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
1
2
3
4
[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
1
2
3
4
5
5
6
7
8
