The transition from the internal combustion engines (ICE) age to a fully electric mobility scenario is one of the main challenges to be overcome, to reduce the impact of climate change. The roadmaps and targets for the optimisation of Li-ion technologies and for the development of new chemistries, such as Li-S, Li-air, or solid-state batteries, are then defined in the Integrated SET-Plan (Action 7).
HELIOS addresses the need for increasing the density of battery packs in terms of weight and package space to improve the performance and range of EVs fleets utilised in growing urban electromobility models. A hybrid approach combining different Li-ion modules within the battery pack is developed to maximise energy and power capabilities depending on the application while optimising dimensioning. This hybrid configuration of the battery pack influences the electrical and thermal behaviour of the system. It also affects the design of the thermal management system, as well as the overall configuration of the different components and sub-systems within the battery pack. The proposed battery pack design makes use of advanced materials in the structural components, such as polymers and composites, to enhance mechanical resistance and lightweight, as well as in the thermal management system. Optimised designs for the electric and thermal management systems, casing and insulation, wiring, and other structural components, are reduced within the battery packs.
In HELIOS, the architecture of the different Li-ion modules, the electrical connections, current collectors, and wiring are optimised to ensure high efficiency, cost, and compact design. Advanced concepts of BMS relating to hardware and software enabling cell/module/pack communication need to be developed. IoT technologies connected to the BMS reduce the computational resources significantly, save space and time for data storage, and improves security. Finally, manufacturing processes of modules and their easy and efficient integration into packs need to consider the choice of materials and requirements related to safety, quality, and fast and cost-efficient fabrication.
