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Battery Tray

Evolution and Innovation in EV Battery Tray Design and Technology

2024-01-18

Development and Trends of Battery Trays in New Energy Vehicles Facebook Twitter LinkedIn Project Contact: Chris +86 193-5550-1188 info@xdthermal.com Development and Trends of Battery Trays in New Energy Vehicles What are Battery Trays? Battery trays are essential components of the power system in new energy vehicles, specifically designed to support, secure, and protect batteries. This ensures their safe and stable installation in vehicles or energy storage systems. Being crucial to the safety of electric vehicle battery systems, battery trays are highly customizable. They offer robust support, waterproofing, dust resistance, fire prevention, heat diffusion control, and anti-corrosion capabilities. Evolution of Battery Trays Initially made from steel, battery trays in electric vehicles have evolved to aluminum alloy trays, aiming for lighter and more efficient metal alloy designs. This evolution is driven by the need for lighter vehicles, as electric cars are heavier than traditional fuel vehicles and strive to match their mileage range Battery tray production process Types of Battery Trays Steel Battery Trays Steel battery trays, made primarily from high-strength steel, play a key role in the battery systems of new energy vehicles. Advantages: ● Cost-effective: Offers manufacturers a cost advantage. ● Excellent processing and welding capabilities: Simplifies and adds flexibility to the manufacturing process. ● Strong resistance to stone impacts: Adapts to various road conditions, enhancing battery safety. Disadvantages: ● Heavier weight: Affects the driving range negatively. ● Lower rigidity: Prone to deformation under pressure, potentially damaging the battery and increasing fire risks. ● Poor corrosion resistance: Leads to internal battery damage Cast Aluminum Battery Trays Cast aluminum battery trays are single-piece structures typically used in smaller energy battery packs. Advantages: ● Single-piece molding simplifies the manufacturing process. ● Flexible design options to meet diverse requirements, allowing greater design freedom. ● High overall mechanical performance ensures good structural stability. ●…

Development of battery pack technology

Powering the Future: What Path is Battery Pack Technology Taking in the Evolution of Energy?

2024-01-04

The rise of electric vehicles has spurred the rapid development of battery technology, and the evolution of battery pack technology is a crucial component of this technological revolution. From the initial stages of CTP to CTB, MTC, and further to the CTC phase, each stage of innovation aims to enhance energy density, reduce costs, and improve the overall performance of the battery system. The continuous innovation in battery pack technology has not only brought about a qualitative improvement in the range of electric vehicles but also propelled the entire industry forward. CTP (Cell-To-Pack) CTP (Cell-To-Pack) is a technology that reduces or eliminates the three-tier pack structure of battery cells, modules, and the overall pack. It bypasses the standard module step by directly integrating the battery cells onto the pack, eliminating the intermediate module stage and effectively enhancing the space utilization and energy density of the battery pack. Currently, there are two main technological approaches: the fully module-less method and the use of larger modules replacing smaller ones. The release of the Kirin battery by CATL adopts the third-generation CTP technology. This technology completely eliminates the module-based layout, discarding the separate design of battery pack crossbeams, bottom cooling plates, and thermal insulation pads.  Instead, it integrates them into a multifunctional elastic interlayer. This design enables the Kirin battery to possess advantages such as rapid temperature control, improved safety, support for 4C high-voltage fast charging technology, and increased battery lifespan. Advantages Lower manufacturing cost Relatively simple maintenance Easy adaptation to different vehicle models and application scenarios Improved volume utilization Increased energy density Disadvantages Increased difficulty in managing thermal runaway High process requirements Difficulties in maintenance and replacement Long battery pack assembly time Challenges in the reuse of cells CTB (Cell-To-Body) In CTB technology, the design of modules and the casing on the…

