Compact Cooling for Battery Thermal Management Systems (BTMS)
Cooling Systems Engineered for Your BTMS Architecture
Aspen Systems designs compact, energy-efficient refrigeration-based cooling systems for integration into OEM Battery Thermal Management Systems. Our compact liquid chillers, direct refrigerant cooling, and application-specific refrigeration systems are engineered for high coefficient of performance (COP) and can be configured around the thermal capacity, space constraints, and operating requirements of the BTMS and the equipment in which it operates.
Energy-Efficient Cooling for Battery-Powered Equipment
BTMS requirements vary significantly by equipment type, operating environment, and duty cycle. Aspen cooling systems can be integrated into applications including:
- Electric forklifts and material-handling equipment
- Construction and earthmoving equipment
- Agricultural and off-highway vehicles
- Specialty electric vehicles
- Autonomous vehicles and mobile robotics
- Utility and work vehicles
- Recreational and powersports vehicles
Cooling requirements should be based on battery heat generation, power and efficiency considerations, charging and discharge loads, duty cycle, ambient temperature, available airflow, and installation constraints.
Select the Cooling Architecture
Aspen supports air cooled, liquid-cooled, and direct-refrigerant (plate cooling) for BTMS architectures depending on the application’s thermal and packaging requirements.
Air Cooling
Forced-air cooling can be effective for lower heat loads where sufficient temperature difference exists between the battery and ambient air. It offers relatively simple packaging but becomes less effective as heat density increases or ambient temperature approaches the required battery temperature.
Liquid Cooling
A compact liquid chiller supplies temperature-controlled coolant to battery cold plates or an existing BTMS coolant loop. This provides active heat removal when a radiator or ambient air cannot maintain the required coolant temperature.
Direct Refrigerant (Plate) Cooling
Direct Refrigerant Cooling circulates refrigerant through an evaporator or cold plate at the battery thermal interface. Eliminating the secondary coolant loop can reduce pumps, reservoirs, plumbing, weight, and packaging volume.
Custom Cooling Systems for BTMS Integration
When a standard cooling configuration does not fit the application, Aspen can design the refrigeration system around the BTMS and equipment requirements.
Custom integration can account for:
- Available installation envelope
- Required cooling capacity
- DC input voltage and available power
- Mounting location and orientation
- Coolant or refrigerant connections
- Condenser location and airflow
- Shock, vibration, and ruggedization
- Dust and water exposure
- Weight limitations
The core refrigeration system will typically include the compressor, condenser, evaporator, and heat exchanger. Optionally, the fluid pump, reservoir, sensors, controller, and other thermal components can be designed into custom systems manufactured by Aspen Systems.
Miniature BTMS Cooling Designed for Your Application
Aspen Systems can design a compact cooling system around the specific thermal, mechanical, electrical, and environmental requirements of your BTMS application. Our engineers work with your team to integrate the refrigeration system into the available equipment envelope, providing the cooling capacity, temperature control, and system configuration required for demanding battery-powered equipment.
Frequently asked questions
What is a Battery Thermal Management System (BTMS)?
A Battery Thermal Management System controls battery temperature to support performance, reliability, charging, and service life. Depending on the application, a BTMS may use air cooling, liquid cooling, refrigeration, heating, cold plates, pumps, heat exchangers, sensors, and control systems.
What is the difference between a BMS and a BTMS?
A Battery Management System (BMS) monitors and controls electrical battery functions such as cell voltage, current, state of charge, temperature, and protection. A Battery Thermal Management System (BTMS) manages the battery’s physical thermal conditions through heating and cooling. The two systems often work together.
When does a battery cooling system need active refrigeration?
Active refrigeration may be appropriate when ambient air cannot provide sufficient heat rejection, coolant temperature must be tightly controlled, high ambient temperatures are expected, or the application requires cooling below ambient temperature.
What is the difference between liquid cooling and refrigeration?
Liquid cooling transports heat from the battery to another location using circulating coolant. Refrigeration actively removes heat from that coolant and can maintain coolant temperatures independent of ambient conditions within the system’s designed operating envelope. The two technologies are often used together.
Can Aspen develop custom cooling systems for OEM battery applications?
Yes. Aspen Systems develops compact liquid chillers, direct refrigerant cooling systems, and custom refrigeration solutions for integration into OEM equipment. Cooling architecture can be designed around the application’s thermal load, temperature requirements, available space, electrical power, environment, and other system constraints.
Get a Quote | Application Questions
Please send us your requests; our team is happy to help.
You can also reach us by email at: info@aspensystems.com
or by phone number at (508) 281-5322