Battery System Development

Outset

Due to the high currents transmitted from charging stations to vehicles and the physically inevitable contact resistance, there is considerable danger of a massive voltage drop at the contact point. This difference in voltagesleads to a loss of useful energy, which is converted to heat at the contact point. This, in turn, may lead to an unwanted heat build-up in the components, causing thermal and mechanical wear or even a breakdown of the overall system.

The Fraunhofer IVI has been carrying out work in the field of the development and testing of contact partners for the fast transmission of electric energy to vehicles since 2009. A test stand for the characterization of contact bodies and systems has been developed and installed. Due to its fast measuring data recording capacity (sampling rate of the control and measuring signals of up to 220 kHz), even dynamic processes can be analyzed and evaluated. It is also possible to accompany the experimental investigations by model-based simulations, with the result that interrelations between individual input paramters and their effects on the overall system can be monitored better.

• Design, simulation, implementation and testing of systemic solutions for the fast transmision of electric energy to vehicles
• Analysis and optimization of existing contact systems
• Characterization of battery contacts
• Thermal investigations

• Development and testing of suitable contact and connection concepts for SuperCap cells within the scope of the FSEM project
• Prototypical development of a contact system for the fast charging of electric vehicles
• Characterization of electric resistances in metallic welding seams
• Testing of the contacts in an industrial solution for the fast charging of a public transport bus within the scope of the »SEB - EDDA-Bus« project (2014)