Ref.

Ares(2018)2289452
This project has received funding from the European Union's Horizon 2020 Programme under Grant Agreement No. 653514.- 30/04/2018

Optimised and Systematic Energy

Management in Electric Vehicles

Deliverable Demonstrator Thermally controlled battery subsystem

Involved SCs Deliverable type Confidential

Grant Agreement 653514-OSEM-EV

Project OSEM-EV
Number H2020-GV-2014

Deliverable File D3.5 Last Modified 27.04.2018 17:31

Actual Submission
Due Date Month 14 35
Date

Status Final Version 1.0

Contact Person Stefan Waldhör Organisation FhG

stefan.waldhoer@iisb.fraunhofe
Phone +49 (0)9131/761-433 E-Mail
r.de

.
Document history
V Date Author Description
0.1 2018-03-08 Waldhör Stefan Initial Version
0.2 2018-03-16 Waldhör Stefan Added Photos of prototype
assembly
0.3 2018-03-28 Waldhör Stefan Added Photos of demonstrator
assembly
1.0 2018-04-26 Waldhör Stefan Final and reviewed Version

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
2
 Table of contents
1 Executive summary ......................................................................................................................... 4
2 Publishable summary ...................................................................................................................... 4
3 Non publishable information .......................................................................................................... 4
4 Introduction & Scope ...................................................................................................................... 4
4.1 Purpose and target group ....................................................................................................... 4
4.2 Contributions of partners ........................................................................................................ 4
4.3 Relation to other activities in the project ............................................................................... 5
5 Assembly of the Thermally Controlled Battery Subsystem Demonstrator ..................................... 5
5.1 Assembly of the Battery Modules ........................................................................................... 5
5.1.1 Temperature Sensor Foils................................................................................................ 7
5.2 Assembly of the Battery Pack .................................................................................................. 9
5.2.1 Cooling Plate .................................................................................................................... 9
5.2.2 Battery Pack Insulation .................................................................................................. 10
5.2.3 Battery Pack Housing..................................................................................................... 10
5.3 Battery Junction Box.............................................................................................................. 11
5.4 Battery Management System ................................................................................................ 12
5.5 Battery Electrics and Electronics Overview ........................................................................... 13
5.6 Battery Subsystem................................................................................................................. 13
6 Conclusion ..................................................................................................................................... 14
7 References ..................................................................................................................................... 15
8 List of figures ................................................................................................................................. 15
9 List of tables .................................................................................................................................. 15

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
3
1 Executive summary
This document is intended to give an overview of the battery system demonstrator. The
development and detailed assembly of battery submodule demonstrator is described in D3.6.
“Report on the development of the thermally controlled battery subsystem”.
The assembled demonstrator has an insulating casing made of “Vacuum Insulating Panels”, which
leads to a very low heat transfer coefficient of the battery pack (h = 0.05 W/m².K). This strongly
decouples the battery cell from ambient temperature influences during average parking and resting
periods. For example, when considering a battery pack temperature of 22 °C after driving, the
battery pack can keep the battery cell temperature of above 10°C at an ambient temperature
of -10°C for more than 12 hours. Additionally, the insulation allows an efficient way of
preconditioning the battery pack while charging, as the waste heat during charging can be stored
inside the battery pack and it can be used to keep the battery cells at an appropriate temperature for
maximum lifetime. Therefore, using this insulation technique on the battery subsystem not only
enhances the battery cells’ life time, but also increases the overall energy efficiency of the battery
subsystem.

2 Publishable summary
This deliverable describes the assembly the battery subsystem components (module, Battery
Junction Box, Battery Management System and the battery pack) and shows the completed
thermally controlled battery subsystem.

3 Non publishable information

This deliverable is classified as confidential, i.e. all sections are non-publishable, except the
summaries in section ‎1 (“Executive summary”) and ‎2 (“Publishable summary”).

