EV, Battery and Rapid Charging Cooling

The growth of Electric Vehicles (EV) ushers in a need for novel thermal management solutions.  Heat loads driven by higher energy densities in battery technology, electronics, and rapid charging require high-efficiency cooling systems in compact packages.  The thermal issues are exacerbated by the necessity to keep batteries within tight thermal boundaries in order to maintain performance and reliability for extended use.  Engineers are increasingly reliant on active cooling for electric vehicles to meet these requirements.

‘Coolest’ race car in the American Solar Challenge

  • Universities across the country race their cars in the American Solar Challenge.
  • Safety constraints dictate that when the battery compartment reaches 40 degrees C, the team solar must exit the race until the temperature falls to safe levels.
  • One of the race participants, Principia College employed an Aspen Systems Liquid Chiller Module (LCM) to actively cool the batteries and power electronics for a competitive edge.

Cooling Rapid EV Charging

  • A common complaint from owners of electric vehicles is the amount of time to recharge the batteries.
  • Rapid charging stations dramatically reduce the charging time to a few minutes.
  • With currents of over 500 Amps in rapid EV charging, the cable needs to be actively cooled to prevent meltdown.
  • Aspen Systems developed a custom liquid chiller small enough to fit within the charging station and operate in extreme environments.

Cooling of 9kW Battery Storage System

  • Hybrid power stations consist of a bank of batteries to provide kilo-Watts of electrical power in remote locations where power from the grid is unavailable.
  • Battery performance degrades in hot environments.
  • Aspen Systems supplied an ECU-1800, a ruggedized air cooling system to keep battery temperature stable.

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