Rugged Monitoring designs, manufactures and commercializes rugged fiber optic

temperature sensors and monitors for laboratories, utilities, industrial, process,

medical and OEM applications.

Rugged Monitoring Company Proprietary & Confidential

info@ruggedmonitoring.com, Tel: (+1) 418 767 0111
Not for Distribution
 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: 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 Testing Module • Certification
• 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: Cylindrical Cells (Core Temperature Measurement)

Why Temperature Monitoring

• Cell chemical analysis for Performance Maximization
• Identify root cause of heating in Fast Charging Cells
• Identify optimal material for Anode, Cathode and Separator for Fast Charging Batteries

Fiber Optic Monitor

Why Fiber Optic Temperature Sensors
1. Safety: No risk of fire from damage to cell composition
2. Lower cost of installation – No expensive Isolation needed
Fiber Optic Sensors 3. Ultra Small footprint (0.4mm) to fit into Cell Core
1. Adjustable to fit at diferent 4. Accurate and Noise Free readings – No Impact of Strain /
locations inside the cell core
Pressure inside Cell
2. Silica Glass with Polyimide 5. Sensors Stability: Electrically, Magnetically and Chemically stable
coating suitable for Cell
chemical environment

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 EV Battery: Pouch Cells (Anode Thermal Profiling)

Why Temperature Monitoring

• Cell chemical analysis for Performance Maximization
• Identify root cause of heating in Fast Charging Cells
• Identify optimal material for Anode, Cathode and Separator for Fast Charging Batteries

Why Fiber Optic Temperature Sensors

1. Safety: No risk of fire from damage to cell composition
2. Lower cost of installation – No expensive Isolation needed
Fiber Optic Sensors
3. Ultra Small footprint (0.4mm) to fit into Cell Core
1. Adjustable to fit at diferent
4. Accurate and Noise Free readings – No Impact of Strain /
locations inside Call Anode
Pressure inside Cell
2. Silica Glass with Polyimide
coating suitable for Cell
5. Sensors Stability: Electrically, Magnetically and Chemically stable

chemical environment

Fiber Optic Monitor

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 EV Battery: Prismatic Cells (Anode Thermal Profiling)

Why Temperature Monitoring

• Cell chemical analysis for Performance Maximization
• Identify root cause of heating in Fast Charging Cells
• Identify optimal material for Anode, Cathode and Separator for Fast Charging Batteries

Why Fiber Optic Temperature Sensors

1. Safety: No risk of fire from damage to cell composition
2. Lower cost of installation – No expensive Isolation needed
Fiber Optic Sensors
3. Ultra Small footprint (0.4mm) to fit into Cell Core
1. Adjustable to fit at diferent
4. Accurate and Noise Free readings – No Impact of Strain /
locations inside Call Anode
Pressure inside Cell
2. Silica Glass with Polyimide
coating suitable for Cell
5. Sensors Stability: Electrically, Magnetically and Chemically stable

chemical environment

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 EV Battery: Module Level Testing

Key Benefits of Fiber Optic Temperature Sensors

1. Rugged and Compact Design with ring terminal connectors
2. Standard and Custom Ring Terminal Sizes
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
6. Easy to route cabling with Bundled Sensors

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 EV Battery: Pack Level Testing

Key Benefits of Fiber Optic Temperature

Sensors
1. Suitable for Air-Cooled and Water/Gel Cooled
Batteries
2. Faster response time for accurate Thermal
Profiling
3. Accurate and Noise Free readings with 100%
Fiber Optic Sensors Repeatability
1. Adjustable to place at 4. Sensors Stability: Electrically, Magnetically
different locations into and Chemically stable
cooling chamber
5. Safety: Avoid Short-Circuit risk and protect
2. Leak Proof up to 50bar
Researchers and Test Environments
3. Bundled sensors to
optimize cable routing