BSDC contribution to battery pack development process:
Capabilities
- Up to: 250kW, 1000A, 900V
- Module or full pack testing
- Temperatures up to +60C
- Li-ion, NiMH, Lead-Acid and other rechargeable chemistries
- Hardware in the Loop (HIL) System
- 12 ft. x 12 ft. test chamber to accommodate large packs
- Liquid or air cooled battery packs
- High voltage instrumentation
Applications
- HEV, PHEV, EV
- Passenger cars
- Heavy duty vehicles
- Military vehicles (ITAR controls in place)
- Stationary and niche applications
- On-road or off-road
Thermal Evaluation
- Evaluate air flow and structure location
- Optimize fan size and location
- Minimize thermocouple
count through smart sensor location
- Integrate thermal control system with the rest of the vehicle
- Evaluate cell-to-cell temperature variation
Battery Management System Development
- State of charge/state of health algorithms
- Cell balancing and instrumentation
- Pack and vehicle communications
- Functional testing and failure response
Vehicle System Optimization
Global Battery System Capabilities
A highly multi-disciplinary process - Ricardo has the necessary team in-house:
Battery Pack Design and Vehicle Integration
- Structural - optimization of existing design or clean sheet design to drawing release for manufacture
- Thermal - analysis of existing design (thermal imaging and/or CAE), suggestions for improvement
- Electrical - sensor selection, safety system design, high voltage electrical component selection and design
- Controls - SOC algorithm development, BMS design and development, vehicle control strategy
- Manufacture - material selection and cost reduction, production supplier identification
- Integration - vehicle packaging, conditioning of cooling air, vehicle performance/fuel economy optimization
Electronics and Battery Management Systems Design
- Concept definition and specification development
- Electronic circuit board design and development
- State of charge/state of health algorithms
- Battery control functions
- Failure mode effects analysis and hazard analysis
- Diagnostics and prognostics development
- Hardware in the loop development including simulated failure response assessment
