E-MOBILITY
corresponding software. It provides primary safety functions including over-temperature, over-/under-voltage and over-current protection and also performs detailed diagnosis of all actuators and sensors, as well as innovative high-level functions such as battery state estimation. The UHE battery pack is equipped
with extremely eff ective liquid cooling at module level to provide even temperature distribution and operation within the preferred temperature range, ensuring high availability of power
and energy, and contributing to slow aging of the battery cells.
SAFETY IN OPERATION Maximum protection against fi re propagation resulting from a thermal event is
achieved with a combination of active and passive safety devices at
both CYC module and battery pack level. Each cell in the CYC module is
separated from the next by a carefully calculated gap and covered by an optimized potting compound. If a thermal event were to occur at cell level, thermal propagation between neighboring cells would be prevented and hot gases safely dissipated in a controlled manner. Triggering of adjacent cells inside the module or
in the neighboring module does not occur; they do not even change their state of charge. As an additional safety measure in the event of an internal or external short circuit, the wire bonds connecting the cells to the side PCBs would act as fuses for groups of cells. CYC modules are separated from each other by fl ame- retardant materials to prevent inter- module fi re propagation. At battery pack level, there are
extra safety elements within the hardware and software. The rigid steel construction of the CYC module is supplemented with further bracing between the modules, and a robust stainless steel housing protects the complete battery pack against damage in the event of a vehicle crash. Thermal isolation material surrounds the battery cells to protect against environmental hazards such as a fuel fi re. Additional layers of safety are provided by the eff icient cooling system and predictive algorithms built into the battery management system software.
CHARGING AND MAINTENANCE Using quick charge facilities, the UHE battery pack can be charged at a rate of up to 1C. Fast charging infrastructure up to 500kW is also compatible. All of the main electronic components
apart from the CYC modules are housed in a removable contactor box, allowing the electronics compartment to be exchanged in the fi eld without the need for high-voltage trained technicians or demounting the battery pack from the vehicle.
INDUSTRY RECOGNITION BorgWarner AKM battery technology earned an Innovation Award from Busworld, the leading trade show of the European bus industry and has already been chosen by the two largest European OEMs for bus and truck applications.
Each CYC module contains 600 Li-ion cells
www.borgwarner.com
Environmental sustainability
According to a TÜV (Technischer Überwachungsverein) certifi ed calculation method in Germany, BorgWarner’s UHE battery system is rated highly sustainable. Some examples demonstrating its sustainability follow: • Low weight of the battery system reduces the vehicle’s energy consumption
• High cycle life of battery
cells reduces the number of battery changes, minimizing cost and maximizing environmental sustainability
• Extended circular value stream of the batteries, e.g. maximum recyclability of raw materials, fi nding second life applications for used batteries
• As higher availability of energy from the vehicle’s
The ultra-high energy (UHE) battery system signifi cantly increase EV range
batteries increases operational range, longer distance applications can be electrifi ed.
www.engineerlive.com
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