and dissipation at the cell, module, and pack levels.

Experimental evaluation has demonstrated solid predictive performance for each component. The modified pseudo-two-dimensional (P2D) electrochemical model has achieved high voltage prediction accuracy (mean absolute error: 8.5 mV), and the 3D thermal model has captured battery module temperatures with an average error of ± 1.5 °C.

The machine learning model has exhibited 96.8% accuracy, excellent classification precision, and an 18.3-minute early warning time. It was also demonstrated that the integrated multi-scale model outperformed standalone single-scale models with 15% higher prediction accuracy and 32% higher average early warning time.

Based on these findings, adaptive cooling techniques, unique charge/discharge procedures, and early isolation methods were created. Simulations showed that these mitigation techniques decreased thermal runaway occurrence by 78% and severity by 93%. Despite its high computing cost, this technique might improve EV battery safety, guide battery pack design, and accelerate EV adoption, which would cut carbon emissions.