4 Introduction & Scope

4.1 Purpose and target group

The purpose of this work is to show the assembly of the thermally controlled battery subsystem,
including all its subcomponents, and the final result, the thermally controlled battery subsystem.
The document is directed to all project partners.

4.2 Contributions of partners

The following partners were involved in this deliverable. Their activities in the various sections are
listed in Table 1.
TABLE 1: CONTRIBUTIONS
Chapter Partner Contribution

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
4
1, 2, 3, 4, 5, 6, 7 Fraunhofer Building the battery modules, battery pack, Battery
Junction Box, Battery Management System
5 Hutchinson Building the thermal housing of the battery pack
5 AVL Providing temperature sensor foils on module level

4.3 Relation to other activities in the project

This deliverable shows the demonstrator of the thermally controlled battery subsystem, using parts
developed by FhG, AVL and Hutchinson.

5 Assembly of the Thermally Controlled Battery Subsystem

Demonstrator
The following section shows the assembly of the sub components of the battery subsystem, starting
from cell level and going up to battery subsystem level.

5.1 Assembly of the Battery Modules

The assembly of the battery module starts with placing a NTC resistor on the cell and electrically
insulating the battery cells. After that, three strips of foam are applicated to the insulating tape. This
ensures pressure on the battery cells, when the module frame is assembled around the cells,
increasing the battery lifetime. After that, the 12 cells are positioned in the way that they are inside
the battery module. Therefore, the frame can be assembled around the battery cells. After these
steps, the busbars for connecting the battery module electrically can be placed on the battery cell
terminals. Next, the busbars are laser welded to the terminals. With this step, the module assembly
is finished. In the following Figures this procedure is shown and explained step by step.
The battery cells casings are cleaned (Figure 1). On the cleaned surface a 10 kΩ NTC resistor is placed
next to the negative cell terminal. After that an electrical insulating tape is applicated to the battery
cell (Figure 2). This needs to be done as the cell casing has the same potential as the positive cell
terminal.

FIGURE 1: BEV4 PRISMATIC NMC CELL FIGURE 2: INSULATED BATTERY CELL WITH NTC SENSOR

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
5
Next, the 3 stripes of adhesive foam are applied onto the insulating tape (Figure 3). This is necessary
in order to generate pressure on the battery cells when they are assembled to the module. The
forced pressure on the cells ensures a longer lifetime of the cells, as the pressure decreases swelling
of the cell. The prepared battery cells are positioned in the way the module is assembled (Figure 4).

FIGURE 3: APPLIED FOAM TO BATTERY CELL FIGURE 4: PREPARED AND POSITIONED BATTERY CELLS

Next, the battery cells are assembled in the module frame (Figure 5 and Figure 6). The aluminium
tube shown in Figure 6 ensures that outgazing of a defect cell will not damage the wiring harness to
the monitoring electronics.

FIGURE 5: PARTS OF THE FRAME ASSEMBLY FIGURE 6: ASSEMBLED BATTERY MODULE

Figure 7 shows the laser welding of the busbars to the battery cell terminals. Figure 8 shows the
completely assembled battery module with voltage and temperature sensing wire harness to the
monitoring electronics.

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
6
 FIGURE 7: LASER WELDING OF THE MODULE’S BUSBARS FIGURE 8: ASSEMBLED BATTERY MODULE WITHOUT TOP COVER

5.1.1 Temperature Sensor Foils

One additional module is assembled with the temperature sensor foil provided by AVL. This module
can be operated inside a climatic chamber for thermal investigations.
In Figure 9, a temperature sensor foil is applied to the cell. The sensor foil is adhesive. After the
temperature sensor foil is applied, the electrical insulation and the foam are applied on top of the
sensor foil as seen in section ‎5.1 (“Assembly of the Battery Modules”). Figure 10 shows the
temperature sensor foils (with the CAN bus already connected) inside the module before the busbars
are laser welded.

