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Spin’s technical team has developed expertise and experience in the field by analyzing and designing battery packs for electric mobility whose application areas range from cars to electric buses, from commercial vehicles to e-bikes and scooters.

The consultancy services offered by Spin include, as a qualifying point, the study of the battery pack not as a stand-alone element but rather this is considered as one of the components of the electric propulsion system, together with the converter/inverter and electric motor. The package of simulations and study methodologies developed by the company over the years can be turned to the study of power flows circulating in the drive and the efficiency of the complete device, with the possibility of assessing the operating conditions of the cooling system and the sizing of pumps and heat exchangers with increasing degrees of accuracy and complexity.

Electrical modelling of the battery pack

The integration of the battery pack into the overall electric vehicle model requires the creation of a dynamic subsystem to predict the battery’s performance, considering different operating conditions (e.g. regulated driving cycles) with the aim of estimating its charge level.

1D thermal modelling (concentrated parameters) of the battery pack

The thermal models of each battery module, suitably interconnected on the basis of the cooling scheme, can be used to predict the heat flows that depend on the thermal properties of each component.

CFD analysis of the battery pack cooling system

It is important to precisely define the amount of coolant flowing through each segment of the cooling circuit by means of CFD simulations of the entire cooling system. The analysis allows the pump or compressor of the cooling fluid to be sized with the highest degree of accuracy according to the absorption conditions of the pack.

Electrical analysis of the connection busbars of the battery pack modules

The electrical connections between the different cells forming a module and between the modules of the same battery pack are made by solid conductors called ‘busbars’. It is important to calculate the equivalent electrical parameters of the pack busbars in order to predict the transient behavior of the battery pack. Furthermore, the distribution of electromagnetic fields in the vicinity of the pack obtained from the calculation models can be correlated with the human exposure limits prescribed by national or international standards (e.g. ICNIRP).

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