DMT GROUP 12

BATTERY THERMAL MANAGEMENT

Timothy Engstrom

Willem Hilbers

Ryan Prosser

Sofie Shackcloth

Kulwinder Basuta

TEAM MEMBERS

OBJECTIVES

Create a TMS system that maintains cell tab

temperature below 40oC

Design cases to protect and mount the battery

modules onto the bike

Design module interconnection system,

considering electrical safety

74 cells integrated onto bike

giving predicted range > 80 miles.

Batteries fit within BMW R65

envelope

Welded aluminium cases built to

withstand impact at 70mph.

Cases lined with foam to absorb

vibrations and impact energy.

Simple cable and pipe routing

allowing easy assembly.

RESEARCH SUMMARY Degradation of battery is increased as temperatures rise above

50°C. Active thermal management enables fast charging while

maintaining battery longevity.

Tab cooling design:

Reduces cell degradation compared to conventional surface

cooling increasing life cycle by a factor of 3 [1]

Space efficient allowing a higher energy density and extended

range

THE THERMAL MANAGEMENT SYSTEM

Reduced the temperature increase from a 40 minute (1.5C)

discharge by 25%.

Increased the cooling rate by a factor of 2.1.

Reduced intra-cell temperature variation by 10%, which improves

cell resistance balancing.

PARALLEL AND SERIES FLOW

Parallel gives constant fluid

temperature

Series is easier to obtain consistent

flow

Series was chosen as temperature

change is minimal.

MODULE COMPONENTS

The module includes the following features:

Compression plate

Electrical connection and fuse mount

Skirt Clamps

Slit plate with hidden Cooling Block

Assembly - connects cell tabs to each other

Cooling Mount—Supports TMS

Slit plate support bars

Battery Management System

Cooling Block Assembly

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[1]I. A. Hunt, Y. Zhao, Y. Patel and G. J. Offer, “Surface cooling causes accelerated degredation compared to tab cooling for lithium-ion pouch cells,” (under review), 2016.

COOLING BLOCK ASSEMBLY

MODULE CASING AND BIKE INTEGRATION

Acetal Waterblock

O-ring

Aluminium Cold plate

Polypropylene Insulator/

Locator

Thermally conductive,

electrically insulating

Alumina

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