We offer comprehensive services for the development of high-voltage battery variants which start with the concept of how primary batteries can be transferred into newly developed vehicles and derivatives and also include mechanical, electric and thermal design and testing.
Battery design and thermal management
In addition to the storage capacity, the design and development of batteries also involves determining their shape and the way that they are integrated into the vehicle structure. However, the available installation space is not the only important consideration when developing a battery package. Other issues include the performance requirements, the resulting design and the number of individual battery cells. The ideal arrangement, the composition of the cell packs and the provision of additional space for cooling systems and control units also have to be taken into account. Crash safety also plays a key role, together with the thermal design of the system. We use virtual development methods and simulation to identify the type of cooling system required.
Battery cell modules are connected together electrically via busbars. We develop the electric circuit for the cell modules to meet the performance requirements. We also fine-tune connection systems, make the connections more robust and identify how to provide the largest possible capacity.
Bertrandt integrates sensors and electronic systems that monitor the temperature and voltage and transfer data to the battery management system (BMS).
Battery management systems
Bertrandt develops software algorithms for battery management systems (BMS). Using the temperature and voltage data we have collected, we ensure that the cells remain within the ideal operating range, by achieving the best possible cell balance and improving the charging strategies.
Modern vehicle architectures make it possible for us to transfer BMS data to higher level vehicle systems. Connectivity and back-end systems enable data to be sent to cloud solutions such as the Bertrandt Automotive Cloud. This allows vehicle owners to see the battery status and manage the charging process via mobile devices and smartphone apps.
Test centres for high-voltage batteries
Bertrandt has several in-house test centres where all aspects of the electric powertrain and batteries in particular can be assessed and validated. We test a variety of mechanical and electrical features in accordance with the latest standards and have the flexibility to design test processes to meet customers’ requirements. We provide a selection of multi-channel test systems with power categories up to 1000 V/1000 A. Our comprehensive safety features ensure that these systems operate safely.
We can build prototype batteries in our own high-voltage workshops. In addition, high-voltage batteries can be tested under extreme climatic conditions and loads in climate test chambers (using multi-axis shaker tables). We can also dismantle batteries for analysis purposes after testing has been completed or when the batteries have been returned from use in the field.
We are continuously increasing the scope and performance of our high-voltage testing resources. Highly trained engineers and battery specialists ensure that the tests produce high-quality results.
Other aspects of the process of developing variants of high-voltage batteries
- Energy storage concepts
- Complete development of battery variants
- Testing and analysis of batteries in high-voltage testing centres