battery liquid cooling system

Battery liquid cooling system: The crucial role of liquid cooling plates

2023-12-27

Battery liquid cooling system: The crucial role of liquid cooling plates Facebook Twitter LinkedIn Project Contact: Chris +86 193-5550-1188 info@xdthermal.com Battery liquid cooling system: The crucial role of liquid cooling plates Key Role of the Battery Liquid Cooling System: efficiently balances heat, precisely controls temperatures to boost battery system power density, and prolongs battery lifespan.   What is battery liquid cooling system? In the design of battery systems, engineers pay particular attention to the internal liquid cooling system. Unlike natural cooling and air-cooling techniques (which rely on airflow and have limitations in high-power lithium-ion battery applications), the liquid cooling system utilizes a high thermal conductivity liquid coolant (usually a cooling fluid or a thermal-conductive liquid) to regulate the battery’s temperature. The liquid is typically sealed inside the battery pack and can come into indirect or direct contact with the battery cells. Indirect liquid cooling, employing cooling plate technology, is well-established and widely used in energy storage stations and electric vehicles. On the other hand, direct liquid cooling, known as immersion cooling, demonstrates superior cooling effectiveness, but its maintenance is more complex. Active Air Cooling System Passive Air Cooling System Typical Liquid Cooling System Working Diagram Power Battery Liquid Cooling System(indirect liquid cooling) The power battery pack’s liquid cooling system is a sophisticated setup consisting of a control system, cooling fluid circulation system, temperature sensors, coolant, and the pivotal battery liquid cooling plate. The cooling plate emerges as a critical element in the system, enabling precise and efficient regulation of the battery temperature to maximize its functionality. When the battery starts operating, temperature sensors detect changes inside the pack. If the temperature rises, the system activates coolant circulation. The coolant absorbs heat from battery cells and, through the liquid cooling plate, exchanges heat with external air. The control system, using temperature…

IGBT's Utilization in the Electric Vehicle Field

IGBT’s Utilization in the Electric Vehicle Field

2023-12-14

What is IGBT? IGBT, or Insulated Gate Bipolar Transistor, is a type of semiconductor device used for output control of AC electric motors in electric vehicles, railway locomotives, and EMUs (Electric Multiple Units). While traditional Bipolar Junction Transistors (BJT) have low on-state resistance, they require a large driving current. On the contrary, Metal-Oxide-Semiconductor Field-Effect Transistors (MOSFET) have high on-state resistance but the advantage of a small driving current. IGBT combines the advantages of both: not only does it have a small driving current, but it also has low on-state resistance.   The working principle of IGBT involves the formation of a conductive channel by applying a positive gate voltage, allowing the flow of current and enabling switch operations. Additionally, adjusting the gate voltage controls the current, making it efficiently controllable for applications in power electronics. Advantages of IGBT ● It possesses higher voltage and current handling capabilities along with extremely high input impedance.● It can switch very high currents using very low voltages.● It is a voltage-controlled device, resulting in no input current and low input losses.● The gate drive circuit is simple and inexpensive, reducing gate drive requirements.● It can be easily turned on and off by applying voltage.● It has very low on-state resistance and exhibits high current density (with smaller chip size).● It offers higher power gain compared to BJT and MOSFET (higher switching speed than BJT).● Its bipolar nature enhances conductivity. Applications of IGBT IGBT finds a wide range of applications, commonly used in power electronic systems, including inverters, motor drives, power supplies, and frequency converters. It is extensively employed in electric vehicles for motor drives and battery management systems. Its high power density and controllability enable efficient energy conversion and intelligent power management in electric vehicles, driving advancements in electric vehicle technology. Moreover, IGBT plays…

