Day 2 - June 21, 2023 Improving The Efficiency Of The Thermal System Design, For Multiple Powertrains  Optimizing The BMS & Battery Interface To Ensure Efficient Delivery To The Powertrain SIMPLIFYING THE OVERALL ARCHITECTURE SOLUTION TO IMPROVE RANGE AND REDUCE COST

8:30 Coffee and Registration

09:00 Chair’s Opening Remarks 

Joachim Kupe, Head of Systems Engineering, Head of R&D Mildhybrid eDrives Segment & Battery Segment -NA, Continental

OPENING PANEL – MAXIMIZING THERMAL EFFICIENCY & SAFETY AT A REDUCED COST
09:15 Exploring Cost-Effective Thermal Management Strategies For A Range Of Battery Packaging Designs And Modular Cooling Solutions 
How can the design of a thermal management system be future-proofed for changes in battery pack design? And what is the most cost-effective approach for thermal management?  The panel evaluates the trade-offs between different thermal management approaches and how new technologies can be integrated into multiple types of battery packaging designs and modular cooling solutions. The panel will provide valuable insights into the key technical and commercial considerations that must be considered when designing and implementing thermal management systems for the next wave of technologies, including solid-state batteries and the battery as a structural component.

09:15 MODULAR THERMAL DESIGN 
Assessing The Flexibility, Scalability & Cost Benefits Of A Modular Design Approach To Thermal Management
-  Addressing the separate cooling requirements for the 
      -  Battery cooling
      -  electronics cooling
      -  and climate control
-  Evaluating the cost benefits of modular solutions versus traditional thermal management designs
-  Investigating the impact of modular solutions on the overall vehicle design and packaging
-  Understanding the integration challenges and limitations of modular solutions with the existing powertrain and vehicle systems
-  Evaluating the reliability and durability of modular solutions over the vehicle's life
-  Considering the regulatory and safety requirements for thermal management systems in BEVs

Karl Plattenberger Chief Engineer – Powertrain Integration US, Quantron US, Inc.

09:45 Questions & Discussion

09:55 3D PRINTED BATTERIES FOR EV
Next Level Battery Pack Density - Integrating Custom 3d Printed, High Energy Batteries In EV Architecture

Arwed Niestroj, SVP E-mobility, and Product, Sakuú Corp.

10:25 Questions & Discussion

10:35 CASE STUDY INTEGRATED BATTERY COOLING
Cost Benefit Analysis Of Battery Cooling Integration In Their Electric Vehicle Models

Several OEMs are exploring or implementing battery cooling integration in their electric vehicle models. Some OEMS use a liquid coolant that circulates through a series of channels within the battery pack to maintain optimal battery temperature and improve performance. This session will consider the trade-offs of each approach and balance the need for thermal management with other important factors such as weight, cost, and performance.

Alper Gulyaz, R&D Battery Mechanical Engineer , SUNUM-Sabancı University Nanotechnology Research and Application Center

10:45 Questions & Discussion

11:00 - 11:30 Networking Refreshment Break 

BATTERY SAFETY THROUGH IMMERSION COOLING
11:30 Effect Of Immersion Cooling Using A Dielectric Fluid On Improving The Lifetime And Safety Of Lithium-Ion Batteries

• Immersion cooling vs the conventional air-cooling methods: Looking at the internal temperatures of the Li-ion battery
• Reduced fire hazard during fast charging: Immersion cooling provides a more effective cooling solution, minimizing the likelihood of fire incidents during fast charging.
• Thermal runaway can be suppressed and managed using immersion cooling. The cooling liquid can act as a heat sink and absorb and dissipate the heat rapidly, preventing the escalation of the runaway reaction and minimizing the risk of a fire or explosion.

Dr. Nessa Saniee, Project Engineer Battery Testing, WMG Warwick University

12:10 Questions and Discussion

BATTERY CARRIER WITH AN INTEGRATED COOLING SYSTEM
12:20  An In-Depth Look at Lighter Module, less fastener design, and integrated cooling system battery carrier for EV

• Using aluminum extrusion natural holes for cooling way
• Friction stir welding, to reduce the heat input for sustainability

Gurkan Yilmazoglu, Senior Technical Specialist ,Tofas-FCA

12:50 Questions and Discussion

13:00 - 14:00 Networking Lunch Break
 

BMS INNOVATION Identifying & Implementing More Efficient Battery Management Systems

