Work

Pareto-Active-Region-Guided Sequential Surrogate Modeling for CFD-Based Multi-Objective Optimization of Liquid-Cooled Battery Thermal Management Systems

Year: 2026

Type: article

Abstract: Computational fluid dynamics (CFD)-driven optimization of engineering systems is often constrained by high computational cost, particularly when surrogate models must be constructed from limited simulation samples. Although surrogate-assisted multi-objective optimization can substantially reduce CFD evaluations, local prediction errors in decision-sensitive Pareto regions may alter feasibility classification and engineering recommendations near active constraints. To address this issue, this study proposes a Pareto-active-region-guided sequential surrogate modeling framework (PAR-SSM) for multi-objective optimization of liquid-cooled battery thermal management systems. Starting from 15 face-centered central composite design (FCCD) samples, the framework selectively introduces additional high-fidelity CFD evaluations into Pareto-active and constraint-sensitive regions, yielding a 21-sample refined surrogate model. Rather than uniformly improving global prediction accuracy, PAR-SSM directs the limited CFD budget toward regions where surrogate errors can directly influence engineering decisions. After model freezing, three independent Fluent cases were used exclusively for validation, yielding mean absolute deviations of 0.098 °C for maximum temperature and 0.341 °C for temperature difference, while also revealing residual feasibility risk near active constraint boundaries. Application to an autonomous underwater vehicle (AUV) battery module showed that the N = 3 configuration dominated the nominally constrained Pareto set and provided a favorable thermal–hydraulic trade-off under low auxiliary energy consumption. Overall, PAR-SSM provides a decision-oriented strategy for balancing computational cost and optimization credibility in CFD-intensive, constrained multi-objective design.

Source: Processes

DOI: 10.3390/pr14162675

Authors: Zhanming Luo, Lei Wang, Deyong Song

Institutions: China Ship Scientific Research Center, Shanghai Jiao Tong University

Language: English

Topic: Advanced Multi-Objective Optimization Algorithms

Subfield: Computational Theory and Mathematics

Field: Computer Science

Domain: Physical Sciences

SDG: Affordable and clean energy

Open Access status: gold

Estimated APC paid: $2,896