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Integrated Liquid Cooling Battery Enclosure

2023-09-18

The battery enclosure serves as the outer housing that accommodates all critical components of the battery pack, safeguarding elements such as battery modules, electrical systems, thermal management systems(TMS), battery management systems(BMS), and others from the effects of moisture, dust, and other harmful substances. Additionally, it provides impact resistance and protection against external collisions. It’s widely recognized that reducing the weight of the battery enclosure by around 10% can potentially increase the electric vehicle’s range by approximately 6%. The battery enclosure typically accounts for about 20-30% of the total system weight, making it a primary structural component. Consequently, achieving lightweight battery enclosures has become a major focus in improving battery systems while ensuring both the functionality and overall safety of the vehicle. R&D We have dedicated over two decades of experience and resources to our endeavors. With a team of 40+ engineers,who specialized in Metal Process, Thermal Design and Welding. We undertake hundreds of research and development projects every year. Simulation and Modeling We leverage state-of-the-art simulation software and hardware resources for comprehensive product testing and validation. Each product undergoes hundreds of hours of simulation and testing before entering production.(Design For Manufacturer, CFD and more) Testing and Validation Testing and validation are crucial steps in ensuring product quality and reliability. We possess a range of laboratory equipment capable of conducting complex performance and environmental tests. Including flow resistance, coolant temperature impact, burst pressure and so on. Manufacturing Production Our highly automated factories meet large-scale production demands while ensuring product consistency. Our data-driven quality control system maintains a product qualification rate of over 96%. https://youtu.be/kMC1ra-OpcE?si=78iyWORNkNLPOlaX With a comprehensive in-house manufacturing process, XD THERMAL can efficiently select various types of base plates or liquid cooling plates for small-scale thermal management. Coupled with multiple connection methods, our production process strikes a balance between strength and cost-effectiveness when creating…

Liquid Cooling Plate(for prismatic battery)

2023-09-18

Types of Liquid Cooling Plates Produced by XD Thermal Electric vehicle battery and energy storage system production facilities require precise temperature control through heating and cooling to optimize battery operations and associated equipment, thereby enhancing operational efficiency. XD Thermal offers professional research and development expertise along with advanced production technologies, delivering the comprehensive liquid cooling solutions to clients. Our solutions aid in the smooth initiation and continuous operation of facilities, ensuring a path to success in the future. Characteristics of a Great Liquid Cooling Plate High Quality-price Ratio Excellent Thermal Conductivity Stable and Safe Ease of Use What Is A Punching Brazed Liquid Cooling Plates? Punched and brazed liquid cooled plates（cold plate) are a special type of heat sink that allows the coolant to be directed directly to the heat source, and the coolant is circulated through the coolant to achieve precise temperature control and efficient heat dissipation. It combines the advantages of the stamping process and brazing technology by stamping the liquid cooling plate to form a certain internal piping or channel system for the flow of coolant (usually water or other cooling media), and then brazing the cooling structure to the heat dissipation surface using brazing technology, which can steadily and uniformly transfer heat from a heat source (such as a battery, a chip, an electronic component, or another), thus achieving effective thermal management. This enables stable and uniform heat transfer from the heat source (e.g. battery, chip, electronic component or other) and thus effective thermal management. Why Choose Punching Brazed Liquid Cooling Plates? Punching: The stamping process has the advantages of low cost and high production speed, and can efficiently produce large quantities of liquid-cooled panels. For example, with a production quantity of more than 1,000 sets, the finished product speed of stamping and brazing production…