automobile lightweighting- XD THERMAL

Electric Vehicle Lightweighting

2023-12-08

Electric Vehicle Lightweighting Facebook Twitter LinkedIn Project Contact: Chris +86 193-5550-1188 Chris@xdthermal.com Electric Vehicle Lightweighting Why Achieve Automotive Lightweighting Automotive lightweighting is not merely about reducing the weight of a car; rather, it constitutes a comprehensive systems engineering approach. It involves, under the premise of ensuring the strength and safety performance of the vehicle, minimizing the curb weight as much as possible. This, in turn, enhances the vehicle’s range, energy efficiency, performance, and safety, while simultaneously reducing air pollution and contributing to the achievement of “carbon neutrality.” Range Capability: Although electric vehicles lack an engine and gearbox, the current weight of the battery pack exceeds that of the engine and gearbox. The range of an electric vehicle is directly influenced by the weight of the vehicle. Through lightweighting design, automakers can optimize the layout of power battery modules, thereby reducing the overall vehicle weight, extending the battery range, and further enhancing the competitiveness of electric vehicles. Energy Efficiency: A lighter vehicle weight translates to reduced energy consumption. Lightweighting electric vehicles helps improve energy utilization efficiency, lower operating costs, and further decrease dependence on finite resources. Performance and Safety: Electric vehicle lightweighting not only enhances the acceleration performance but also contributes to improved braking efficiency and handling stability. Additionally, a lightweight structure aids in reducing collision energy absorption, lowering the risk of injury to both the vehicle and passengers. Reducing Air Pollution: Carbon emissions from cars are typically influenced by factors such as the overall vehicle weight, fuel economy, and regional policies. Therefore, lightweighting electric vehicles is a crucial means of reducing carbon dioxide emissions. As automotive lightweighting, electrification, and intelligent technologies advance in the future, the overall carbon emissions throughout the lifecycle of a car will decrease.  How to Achieve Lightweighting in Electric Vehicles 1. Lightweight Application of Materials 1….

visa

China Welcomes Visitors: Expanded Visa-Free Access!

2023-11-24

China Welcomes Visitors: Expanded Visa-Free Access! On November 24th, the spokesperson of the Ministry of Foreign Affairs, Mao Ning, announced that, in order to facilitate the high-quality development and high-level opening-up of services for the exchange of personnel between China and foreign countries, China has decided to experiment with expanding the scope of unilateral visa-free arrangements. This policy applies to ordinary passport holders from six countries: France, Germany, Italy, the Netherlands, Spain, and Malaysia. From December 1, 2023, to November 30, 2024, individuals holding ordinary passports from these countries who come to China for business, tourism, family visits, or transit for a duration not exceeding 15 days, will be exempt from the visa requirement for entry. Share: Facebook Twitter LinkedIn

Swiftly Grasp Liquid Cooling（Bookmark for Reference)—XD THERMAL

Swiftly Grasp Liquid Cooling(Bookmark for Reference)

2023-11-15

Swiftly Grasp Liquid Cooling（Bookmark for Reference） Facebook Twitter LinkedIn Project Contact: Chris +86 193-5550-1188 Chris@xdthermal.com Swiftly Grasp Liquid Cooling（Bookmark for Reference） What is liquid cooling? Liquid cooling is a method that uses liquid instead of air to come into contact with the heat source for cooling. Depending on the type of contact between the cooling liquid and electronic components, it is divided into indirect liquid cooling and direct liquid cooling. Indirect liquid cooling is mainly based on cold plate liquid cooling technology, which allows for standardization and generalization. Direct liquid cooling is primarily based on immersion liquid cooling technology and can be further classified into phase-change and non-phase-change types. Although direct liquid cooling is more efficient, it requires higher operational and maintenance costs as well as a more rigorous and complex design. Indirect liquid cooling Liquid Cooling Plate   A liquid cooling plate utilizes liquid as a heat transfer medium, flowing through internal channels within the plate. It is a non-contact liquid cooling technology that achieves cooling of the heat source through heat transfer. In a liquid cooling plate system, heat-generating components such as batteries and server chips do not directly contact the liquid. Instead, heat dissipation is achieved through the assembly of a cooling plate attached to the electronic components requiring cooling. This approach results in minimal modifications to existing heat-generating components and associated parts, enhancing operability. It is currently the most mature and widely applied liquid cooling solution. (Cooling plates can be produced through various methods such as stamping, brazing, CNC machining, etc., and different manufacturing processes contribute to distinct performance characteristics of the product). Liquid Cooling Tube/Cooling Tube/Serpentine Tube   Composed of thermally conductive metal, typically copper or aluminum alloy, the tubes undergo extrusion and corrugation processes to create an internal structure with a specific number of…

