During this project, in the context of WP2 the objective was to analyse, understand and check the thermal behaviour of the current standard and future disruptive (the one developed in i-HeCoBatt project) BP in extreme conditions. The results show the current status of the thermal system and the performance improvement of the novel system respect to the current one. To do so, relevant experimental data set has been generated for either setting a reference for the evaluation of the improvement given by the new heat exchanger and the new thermal controlsystem, the evaluation of the interest of additional sensors / heating systems, and calibrating the necessary models. These experimental data, with CFD simulation realized in WP5, enabled to define both mesh sizing and empirical parameter fitting, on a two-scale approach: fine scale (CFD scale) and coarse scale (1D). The objective has been to evaluate by simulation the standard battery pack thermal architecture and control strategies, simulating the performances of the SoA standard solution vs the novel one. Thanks to these models, the development of an advanced and smart thermal control strategy was done. Additionally, the methodology to design a thermal controller based on machine learning algorithms was validated.
In WP3 the first version of the main component of the cooling system has been done, based on the CAD data and packaging information of the current standard device. In parallel a model of the heat exchanger and battery were built and simulations carried out in order to decide between various variants of the heat exchanger and evaluate the performance. The full sensorized heat exchanger has been developed in close collaboration between WP3 and WP4.The principles and concepts of the sensors and heaters have been developed and integrated on the heat exchanger. Besides, electronic integrated circuits have been developed for the control, readout and data transmission.
The work done in WP6 has focused on enhancing the access and availability of the sensors data by developing a specific SW and cloud based platform to monitor and share the data. The overall architecture and low and high level requirements were defined, communication protocols agreed and the SW as well as the communication between the sensors and the control box developed. Partners also developed the data transfer method between this device and the external device, which included a graphical user interface. Finally, the design and development of the cloud system was done.
Regarding WP7, the development of the industrial version of the heat exchanger was prepared and based on the results obtained for the A-Sample, a virtual industrialized sample (B-sample) was designed and validated through simulations. LCA and LCC studies were carried out and applied to identify some initial impacts, looking into the materials used and the heat exchanger production. These data has been used to support the design of this device with a view on the B-Sample prototype. The initial layout of the pilot line was installed to manufacture the A-Sample prototype. The industrialization of all the manufacturing processes have been planned.
Finally, in WP8 the A-Sample prototype was assembled, and all the communication and monitoring SW were integrated on the sample so as to conduct the tests at lab level.