Fully Liquid-Cooled Supercharger Brief Analysis

2023-09-15

New Energy Vehicle Pain Points Despite the rapid growth of electric vehicles, the persistent challenges faced by consumers, such as the difficulties in charging, long charging times, and limited driving range, have continued to hinder their development. These issues have repeatedly become hot topics, highlighting the critical obstacles that need to be addressed in the advancement of electric vehicle technology. Fully Liquid-cooled Supercharger The statement “5 minutes of charging for a 300-kilometer range” has now become a reality, seemingly addressing the issue of “slow charging” in electric vehicles. Liquid-cooled fast-charging technology, as a novel solution to the challenges of electric vehicle charging, has emerged as a focal point in the industry. Liquid-cooled fast charging employs a cooling system that utilizes liquid-cooled plates in the battery section and includes a liquid circulation channel between the cables and the charging gun. Within this channel, a cooling fluid is introduced to dissipate heat efficiently. This cooling fluid is circulated by a power pump, effectively removing the heat generated during the charging process. A fully liquid-cooled design offers superior heat dissipation, reduced noise levels, and extends equipment lifespan to 10-20 years or more. The use of fast-charging stations achieves a charging success rate of over 99%. The comprehensive liquid-cooled fast-charging architecture can cater to the charging requirements of various vehicle models, enabling on-the-spot charging, power sharing, and maximizing the fulfillment of vehicle charging needs. In the future, it will support smooth integration of both AC and DC power with energy storage, facilitating intelligent peak shaving, reducing the need for grid modifications, and enhancing the efficient utilization of electrical resources. The fully liquid-cooled fast charging system delivers a higher charging current and faster charging speeds. The output current of the charging station is constrained by the charging gun cable, which uses copper conductors for electrical…

Industrial And Commercial Energy Storage Vs. Mega Storage: Unveiling The Power Play

2023-09-08

Commercial Energy Storage VS Large-Scale Storage Industrial and commercial energy storage systems typically have smaller capacities and simpler system functionalities compared to large-scale storage facilities； The requirements for system control in industrial and commercial energy storage are lower than those in energy storage power stations. Additionally, some Power Conversion System (PCS) products in this category also incorporate Battery Management System (BMS) functionality； Regarding Energy Management Systems (EMS), industrial and commercial energy storage systems only require the configuration of charge and discharge times to achieve energy management, with lower functional demands compared to energy storage power stations. Batteries In the realm of industrial and commercial energy storage, there exists a relatively lower demand for rapid response times, influenced by factors such as cost, cycle life, and response time. Consequently, these applications predominantly employ energy-type batteries. Conversely, energy storage power stations utilize power-type batteries for frequency regulation. While many also use energy-type batteries, the necessity to provide auxiliary power services in frequency-regulation power stations imposes higher requirements on cycle life and response time, necessitating the selection of power-type batteries. Battery Management System (BMS) In the realm of industrial and commercial energy storage, the Battery Management System (BMS) for batteries offers the following functions:1.Overcharging, overdischarging, overcurrent, overtemperature, undervoltage, short-circuit protection.2.Voltage balancing during the charging process.3.Parameter configuration and data monitoring through backend software.Integration with various types of Power Conversion Systems (PCS) for intelligent management of the energy storage system. Battery Management System (BMS) In the realm of industrial and commercial energy storage: 1. Overcharging, overdischarging, overcurrent, overtemperature, undervoltage, short-circuit protection. 2. Voltage balancing during the charging process. 3. Parameter configuration and data monitoring through backend software.Integration with various types of Power Conversion Systems (PCS) for intelligent management of the energy storage system. For Energy Storage Power Stations: 1. Hierarchical and stratified unified management, resulting in…

How hard is it to ensure temperature consistency?

Battery Thermal Management: How difficult is it to ensure battery temperature uniformity?

2023-08-18

The battery production process introduces inconsistencies between individual battery cells, which gradually become more pronounced during actual usage. The performance of batteries is influenced by factors such as charge-discharge cycles, ambient temperature, and discharge currents. As a result, practical battery performance may exhibit deviations from theoretical expectations. During operation, batteries tend to follow a ‘weaker gets weaker, and at a faster rate than the stronger’ trend. This undoubtedly poses significant challenges to battery thermal management and energy conversion. So, how difficult is it to achieve uniform battery temperature? In one-dimensional designs, where batteries are neatly arranged, the flow direction and battery temperature changes can be observed clearly as the cooling medium flows from left to right. (Temperature is lower near the cooling medium and higher away from it.) In two-dimensional designs, when multiple rows of batteries are staggered, it becomes less intuitive to determine the flow direction, speed of the cooling medium, and cooling conditions. Which battery experiences a higher temperature rise? Which battery exhibits greater temperature differences? This requires the use of fluid dynamics and heat transfer simulations to make informed judgments. In three-dimensional designs, one must take into account vehicle structure and battery cell arrangement (such as the irregular distribution seen in Tesla’s battery pack, as depicted in the diagram). This complexity adds considerable challenges to the design, simulation, and testing of thermal management systems. Batteries, despite being unassuming, are remarkably intricate devices. This becomes particularly evident in the realm of new energy vehicles, where they involve disciplines like measurement and control technology, energy conversion techniques, power transformation strategies, system integration, and manufacturing processes. Even though perfect cell uniformity may not exist, we continue to strive for minimal disparities in battery temperatures. This isn’t merely an isolated concern; it’s a systemic challenge that necessitates interdisciplinary collaboration…