Lightweighting of battery packs

Lightweighting of battery packs

2023-11-10

Battery pack and battery enclosure The battery pack is a complete unit assembled from multiple battery modules, designed for the storage and provision of electrical energy. It is a higher-level component in the battery system, typically composed of several battery modules, connectors, battery management system, cooling system, electrical interfaces, and casing. The battery enclosure is the primary structural component of the battery pack. Only when the enclosure is stable in both static and dynamic conditions (such as rigidity, modal properties, etc.) can it ensure that the power battery operates under normal conditions, enabling the power system to run smoothly. The main function of the battery pack enclosure is to support components of the power battery system, such as battery modules, electrical modules, cooling modules, etc. Additionally, it serves to protect the battery and electrical system from damage in the event of external collisions or compression. Why is it necessary to lightweight the battery Lightweighting is an effective energy-saving and emission-reducing technology. Global automotive industry policies on energy efficiency and emissions are becoming increasingly stringent, with constant advancements in fuel consumption and emission standards. Lightweighting technology, as a crucial avenue for enhancing energy efficiency and reducing emissions in automobiles, achieves weight reduction while meeting safety and cost control requirements. Simultaneously, reducing vehicle weight can lessen the load on the power system, improve vehicle power performance, decrease braking distance, and enhance driving stability. Lightweighting is beneficial for cost control in new energy vehicles, particularly in pure electric vehicles where the battery pack contributes significantly to the overall weight, resulting in a higher weight compared to equivalent conventional fuel vehicles. Taking Tesla Model 3 as an example, with a range of 556 km, the curb weight of the vehicle is 1761 kg, and the 60 kWh power battery pack weighs 480 kg. Assuming…

how to prevent battery thermal runaway-XD THERMAL

How to Prevent Battery Thermal Runaway

2023-11-02

How to Prevent Battery Thermal Runaway Facebook Twitter LinkedIn Project Contact: Chris +86 193-5550-1188 Chris@xdthermal.com How to Prevent Battery Thermal Runaway The Majority of Batteries are Lithium-ion Batteries Wind power facilities, solar power farms, microgrids, data centers, and telecommunication facilities all share at least one common feature: they rely on battery energy storage systems (BESS) composed of thousands of lithium-ion batteries.     While lithium-ion batteries offer numerous advantages, they also come with some drawbacks. On one hand, lithium-ion battery energy storage systems require complex Battery Management Systems (BMS) to maintain safe operating parameters for voltage, temperature, and charging. Improper management or misuse of the batteries can lead to failure, resulting in venting or overheating. If a battery catches fire (thermal runaway), it can quickly escalate into a catastrophic fire, and even lead to explosions. Such fires are extremely challenging to extinguish and can propagate rapidly to neighboring batteries in a domino effect.   What is Battery Thermal Runaway Battery thermal runaway refers to a cumulative amplification of current and battery temperature during constant voltage charging, resulting in gradual damage to the battery. In typical batteries, due to the absence of gaps between the positive and negative plates filled with liquid, oxygen generated at the positive electrode during the charging process cannot reach the negative electrode, making it prone to hydrogen generation along with the escape of oxygen from the battery. Cause of Battery Thermal Runaway The reasons for causing battery thermal runaway stem from inadequate battery selection and thermal design, or external factors such as short circuits leading to elevated battery temperatures, loose cable connections, etc. The solution should address both battery design and battery management.   Thermal runaway triggered by overcharging specifically occurs when the battery management system itself lacks circuit safety features for overcharging, causing the battery’s…

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