Pack2Pack Battery Testing
-Innovative Process for Cost-Effective Investigation of High-Voltage Batteries-

Karsten Mueller･Joerg Mueller･Sven Hoenicke (IAV)

The high-voltage batteries used in current vehicles play a key role in product development. A major cost driver in the development of energy storage systems are the very extensive functional and endurance tests. To limit the costs of the test infrastructure, it makes sense to test several batteries in parallel.
The article presents a new, energy-efficient battery test center. The following aspects are dealt with in particular:
-Simulations to define the requirements profile
-New test infrastructure, mode of operation and safety concept
-Innovative energy management to reduce energy costs
-Evaluation against state-of-the-art solutions for testing batteries

Topology Optimization of Cooling Plates for Electric Vehicles
-A Strategy for Rollbonded Cooling Plates-

Frederik Schewe (Mubea Rollbonding Products)･Takehiko Tsukamoto (Mubea Japan)･Joerg Neubrand (Mubea KG)･Ali Elham (University of Southampton)

Battery thermal management plays an important role for the electrification of vehicles. For realization of such systems sheet metal cooling plates with internal channel structures which are passed by a fluid are common. The most innovative technology to produce such cooling plates is Rollbonding as it offers unmatched design freedom for channel structures and a competitive cost structure. For the design of channel patterns conflicting thermal and hydraulic targets must be considered while ensuring manufacturability. The authors present a topology optimization strategy that take these challenges into account and demonstrate the feasibility by application on an exemplary cooling plate.

Battery Health Monitoring for Enhanced Electrical Vehicle Performance
-Integrating Data Analytics, Modeling Techniques and Anomaly Detection-

Nikolaus Keuth･Gerhard Schagerl･Alwin Tuschkan (AVL List)

Battery electric vehicles (BEVs) are becoming established as sustainable mobility solutions. However, there is still considerable potential for optimization in the development process of electric drives, especially the battery system. Advanced data analysis, using field data and data from the development phase, provides valuable support for design decisions. AVL introduces data-driven methods and tools that contribute to product quality assurance and significantly enhance development efficiency.