电动汽车BMS从控板热分析及散热优化

doi:10.19562/j.chinasae.qcgc.2024.01.014

Abstract

Abstract:

For the problem of high temperature and uneven distribution affecting the power and safety of the electric vehicle during the battery management systems slave control board's service， a commercial BMS slave control board thermal analysis model is built and verified using the CFD theory and Icepak software. For the first time under vehicle service conditions， temperature field analysis and thermal uniformity optimization research are carried out based on the thermal analysis model. The BMS slave control board thermal simulation analysis shows that the balancing and power supply modules exceed the BMS's design temperature limit of 60 °C due to local heat accumulation， with the maximum temperature difference of the entire BMS slave control board being 21.0 ℃. A heat dissipation path analysis of the BMS slave control board is further carried out， and heat dissipation optimization design is realized by altering the distance， layout of the balancing resistor， PCB substrate and adding thermal pads. By increasing the heat dissipation capacity of the BMS slave control board， the highest temperature of the BMS slave control board can be controlled below the design limit of 60 ℃， and the temperature difference of the entire circuit board can be reduced to 6.9 ℃， which enhances the safety and reliability of the BMS slave control board under actual vehicle service conditions， providing theoretical methods for the thermal design and optimization of the BMS slave control board.

Key words: new energy electric vehicles, battery management system slave control board, thermal analysis, heat dissipation optimization

Jiangxin Yuan, Liping He, Yaodong Li, Gang Li. Thermal Analysis and Optimization Design of a BMS Slave Unit for Electric Vehicles[J].Automotive Engineering, 2024, 46(1): 128-138.

Figures/Tables 25

References 24

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元器件编号	器件类别	功耗/ mW
R1， R3， R5， R7， R9， R11， R13， R15	均衡电阻	0
R2， R4， R6， R8， R10， R12， R14， R16	均衡电阻	235.2
U1	主控芯片	38.5
R52，R54	负载电阻	9.8
Q17	三极管	407.4

器件类别	主要材料	导热系数/（W?m^-1?K^-1）
PCB	FR-4，铜	25.23 （XY） 0.37 （Z）
主控芯片	封装树脂	47.90
均衡电阻/负载电阻	氧化铝陶瓷	24.70
三极管	封装树脂	113.30
外壳	AL 6061-T6	154.00

元器件编号	试验结果/ ℃	仿真结果/ ℃	相对误差/%
R2	50.9	51.8	1.8
R4	52.8	53.3	1.0
R6	54.5	54.2	0.6
R8	54.6	54.5	0.2
R10	55.1	54.6	0.9
R12	55.3	54.4	1.6
R14	53.0	53.9	1.7
R16	51.7	52.6	1.7
U1	40.6	39.5	2.7
Q17	49.4	48.9	1.0

元器件编号	温度/°C
R2	70.2
R4	71.6
R6	72.4
R8	72.8
R10	72.9
R12	72.7
R14	72.1
R16	70.9
R52	60.1
R54	59.3
U1	56.9
Q17	67.5

元器件编号	Layout 1	Layout 2	Layout 3	Layout 4	Layout 5
R2	69.5	69.6	69.6	69.0	69.2
R4	69.7	70.3	69.5	70.0	69.9
R6	70.4	69.9	70.5	69.9	69.3
R8	70.1	70.6	70.1	70.6	70.0
R10	70.8	70.3	70.7	70.3	69.7
R12	70.4	70.7	70.4	70.8	70.2
R14	70.8	70.4	70.4	70.2	70.1
R16	70.2	70.1	69.8	70.2	70.5
R52	60.2	60.3	60.3	60.2	60.3
R54	59.4	59.5	59.5	59.4	59.5
U1	56.8	56.8	56.8	56.8	56.8
Q17	67.3	67.4	67.4	67.3	67.4

Thermal Analysis and Optimization Design of a BMS Slave Unit for Electric Vehicles

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Figures/Tables 25

References 24

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基板材料	FR-4	RO3010	92ML
水平方向（XY）导热系数/（W?m^-1?K^-1）	25.23	25.79	26.77
垂直方向（Z）导热系数/（W?m^-1?K^-1）	0.37	1.02	2.14

元器件编号	FR-4	RO3010	92ML
R2	69.6	66.1	64.7
R4	70.3	66.7	65.3
R6	69.9	66.4	65.0
R8	70.6	67.1	65.7
R10	70.3	66.8	65.4
R12	70.7	67.2	65.8
R14	70.4	66.9	65.5
R16	70.1	66.7	65.3
R52	60.3	60	59.8
R54	59.5	59.6	56.7
U1	56.8	56.8	56.9
Q17	67.4	64.0	62.5