FIGURE 9: APPLIED TEMPERATURE SENSOR FIGURE 10: TEMPERATURE SENSOR FOIL IN MODULE
FOIL

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
7
Figure 11 shows the battery module after the laser welding of the bus bars and with the isolating top
cover mounted. The supply voltage of the temperature sensor foils is 12 V and therefore intended to
work in standard automotive environments.

Supply

CAN Bus

FIGURE 11: FULLY ASSEMBLED BATTERY MODULE INCLUDING THE TEMPERATURE SENSOR FOILS AND CAN BUS
Because of the symmetry of the battery module, 4 sensor foils are enough to get a complete 3D
temperature distribution inside the battery module. Figure 12 shows a simple test setup of the
temperature measurement with the temperature sensor foils.

Measured Battery
temperature module with
temperature
sensor foils
Sensor foil and CAN bus
power
supply

FIGURE 12: TEMPERATURE MEASUREMENT VIA THE CAN BUS OF THE TEMPERATURE SENSOR FOILS

Figure 17 shows the received and already decoded temperature data of a cell inside the battery
module at room temperature.

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
8
 FIGURE 13: RECEIVED CELL TEMPERATURES OVER THE CAN BUS

5.2 Assembly of the Battery Pack

The assembly of the battery pack consists of
1. placing the first 4 battery modules in the pack frame,
2. attaching the battery cooling plate to the first 4 modules,
3. placing the second 4 battery modules to the pack frame,
4. attaching the monitoring electronics,
5. connecting the voltage and temperature wiring harness to the monitoring electronics,
6. connecting the power cabling between the modules and
7. placing the thermally insulating cover over the battery pack.
The cooling plate and the insulating cover are shown next, and then these assembly steps are shown
in the following in more detail.

5.2.1 Cooling Plate

Figure 14 shows the laser welded cooling plate for the battery pack.

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
9
 Meander for
Laser cooling and
welding heating liquid
seams

Spouts

FIGURE 14: COOLING PLATE OF THE BATTERY PACK

5.2.2 Battery Pack Insulation

Figure 15 shows the insulated housing of the battery pack made of Vacuum Insulation Panels (VIP)
made of “Organic Aerogel Monolithic Technology” and Silica VIP. The corners are made of
Hutchinson (Zaltex) material. Figure 16 shows how the battery pack looks after the coating of the
insulation.

FIGURE 15: INSULATING LAYER OF THE BATTERY PACK FIGURE 16: COATED INSULATING LAYER OF THE BATTERY PACK

5.2.3 Battery Pack Housing

The outer housing of the battery pack is shown in Figure 17.The casing is made out of glass-fibre
reinforced plastic (GFRP).

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
10
 FIGURE 17: OUTER HOUSING OF THE BATTERY PACK

5.3 Battery Junction Box

Figure 18 shows the schematic of the Battery Junction Box (BJB) (see also D3.6) and Figure 19 shows
the completely assembled BJB and indicates the connections of the power wiring. The BJB includes 3
contactors per power path (powertrain, AC-charging, DC-charging), therefore in total 9 contactors.
Each power path contains a pre-charging and connecting contactor in the positive power path and
one connecting contactor in the negative power path. The BJB uses an automotive-qualified
Isabellenhütte IVT-mod current sensor. Both charger power paths and the drivetrain can be safely
disconnected for maintenance reasons with a Manuel Service Disconnect (MSD).

FIGURE 18: SCHEMATIC OF THE BATTERY JUNCTION BOX

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
11
 Manual Service Powertrain DC-charger AC-on board
Disconnect charger
Battery
pack inlet
(Not visible)

FIGURE 19: BATTERY JUNCTION BOX

5.4 Battery Management System

The Battery Management System (BMS) is derived from the open source battery management
research and development platform foxBMS, developed by Fraunhofer IISB (1). Figure 20 shows the
circuit board for voltage and temperature measurement (Slave Unit) and Figure 21 shows the BMS
(Master Unit), which controls the Battery Junction Box and the charger and communicates with the
Vehicle Control Unit (VCU).

