As the global transition to electrification accelerates, BATSS is at the forefront of developing battery systems that are not only efficient but also safer and more adaptable. With a focus on addressing real-world industry requirements, BATSS is driving innovations in thermal, mechanical, and electrical domains.
This article delves into the cutting-edge electrical innovations being developed within the project, all following the Safe-by-Design methodology.
Electrical systems for the next generation of batteries
At the heart of BATSS’s electrical innovations is the design and development of an innovative Electrical/Electronic architecture. This layout integrates wireless communication and advanced sensing capabilities into an enhanced Battery Management System (BMS), allowing predictive maintenance and ensuring safer, more efficient operation.
BATSS’s modular design approach enables the system to adapt to various voltage levels, such as 400V and 800V configurations, through a novel DC/DC converter. This converter facilitates efficient voltage scaling without requiring high-voltage batteries, making it a cost-effective and flexible solution for diverse applications.
Wireless communication and enhanced sensing
A major leap forward in the project is the adoption of wireless communication within the BMS. This design eliminates the need for traditional wiring, simplifying assembly and reducing potential points of failure. Beyond communication, the project deals with advanced sensors, including ultrasonic-based technology, which provides real-time structural health monitoring of battery cells.
This innovation enhances the accuracy of battery performance tracking by monitoring cell aging and detecting potential issues such as internal imbalances, which could lead to safety hazards. These predictive capabilities are a cornerstone of BATSS’s commitment to creating safer battery systems.
Voltage scalability with DC/DC conversion
One of the standout developments is a high-efficiency, bidirectional DC/DC boost converter that ensures compatibility with various voltage levels ranging from 400V to 800V. Developed using wide bandgap materials, this converter technology ensures minimal energy loss while enabling the integration of scalable battery sizes for different vehicle configurations.
This breakthrough offers battery manufacturers and end-users the ability to tailor systems to their specific needs without compromising performance or safety, paving the way for a more flexible battery ecosystem.
Smart components integration
The BATSS project also incorporates innovative components to enhance system safety and efficiency. These include advanced power switches and integrated sensors within the battery pack, ensuring optimal thermal performance and reduced electrical risks. Furthermore, the use of sustainable materials and smart designs such as the FLEXcooler® demonstrates the project’s commitment to combining performance with sustainability.
The road ahead
By rethinking traditional electrical layouts and introducing state-of-the-art technologies, BATSS is laying the groundwork for next-generation battery systems that meet the highest standards of safety, efficiency, and adaptability.
As the project advances toward achieving TRL5 readiness, these innovations will be rigorously tested and refined to ensure real-world applicability. BATSS continues to exemplify how collaborative efforts can drive transformative change in the rapidly evolving battery industry. Stay tuned for further updates as the project redefines what’s possible in battery safety and performance!