Battery Thermal Management: Ensuring Temperature Consistency as the First Priority

2023-08-09

In the field of batteries, the ‘Buckets Effect’ can be explained as follows: the performance and reliability of a battery system are determined by the weakest individual cell, while the overall system safety hinges on the most unstable cell. As cells generate heat during operation, temperature differentials arise within the battery pack. Excessive differentials can affect battery cell and pack safety. Consequently, ensuring temperature consistency within batteries has been a hot topic in the new energy industry. While cells from the same batch share consistent material composition and production processes, inherent individual differences cannot be denied. We refer to this as ‘first-order cell inconsistency.’ Once these cells pass quality inspections and are deemed fit for use, this aspect is often overlooked. Our focus remains on minimizing the gradual increase in individual cell discrepancies during their usage, known as ‘second-order cell inconsistency.’ This aspect especially reflects the level of thermal management design. Why? Because batteries exhibit a ‘chain reaction.’ A thermal runaway in one cell leads to significant heat release. Poor inter-cell heat transfer conditions can trigger adjacent cells to also undergo thermal runaway, escalating to module, cluster, and pack level. In a previous Shanghai Tesla fire incident, four battery modules were destroyed. Had it not been for prompt firefighting measures and rapid cooling with water, the likely outcome could have been the ignition of other modules as well. Temperature consistency, a representative function of battery thermal management, serves as a core indicator of the sophistication of battery management technology. XD Thermal has been committed to the field of battery pack thermal management, collaborating with renowned domestic and international automakers, energy storage system manufacturers/integrators. We achieve temperature differentials within 3°C across entire battery packs. All greatness stems from a brave beginning Share: Facebook Twitter LinkedIn

Empowered by Technology: How Liquid-Cooled Charging Stations Elevate Your Electric Car’s Performance ?

2023-08-03

New Energy EV Development Key Point: “Mileage Worry” To mitigate energy risks and achieve carbon neutrality, the electrification and digitization of automobiles have emerged as pivotal developmental trajectories for the global automotive sector. Governments around the world have introduced various plans and initiatives. In 2022, the global penetration rate of electric vehicles exceeded 10% for the first time. During this period of rapid expansion in the market share of new energy vehicles, ‘driving range’ has consistently been one of the decisive factors influencing consumers’ decisions to purchase EVs. As a result, various automotive brands are continuously enhancing their product offerings. The American automotive website Edmunds conducted a comparative analysis of driving range test data for 61 electric vehicle models, including Mercedes-Benz, BMW, and Ford, and the vast majority of electric car brands have exceeded the range stated in the publicity. On the other hand, beyond the inherent driving range capability of vehicles, the accessibility and strength of ‘refueling’ options on roads also significantly impact the ‘driving range.’ Without conveniently located and efficient charging stations, the driving range of new energy vehicles remains constrained Liquid-Cooled Charging Stations: The Power of Technology In 2006, BYD constructed China’s first electric vehicle charging station. By April 2023, China had more than 2 million public charging stations, with alternating current (AC) charging stations slightly higher than direct current (DC) charging stations. The distribution of these two major types has remained relatively stable. In 2022, the United States pre-planning to allocate a budget of $7.5 billion for the establishment of 500,000 public charging piles. Considering this growth trajectory, it is projected that the demand for public charging stations across the entire United States will exceed 1 million by 2030. A similar trend is evident in the European market. According to a report by Euractiv on July…

