Battery Life Cycle Testing | Fiber Optic Temperature Sensors pdf

1. Rugged Monitoring designs, manufactures and commercializes rugged fiber optic temperature sensors and monitors for laboratories, utilities, industrial, process, medical and OEM applications. Rugged Monitoring Company Proprietary & Confidential info@ruggedmonitoring.com, Tel: (+1) 418 767 0111 Not for Distribution

2. Emobility Components Tested with Fiber Optic Sensors Battery and BMS Charging Plug Power Electronics HV Cables, Terminations and Joints EV Motors 2

3. Fiber Optic Temperature Solutions: Batteries Batteries are the key differentiator between the various EV manufacturers: 1. Battery Size 2. Battery Capacity and Performance 3. Battery Charging Time 4. Battery Life Thermal Management is the Key in EV Batteries 1. Higher Capacity and Performance with Smaller Size results into thermal stress 2. Rapid Charging requires high current and hence increases the Thermal Stress 3. Harsh Environmental and Operating Conditions i.e. Extreme Ambient Temperatures (Hot/Cold) result into Reduced Battery Life 4. High Cooling System Efficiency become very critical for Harsh Operating Conditions (Rapid Acceleration / Breaking) i.e. Supercars 5. Battery Management System: Accurate thermal profile characterization increases accuracy of Age Estimation Analytics 3

4. Fiber Optic Temperature Solutions: Batteries •Vendor Evaluation •Life Cycle Testing •BMS Analytics •Design Validation •Certification •Cooling System Efficiency •Design Validation •Certification •Vendor Evaluation Battery Pack Cell Module Battery Pack Testing: - Life Cycle Testing Typical Requirements for Thermal Testing and Monitoring Systems - Abuse Testing 1. Wide Temperature Range to cover the extreme environmental conditions - Performance Testing 2. Higher accuracy and response for better thermal profiling and BMS Analytics - EMC Testing Allowable intercell temperature difference is ~ 2⁰C • - Power Rating Testing Sensors must be fast enough to detect Thermal Runway Situations • 3. Highly Stable and Durable measurement system for EV Conditions Under High Voltage and Chemical Environment • Thermal shock, Vibration Shocks, Mechanical Load etc. • 4. Leakproof sensor design for Cooling System Monitoring 4

5. EV Battery: Cylindrical Cells (Core Temperature Measurement) Why Temperature Monitoring Cell chemical analysis for Performance Maximization • Identify root cause of heating in Fast Charging Cells • Identify optimal material for Anode, Cathode and Separator for Fast Charging Batteries • Fiber Optic Monitor Why Fiber Optic Temperature Sensors 1. Safety: No risk of fire from damage to cell composition 2. Lower cost of installation – No expensive Isolation needed Fiber Optic Sensors 3. Ultra Small footprint (0.4mm) to fit into Cell Core 1. Adjustable to fit at diferent 4. Accurate and Noise Free readings – No Impact of Strain / locations inside the cell core Pressure inside Cell 2. Silica Glass with Polyimide 5. Sensors Stability: Electrically, Magnetically and Chemically stable coating suitable for Cell chemical environment 5

6. EV Battery: Pouch Cells (Anode Thermal Profiling) Why Temperature Monitoring Cell chemical analysis for Performance Maximization • Identify root cause of heating in Fast Charging Cells • Identify optimal material for Anode, Cathode and Separator for Fast Charging Batteries • Why Fiber Optic Temperature Sensors 1. Safety: No risk of fire from damage to cell composition 2. Lower cost of installation – No expensive Isolation needed Fiber Optic Sensors 3. Ultra Small footprint (0.4mm) to fit into Cell Core 1. Adjustable to fit at diferent 4. Accurate and Noise Free readings – No Impact of Strain / locations inside Call Anode Pressure inside Cell 2. Silica Glass with Polyimide 5. Sensors Stability: Electrically, Magnetically and Chemically stable coating suitable for Cell chemical environment Fiber Optic Monitor 6

7. EV Battery: Prismatic Cells (Anode Thermal Profiling) Why Temperature Monitoring Cell chemical analysis for Performance Maximization • Identify root cause of heating in Fast Charging Cells • Identify optimal material for Anode, Cathode and Separator for Fast Charging Batteries • Why Fiber Optic Temperature Sensors 1. Safety: No risk of fire from damage to cell composition 2. Lower cost of installation – No expensive Isolation needed Fiber Optic Sensors 3. Ultra Small footprint (0.4mm) to fit into Cell Core 1. Adjustable to fit at diferent 4. Accurate and Noise Free readings – No Impact of Strain / locations inside Call Anode Pressure inside Cell 2. Silica Glass with Polyimide 5. Sensors Stability: Electrically, Magnetically and Chemically stable coating suitable for Cell chemical environment 7

8. EV Battery: Module Level Testing Key Benefits of Fiber Optic Temperature Sensors 1. Rugged and Compact Design with ring terminal connectors 2. Standard and Custom Ring Terminal Sizes 3. Accurate and Noise Free readings with 100% Repeatability 4. Sensors Stability: Electrically, Magnetically and Chemically stable 5. Safety: Avoid Short-Circuit risk and protect Researchers and Test Environments 6. Easy to route cabling with Bundled Sensors 8

9. EV Battery: Pack Level Testing Key Benefits of Fiber Optic Temperature Sensors 1. Suitable for Air-Cooled and Water/Gel Cooled Batteries 2. Faster response time for accurate Thermal Profiling 3. Accurate and Noise Free readings with 100% Fiber Optic Sensors Repeatability 4. Sensors Stability: Electrically, Magnetically 1. Adjustable to place at different locations into and Chemically stable cooling chamber 5. Safety: Avoid Short-Circuit risk and protect 2. Leak Proof up to 50bar Researchers and Test Environments 3. Bundled sensors to optimize cable routing