Saurabh Rawat, Yaman Yadav, Roushan Kumar
ABSTRACT Air cooling is extensively utilized in lithium‐ion battery powered drivetrains, and this study examines the effects of air velocity and cooling fan arrangement. The pack behavior is tested under 1C, 1.5C, and 2C discharge rates with three different fan arrangements (Single IN, In‐Out, Out‐Out). In the Single IN arrangement, a single fan draws air in, whereas in the In‐Out configuration, one fan pulls air in while another pushes it out, and in the Out‐Out configuration, both fans expel air. Results indicated that increasing the air velocity from 0 to 4 m/s at 25°C significantly enhanced convective heat transfer and reduced local hotspots. At a 1C discharge rate and 4 m/s air velocity, the maximum temperature ( T max ) was lowered by 17.35°C compared to natural convection. The In‐Out fan configuration outperformed the Single IN and Out‐Out configurations, achieving a 2.57°C reduction in T max and a 2.25°C decrease in temperature difference (Δ T max ). The Out‐Out configuration was less efficient due to airflow blockage by holders and connectors. A single rib turbulator positioned at a 45° angle relative to the lateral direction further reduced T max by 6.27°C. The findings highlight the importance of airflow and fan setup in battery thermal performance.