Experimental Hardware Framework for Hybrid Cooling in EV Battery Thermal Safety

Abstract: Electric vehicles rely on lithium-ion batteries whose performance and safety are highly dependent on effective thermal regulation. Excessive heating can reduce capacity, accelerate aging, and trigger thermal runaway. This study focuses on the hardware design and implementation of a hybrid cooling framework that integrates passive and active elements for EV battery thermal management. The system employs a Phase Change Material (PCM) simulation to absorb excess heat and stabilize battery temperature, while an Arduino-based control unit coordinates sensors and actuators. Key hardware components include the Arduino Uno microcontroller, DHT11 temperature and humidity sensor, BLDC motor with driver, potentiometer for speed regulation, cooling fan, buzzer for alarm indication, and LCD display for real-time feedback. The hardware logic ensures that when the temperature exceeds 35°C, the system activates safety measures by stopping the motor, triggering the fan, and sounding an alarm. Once the temperature normalizes, the system resumes operation smoothly. Experimental validation demonstrates reliable monitoring and responsive control, confirming the effectiveness of the hardware framework in enhancing battery safety. This work provides a foundation for scalable EV battery cooling systems and highlights the importance of cost-effective hardware solutions in sustainable transportation.

Keywords: Electric Vehicles, Lithium-Ion Battery, Hybrid Cooling, Phase Change Material, Arduino Hardware, Thermal Management, BLDC motor & driver.