14:00 ROUND TABLE DISCUSSION GROUPS

1. CELL TO PACK TECHNOLOGY

Comparing The Benefits Of “Cell To Pack” With “Module To Pack” Battery Technology To Reduce Cost & Increase The Available Space For Battery Cells Within The Vehicle

Participants are invited to discuss the cost structure and scalability of both C2P and module-to-pack technology


Using "module to pack" to simplify the manufacturing and assembly process, reduce the number of individual components, and improve the reliability of the battery system
o

Utilizing the "cell to pack" approach provides more flexibility in terms of the design and configuration of the battery system, and can offer improved performance and energy density

Addressing the technical complexity of integrating battery cells directly into the battery pack 


Understanding the technical details and nuances of C2P technology to ensure the performance and 
reliability of BEV batteries 


2. SOLID STATE BATTERIES

Future Proofing The Battery Electric Vehicle Architecture For This Game- Changing Battery Technology

Participants will discuss the commercial readiness of solid-state battery technology and consider the engineering strategies for adapting BEV architecture and thermal optimization to accommodate the technology.

• Examining the cost structure and affordability of solid-state battery technology 

• Future-proofing BEV architecture for solid-state battery technology
• Critical considerations for thermal optimization 

• Understanding the interplay between solid-state batteries and the BEV architecture 
​

3. THERMAL MANAGEMENT

Exploring Cost-Effective Thermal Management Strategies For A Range Of Battery Packaging Designs And Modular Cooling Solutions

How can the design of a thermal management system be future-proofed for changes in battery pack design? And what is the most cost-effective approach for thermal management?

Participants are invited to evaluate the trade-offs between different thermal management approaches and how new technologies can be integrated into multiple types of battery packaging designs and modular cooling solutions.

Participants are also invited to explore the challenges and opportunities of using batteries as load-bearing components, and how thermal management strategies can be optimized to meet the demands of modern electric vehicles.

The purpose is to share valuable insights into the key technical and commercial considerations that must be considered when designing and implementing thermal management systems for the next wave of technologies, including solid-state batteries and the battery as a structural component.

14:45 Group Feedback and Questions

15:15 -15:45 Afternoon Refreshment Break

15:45 ROUND TABLE DISCUSSION GROUPS CONTINUED

1. ADVANCING THERMAL MANAGEMENT ON SKATEBOARD DESIGNS 


Innovative Approaches To Improving Thermal Management In Skateboard Battery Packaging Designs 


What experiences do participants have with skateboard-type battery packaging designs and the challenges faced in cooling and managing heat, especially in terms of cost-effectiveness? Participants are invited to explore innovative approaches to improving the thermal management efficiency of skateboard battery packaging designs while reducing costs. 


• Understanding the unique challenges of thermal management in skateboard battery packaging designs 

• Opportunities for cost reduction 

• Evaluating the latest advancements in thermal management solutions for skateboard battery 
packaging concepts 

• Best practices for cost-effective thermal management solutions for skateboard batteries 

• Case studies of successful implementation of thermal management solutions for skateboard 
batteries 


2. POWER ELECTRONICS

Improving The Efficiency Of The Power Electronics Used In Electric Vehicles To Help Reduce Energy Losses And Improve Range

Improving the efficiency of power electronics in electric vehicles is a crucial factor in enhancing their performance and range. Energy losses can be reduced by improving the efficiency of power electronics components, and the range and overall performance of the vehicle can be improved. Participants are invited to join an industry round table discussion on: 

• Evaluating the current state of power electronics technology and identifying areas for improvement
• Developing new and more efficient power electronics components, such as inverters and DC-DC converters
• Optimizing the design of power electronics systems to reduce energy losses and improve efficiency
• Integrating advanced control algorithms and monitoring systems to improve the performance of power electronics in real-world conditions

3. EFFICIENT BATTERY MANAGEMENT SYSTEMS IMPLEMENTATION & INNOVATION  

Determining The Most Appropriate BMS Configuration Based On The Design Of The Powertrain, Battery Packaging, And User Requirements Of The Car

Participants are invited to discuss the optimal BMS design and how it will depend on the specific requirements and goals of the EV, such as cost, performance, range, and reliability. The discussion will include key considerations for BMS design, as well as the latest innovations and best practices for optimizing BMS performance.

16:30 Group Feedback and Questions

16:45 Chairs Closing Remarks & Close Of The Conference