Abstract

The critical element of a Battery Electric Vehicle (BEV) is certainly the battery system. It supplies the power to the motor while driving the vehicle range through its capacity but also represents the highest-cost component. Besides the cost, battery requirements lie on four main expectations, which are driving range, power, lifetime and safety. To combine them efficiently, a system level assessment needs to be performed in addition to a detailed focus on the battery pack itself. Thermal management is a key pillar of these four requirements. Keeping the battery cells temperature within a preset range, generally between 0 and 45°C, is mandatory to ensure optimal battery performance, lifetime and safety. In order to address efficiently this Battery Thermal Management challenge, we propose here to present a powerful step-by-step workflow based on System Simulation. This work describes how quickly a detailed battery model can be built with only a few available data thanks to dedicated and integrated productivity tools. While the resulting model enables to access temperature gradients within the battery pack, the final objective is to integrate it into a full vehicle model in order to assess behaviors on various configurations, this, during real-life critical transients such as fast-charging and RDEs scenarios. This lets endless possibilities for the optimization of the cooling pack design as well as the BTMS (Battery Thermal Management System) control strategies at early design stages. As you progress in the system design, simulation needs are also changing, especially when the control needs to be validated and tested in a Hardware-In-the-Loop (HIL) environment. We are hence proposing at the end of this work a continuity in the simulation framework by presenting how we seamlessly apply Reduced Order Model (ROM) techniques to this model in order to reduce simulation times, comply with fixed-step solver constraints, while preserving the essential behavior and dominant effects.