Customer case studies

Customer case studies

Understand what we can do for you through customer case studies: immersion cooled battery programs, vehicle integration, air conditioning system testing.

Immersion cooled batteries for a car manufacturer

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Immersion cooled batteries for a fluid manufacturer

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Heat pump testing for a fluid manufacturer

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Immersion cooling of batteries

Battery module busbars Technician working on a battery test bench

The customer is a European car manufacturer in the top 5 worldwide

Duration of the program: 22 months in 3 phases

Cell type: NMC > 60 Ah

Role of EXOES before the beginning of the program: participation in the drafting of the specifications, advice and sharing of experience on the definition of the evaluation and validation program of different technologies and different immersion cooling fluids. Support for decision making on the split between simulations and real tests.

The customer’s need

-Define the ideal fluid for monophasic and diphasic cooling
-Carry out an evaluation of the series cost of a complete cooling system according to different cooling architectures
-Calculate the impact of different immersion cooling architectures on the mass of a vehicle
-Design a representative battery module
–Test this module in performance
–Test the module safety with an abuse test (nail puncture test)
–Define an ageing test protocol with several fluids
–Characterize the cell to determine the maximum C-rate at a defined maximum temperature
-Design and manufacture electrical heating elements representative of the heat losses of tomorrow’s cells and assemble them into modules
-Carry out thermal performance simulations and correlate them with test bench measurements

EXOES had to adapt its test benches, develop new battery module prototypes, carry out the tests and analyse all the data, carry out the simulations and correlate the simulations with the test results obtained. In addition to these technical activities, an analysis of the projected costs in series as well as a definition of the specifications of the ideal fluid were carried out by our teams.

Immersion cooled batteries for a fluid manufacturer

Technician analysing test results Battery module cooled by immersion

The customer is a US based fluid manufacturer among the worldwide leaders

Duration of the program: 15 months in 2 phases

Role of EXOES before the beginning of the program: complete definition of the evaluation and validation program of different immersion cooling fluids.

The customer’s need :

-Compare the performance of different fluids for monophasic and diphasic cooling by carrying out tests on existing prototypes and test benches at EXOES

-Evaluate the series cost of a complete cooling system for a given module architecture.

-Publish a white paper for car manufacturers explaining how to fill and drain the fluid and clean the module and battery pack

-Define the sensitivity of the fluid to water absorption and pollution

-Characterize fluid mixtures and define the method for mixing and ensuring homogeneity

-Build a battery module for comparative abuse tests between different fluids

EXOES set up a complete technical roadmap for the battery fluid validation process. We had to develop new test benches and adapt existing ones, develop new battery module prototypes, carry out the tests and analyse all the data. An analysis of the projected costs in series was performed as well as a definition of the specifications of the ideal fluid were carried out by our teams.