[SplendidaVitia]

Hi all,

I am trying to simulate a basic 6s2p battery pack's air cooling problem. However, when I try to carry out the analysis, I encounter:

1. Temperature limited to 5k K in x zone, while using NTGK model
2. Segmentation fault, while using ECM

When I looked closely, I saw the warning in the attached files. Zone 60 is busbar 1. I attached the image of the connection between the tab and the busbar. I checked the connections and they seem fine to me. I cannot solve the problem. Any help would be highly appreciated. I attached the files that I think would be descriptive. Thanks in advance.

[SplendidaVitia]

I am writing this reply to post some more images and give some additional information. When I define the busbar materials through user-defined diffusivity, iterations don't even start, it gives Divergence in amg-solver: uds-0 error. If I switch it to defined-per-uds, it sometimes works. I don't know what to do. Thank you in advance.

[AlexanderZ]

basbar material is defined same way as tabs

when you have a message that some zone is not connected this is a critical error and must be fixed

in your second message I can see, that all zones were defined correctly.

use small timestep to check where heat comes from.

if you are using default parameters of ntgk or ecm, there should be no problems in battery performance simulation on small C-rates

[SplendidaVitia]

Originally Posted by AlexanderZ

basbar material is defined same way as tabs

when you have a message that some zone is not connected this is a critical error and must be fixed

in your second message I can see, that all zones were defined correctly.

use small timestep to check where heat comes from.

if you are using default parameters of ntgk or ecm, there should be no problems in battery performance simulation on small C-rates

Firstly, thanks for your reply.

I both tried it with the default parameters and somewhat modified parameters (Like changing system voltage to my calculation, DoD etc.). I assign the same material to both tabs and busbars (user-defined). As you said, this critical error may be causing the segmentation fault in ECM, I guess.

I tried to go step-by-step with the advanced add-on module tutorials. But as I said, I cannot wrap my head around what might be the cause of this. I tried to define the contacts with automatic connections and also with forming a new part and imprinting the faces. One of the other things that I tried was instead of importing a stp file, drawing the model in Design Modeler. It didn't help either. I am going to fidget with it a bit. Meanwhile, I am open to any other suggestions as well.

[AlexanderZ]

most likely the problem comes from your mesh (quality is not good enough) or boundary conditions.

as you are using contacts make sure you defined coupled boundary condition there.

you may try to make the whole model without contacts (conformal mesh everywhere), this is how you may check if the problem comes from contacts

[SplendidaVitia]

Originally Posted by AlexanderZ

most likely the problem comes from your mesh (quality is not good enough) or boundary conditions.

as you are using contacts make sure you defined coupled boundary condition there.

you may try to make the whole model without contacts (conformal mesh everywhere), this is how you may check if the problem comes from contacts

I'm embarassed to say this, but I solved it. I installed a different version of Ansys, and ta-da! I tried everything I could find and your suggestions, but at some point, I suspected it might be caused by the version that I was using. Because it didn't make any sense. Thank you so much for your suggestions, if I ever encounter a similar problem, I am going to use your suggestions in the future.

[Abhilashk123]

I am using a 6x6 battery pack for simulation while connecting those through busbars divergence is detected at uds 0 i tried with multiple settings but issue is not solved .. please help me with this