Why Electric Vehicle Battery Temperature Matters to Ford

1. Temperature Sensitivity of Lithium-Ion Batteries:

• Lithium-ion batteries, commonly used in EVs, exhibit temperature sensitivity. Their performance, efficiency, and lifespan are significantly influenced by operating temperatures.
• The ideal temperature range for lithium-ion batteries is typically 15°C to 35°C1. Beyond this range, performance can suffer.

2. Impact on Battery Efficiency and Capacity:

• High temperatures increase the internal resistance of lithium-ion batteries, leading to reduced efficiency and capacity.
• Conversely, cold temperatures can also compromise battery performance, affecting the ability to hold a charge and reducing driving range².

3. Charging and Discharging Heat Generation:

• During charging and discharging cycles, lithium-ion batteries generate heat internally.
• Excessive heat can degrade battery materials, reduce capacity, and even cause safety risks.

1. Reduced Range:

• Extreme temperatures impact the driving range of EVs.
• Cold weather requires additional energy for cabin heating, while hot weather reduces battery efficiency, resulting in shorter distances traveled³.

2. Battery Degradation:

• Prolonged exposure to high temperatures accelerates battery degradation.
• Reduced capacity over time affects overall vehicle performance.

Interface Force Measurement Solutions’ innovative product from DDM, the DDM VCT High Precision Flow Sensor, plays a crucial role in effective thermal management by offering the following capabilities:

• Simultaneous measurement: The DDM VCT High Precision flow sensor can simultaneously measure coolant flow rate and temperature, providing valuable insights into the efficiency of the thermal management system.
• Multi-curve measurement: Combined with the VCA or VCA-T flow computer, the sensor can measure up to ten different fluid curves. This allows for precise monitoring of various coolant mixtures and their impact on temperature regulation. These mix ratios and their viscosity profiles are pre-programed in to the VCA flow computer at manufacturing. In this case the coolant is an Ethelyn- Glycol and water mix in three different mix ratios.
• User-friendly customisation: The system enables easy switching between different coolant ratios using an RFID tag, simplifying adjustments based on weather conditions or driving needs.
• Data acquisition: The VCA flow computer provides two 0-10v analogue output signals for flow rate and media temperature, allowing for real-time data collection and analysis. A linearised and viscosity-corrected flow rate output is generated in real time. TEDS data memories enable automatic set up of a connected data acquisition system.

By leveraging the DDM VCT High Precision Flow Sensor, EV manufacturers and operators can gain valuable insights into their thermal management systems, enabling them to:

• Optimise battery performance: Maintain optimal battery temperature for consistent power delivery and extended lifespan.
• Maximise driving range: Ensure efficient battery operation, leading to increased range on a single charge.
• Reduce maintenance costs: Proactive monitoring of the thermal management system can help prevent costly breakdowns and extend component life.

These solutions prioritising battery temperature control not only impact performance and longevity of batteries but also pave the way for a future of efficient, reliable, and sustainable electric vehicle transportation.