Battery test simulation tech helps OEM overcome fast-charge challenge

D2H Advanced Technologies has delivered a project that solves a known charging issue with a production EV. The company deployed its battery simulation and correlation capability to enhance battery thermal management in a fast-charge scenario, accelerating the development process to reduce excess noise from high pumping power and help the dissipation of heat.

The project was delivered in conjunction with chemical company Croda, whose fluids were tested and validated as part of an immersive cooling system for the vehicle’s battery pack. D2H built a 32-cell battery test rig for the physical testing aspects that could evaluate the performance of cutting-edge immersive versus contemporary cold-plate cooling methods before the generation of a computational fluid design (CFD) model to accelerate comparative studies that examined the cooling characteristics of various fluids.

“Battery performance is a critical aspect of inspiring further take-up of EVs and it is a technology that is still in its relative infancy,” said Chris Hebert, D2H Engineering Director. “During development, all areas of battery performance must be considered, especially their behavior during high C-rate charging and discharging when in situ. The work with Croda in considering different types of chemicals as a battery coolant has provided valuable insight that has not only helped to overcome an existing challenge but generated vital data that can streamline the development of new, more efficient EVs. Providing enhanced thermal management of the battery has the potential to offer further accelerated fast-charge times in the future.”

The project’s first stage involved exploring the cause of excess noise during a battery fast charge, which turned out to be the high pump power required with the existing cooling system. CFD modeling then suggested clear benefits to using a Croda dielectric fluid, which was validated in physical tests against alternative fluids. The second stage was to investigate the difference in performance between immersive and cold-plate cooling systems, which used the same simulation correlation process.

Correlation of simulated tests demonstrated that Croda’s fluids promoted more efficient heat transfer, with fewer hot spots and more stable characteristics, making them less likely to negatively impact battery performance.

Source: D2H