Global New Energy Terminal Boom in June

2023-07-18

Domestic: new energy vehicles continue the trend of rapid growth NEW ENERGY VEHICLES QUANTITY YEAR-ON-YEAR June Output 784,000 +32.8 per cent Production 806,000 +35.2 per cent January to June Output 3.788 million +42.4 per cent Production 3.747 million +44.1 per cent TYPE QUANTITY YEAR-ON-YEAR Pure Electric Vehicles Output 548,000 +17.5 per cent Production 573,000 +20.5 per cent Plug-in Hybrid Electric Vehicles Output 235,000 +90.5 per cent Production 232,000 +93.0 per cent In June 2023, the market share of new energy vehicles reached 30.7%, with a month-on-month increase of 0.6 percentage points. According to the China Association of Automobile Manufacturers, it is predicted that the sales volume of new energy passenger vehicles in China will reach 8.5 million units in 2023, and the sales volume of narrow passenger vehicles will reach 23.5 million units, with a expected annual penetration rate of new energy vehicles of 36%. Regarding the upstream battery manufacturers in the new energy vehicle industry, there are also certain layouts. Currently, CATL has established bases in Germany, Hungary, and the United States, Guoxuan High-Tech has bases in Germany and the United States, EVE Energy has bases in Hungary and Malaysia, CATL Innovation has a base in Portugal, Farasis Energy has bases in France, the United Kingdom, Japan, the United States, and Spain, Hefei Guoxuan High-Tech Power Energy has a base in Germany, and BYD has a base in Spain (possibly). In addition to battery manufacturers, battery material companies in the middle stream are also accelerating their expansion overseas. In foreign markets: electric car sales in nine European countries reached 240,000 units, with a year-on-year/increase of 31%/25%, and a penetration rate of 23% for the month. In the United States, electric car sales reached 122,000 units, with a year-on-year/increase of 66%/8%, and a penetration rate of 8.9%….

Know about FSW| Application of new energy

2023-03-08

Friction stir welding, also known as FSW, is a new solid phase connection technology invented by the American Welding Institute in 1991 under the combined action of mechanical force and friction heat. Although this technology started late, it quickly drew the attention of major manufacturers due to its excellent environmental protection and welding capabilities. In the process of FSW, a cylindrical stirring head with a special shaft shoulder and needle protrusion will rotate and slowly insert into the workpiece to be welded. Through intense stirring, friction and pressure, the metal material of the weld will be plastically softened. When the stirring head rotates and moves forward, the thermoplastic metal material will be transferred from the front of the stirring head to the rear, and will be rubbed and forged under the action of the stirring shaft shoulder, and finally turns to a fine forged tissue joint. It makes full use of frictional heat and prevents severe drmation of the heated metal material by means of pressure, and quickly “bonds” two pieces of metal together, ingeniously combine heating and pressing methods.、 Currently, it can be used in the manufacture of a variety of auto parts, such as wheel hubs, rear axles, aluminum alloy battery trays, engine casing linings, side lining reinforcements, door reinforcement structural parts, large extrusion parts bonding, etc. Ford, BMW, Fiat, GM, Mercedes-Benz and Volvo have all been involved for these components. But this technology is mainly developed independently by suppliers, or jointly developed by suppliers and car companies like its scope of use. In terms of technical reserves, suppliers are still dominant. As we all know, light alloys such as aluminum and magnesium alloys have disadvantages of severe joint softening, easy formation of oxide film, generation of pores and thermal cracks and serious welding deformation during welding— FSW can exactly solve this kind of problem. As early as 2005, it…

XD Group

Integrated Liquid Cooling Battery Enclosure

Liquid Cooling Plate(for prismatic battery)

Fully Liquid-Cooled Supercharger Brief Analysis

Industrial And Commercial Energy Storage Vs. Mega Storage: Unveiling The Power Play

Battery Thermal Management: How difficult is it to ensure battery temperature uniformity?

Battery Thermal Management: Ensuring Temperature Consistency as the First Priority

Empowered by Technology: How Liquid-Cooled Charging Stations Elevate Your Electric Car’s Performance ?

Global New Energy Terminal Boom in June

Know about FSW| Application of new energy

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