FIGURE 20: OSEM-EV FOXBMS SLAVE UNIT FIGURE 21: OSEM-EV FOXBMS MASTER UNIT

The BMS is able to control the power paths of the drive train and the on-board AC-charger. The on-
board AC-charger is connected via Mennekes Type 2 connector, which is a well-known and
established European standard. The BMS also supports DC charging of the battery system.

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
12
5.5 Battery Electrics and Electronics Overview
Figure 22 shows the setup of the surrounding electrics and electronics of battery subsystem, namely
the Battery Junction Box connected to the foxBMS master unit and to the on-board AC charger.

FIGURE 22: BATTERY JUNCTION BOX, FOXBMS MASTER UNIT AND ON-BOARD AC-CHARGER

5.6 Battery Subsystem

To finish the battery subsystem assembly, the battery pack power cabling and on-board AC-charger
are connected to the BJB. The monitoring electronics and the BJB are connected to the BMS master
unit. The on-board AC-charger is a proven Valeo/Eltek EV Power Charger 360/3000 250-420 VDC in
an IP67 housing.
Figure 23 shows the complete battery subsystem, including the housed battery pack, battery junction
box, battery management system (foxBMS), and the AC-charger.

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
13
 Battery
foxBMS pack

AC-
charger

Battery
Junction
Box

FIGURE 23: BATTERY SUBSYSTEM

6 Conclusion
This deliverable serves as a documentation of the build-up of the final battery system from D3.6.
The developed thermally controlled battery subsystem enhances the battery pack lifetime by storing
waste heat generated during charging and/or driving in order to increase the battery lifetime by the
means of an optimized cell temperature.

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
14
7 References
1. Fraunhofer IISB. https://www.foxbms.org. [Online] Fraunhofer IISB ; Schottkystrasse 10 ; 91058
Erlangen, Germany, 2017. [Zitat vom: 04. 05 2017.]

8 List of figures
Figure 1: BEV4 prismatic NMC cell .......................................................................................................... 5
Figure 2: Insulated battery cell with NTC sensor .................................................................................... 5
Figure 3: Applied foam to battery cell..................................................................................................... 6
Figure 4: Prepared and positioned battery cells ..................................................................................... 6
Figure 5: Parts of the frame assembly..................................................................................................... 6
Figure 6: Assembled battery module ...................................................................................................... 6
Figure 7: Laser welding of the module’s busbars .................................................................................... 7
Figure 8: Assembled battery module without top cover ........................................................................ 7
Figure 9: Applied temperature sensor foil .............................................................................................. 7
Figure 10: Temperature sensor foil in module ........................................................................................ 7
Figure 11: Fully assembled battery module including the temperature sensor foils and CAN bus ........ 8
Figure 12: Temperature measurement via the CAN bus of the temperature sensor foils ..................... 8
Figure 13: Received cell temperatures over the CAN bus ....................................................................... 9
Figure 14: Cooling plate of the battery pack ......................................................................................... 10
Figure 15: Insulating layer of the battery pack ..................................................................................... 10
Figure 16: Coated insulating layer of the battery pack ......................................................................... 10
Figure 17: Outer housing of the battery pack ....................................................................................... 11
Figure 18: Schematic of the battery junction box ................................................................................. 11
Figure 19: Battery junction box ............................................................................................................. 12
Figure 20: OSEM-EV foxBMS slave unit ................................................................................................. 12
Figure 21: OSEM-EV foxBMS master unit.............................................................................................. 12
Figure 22: Battery junction box, foxBMS master unit and on-board AC-charger ................................. 13
Figure 23: Battery subsystem ................................................................................................................ 14

9 List of tables
Table 1: Contributions ............................................................................................................................. 4

This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
15
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This document and the information contained may not be copied, used or disclosed, entirely or partially, outside of the OSEM-EV
consortium without prior permission of the partners in written form.
16