Fiber Optic Temperature Solutions for EV Battery Testing

Fiber Optic Temperature Solutions: Batteries

Batteries are the key differentiator between the various EV manufacturers:

1. Battery Size
2. Battery Capacity and Performance
3. Battery Charging Time
4. Battery Life

Thermal Management is the Key in EV Batteries

1. Higher Capacity and Performance with Smaller Size results into thermal stress
2. Rapid Charging requires high current and hence increases the Thermal Stress
3. Harsh Environmental and Operating Conditions i.e. Extreme Ambient
Temperatures (Hot/Cold) result into Reduced Battery Life
4. High Cooling System Efficiency become very critical for Harsh Operating
Conditions (Rapid Acceleration / Breaking) i.e. Supercars
5. Battery Management System: Accurate thermal profile characterization increases
accuracy of Age Estimation Analytics

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 Fiber Optic Temperature Solutions: Batteries

• Vendor • Design
• Design
Evaluation Validation
Validation
• Life Cycle Battery • Certification
Cell Module • Certification
Testing
• Vendor Pack • Cooling
• BMS System
Evaluation
Analytics Efficiency

Battery Pack Testing:

- Life Cycle Testing
Typical Requirements for Thermal Testing and Monitoring Systems
- Abuse Testing
1. Wide Temperature Range to cover the extreme environmental conditions - Performance Testing
2. Higher accuracy and response for better thermal profiling and BMS Analytics - EMC Testing
• Allowable intercell temperature difference is ~ 2⁰C - Power Rating Testing
• Sensors must be fast enough to detect Thermal Runway Situations

3. Highly Stable and Durable measurement system for EV Conditions

• Under High Voltage and Chemical Environment
• Thermal shock, Vibration Shocks, Mechanical Load etc.
4. Leakproof sensor design for Cooling System Monitoring
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 EV Battery: Cell Level Testing

R501 T301 O101 L201

Monitoring Options
OR OR OR

FO sensor Cables
Key Benefits of Fiber Optic Temperature Sensors:
1. Adjustable to place at diferent
1. Sensors with Rugged disposable tips, glued to Battery Cells
locations into Battery Cells
2. Sensors can also be placed on the actual cell with out any
2. Option for bundled sensors to
concern for safety, accuracy, noise interference
optimize cable routing
3. Accurate and Noise Free readings
4. Sensors Stability: Electrically, Magnetically and Chemically
stable
5. Safety: Avoid Short-Circuit risk and protect Researchers and
Test Environments
6. Easy to route cabling with Bundled Sensors

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 EV Battery: Module Level Testing

Monitoring Options
FO Sensor Cables
R501 T301 O101 L201

OR OR OR

Key Benefits of Fiber Optic Temperature Sensors:

1. Rugged and Compact Design with ring terminal connectors

BATTERY MODULE BATTERY MODULE BATTERY MODULE 2. Standard and Custom Ring Terminal Sizes
VENDOR-A VENDOR-B VENDOR-C 3. Accurate and Noise Free readings with 100% Repeatability
4. Sensors Stability: Electrically, Magnetically and Chemically stable
5. Safety: Avoid Short-Circuit risk and protect Researchers and Test
Environments

BATTERY MODULE BATTERY MODULE BATTERY MODULE 6. Easy to route cabling with Bundled Sensors
DESIGN-X DESIGN-Y DESIGN-Z

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 EV Battery: Pack Level Testing

Monitoring R501 T301 O101 L201

Options
OR OR OR

FO Extension Cables – Bundled

(this can go up to 100m long) Optical Feedthrough (ultra small
size, need to know the total space
available at each duct to
determine the right part number)
FO sensor Cables Key Benefits of Fiber Optic Temperature Sensors:
1. Adjustable to place at 1. Suitable for Air-Cooled and Water/Gel Cooled Batteries

different locations into 2. Faster response time for accurate Thermal Profiling
cooling chamber 3. Accurate and Noise Free readings with 100% Repeatability
4. Sensors Stability: Electrically, Magnetically and Chemically
2. Leak Proof up to 50bar
stable
3. Option for bundled
5. Safety: Avoid Short-Circuit risk and protect Researchers and
sensors to optimize cable
Coolant Chambers placed above and below the Test Environments
routing Battery Pack

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 Emobility Components Tested with Fiber Optic Sensors

Battery and BMS

Charging Plug

Power Electronics

HV Cables,
Terminations and
Joints

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EV Motors
 Fiber Optic Temperature Solutions: Power Electronics

Power Electronics Testing:

- Design Qualification
- Vendor Evaluation
- Performance Testing
- Life Cycle Testing
- Abuse Testing
- EMC Testing

Major Thermal Challenges in Power Electronics
1. Identify sources of thermal stress in Power Electronics
2. Provide safe testing environment to Researchers / Testers
3. Precise thermal profiling of inverter
4. Understand the performance limits of Power Electronics
5. Fast and timely detection of faulty motors
Key Benefits of Fiber Optic Temperature Sensors:
1. Ultra small footprint for direct installation at MOSFETs, Capacitors & Junctions
2. Intrinsically safe sensors to fit directly at high voltage terminations
3. Accurate and Noise Free readings without any compensation requirement
4. Sensors with Rugged disposable tips for reuse
5. Sensors Stability: Electrically, Magnetically and Chemically stable
6. Safety: Avoid Short-Circuit risk and protect Researchers and Test Environments

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 Emobility Components Tested with Fiber Optic Sensors

Battery and BMS

Charging Plug

Power Electronics

HV Cables,
Terminations and
Joints

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EV Motors
 Fiber Optic Temperature Solutions: Charging Plug/Points

Charging Plug/Point Testing: HV Cable and Terminations

- Performance Testing - Drivetrain Testing
- Design Qualification - EV Testing
- Vendor Evaluation - End of Line (EOL) Testing
- Life Cycle Testing
- Abuse Testing
- EMC Testing

Major Thermal Challenges in Charging Plug/Point Key Benefits of Fiber Optic Temperature Sensors:
1. Direct temperature measurement at charging point 1. Ultra small footprint for direct installation at Charging Point
2. Accurate thermal profiling of Charging Plug 2. Thermal profile characterization with intrinsically safe sensors
3. Identify performance limits under fast charging scenario 3. Accurate and Noise Free readings
4. Select most effective cooling system for charging plug and 4. Sensors Stability: Electrically, Magnetically and Chemically stable
onboard chargers 5. Safety: Avoid Short-Circuit risk and protect Researchers and Test Environments

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