High Voltage Battery

The development of a cell cluster begins with the specified battery cell. Its format, chemistry, and performance requirements determine the basic module parameters as well as its geometry, dimensions, and tolerances. Other key influencing factors include electrical characteristics such as voltage, current, and internal resistance; heat generation during operation and fast charging; and mechanical properties such as stiffness, swelling, and mass. Additionally, the connection points for contact and cooling play an important role. Taken together, these factors form the basis for the design of the cell cluster architecture.

Cooling is an integral part of the cell module and is developed in parallel with the mechanical design. Its primary functions include the targeted dissipation of waste heat from each individual cell, ensuring the most uniform temperature distribution possible, and preventing hot spots. It also serves to limit cell temperatures during fast charging and under peak loads.

At the module level, cooling plates (under, beside, or between the cells), thermal pads, or gap fillers are typically used to improve thermal connectivity, along with flow guides for liquid or air cooling. Another important aspect is the decoupling of thermal function and mechanical preload.

The design is usually carried out using CFD simulations and is iteratively coordinated with the cell arrangement and the electrical connections.

Cell interconnections electrically link the individual cells to one another and also serve as the interface to the high-voltage level of the battery system. Cell-to-cell interconnections include both series and parallel connections, depending on the required system voltage. Key design considerations include the selection of appropriate conductor cross-sections, the design of busbars or flexible connections, and the consideration of thermal expansion and manufacturing tolerances.

In addition, the interconnection involves the design of the module’s high-voltage terminals (positive/negative) as well as the integration of HV cables, connectors, or busbars. In this context, particular attention must be paid to insulation, creepage, and clearance requirements in accordance with relevant high-voltage standards, as well as the mechanical protection of the conductors within the module.

A special focus is placed on low contact resistance, vibration-resistant connections, and reproducible contacting processes, for example through the use of laser welding methods.

The cells are securely fastened and guided within the module and arranged in such a way as to create defined force paths and uniform thermal contact. Key considerations include the design of the cell mounting, appropriate preload concepts, and tolerance compensation, with a clear separation between mechanical fastening and electrical function.

The challenge lies in the coordinated interaction of all functions: Contacting, cooling, and mechanics must not interfere with one another and must collectively be robust against crashes, vibration, and aging.

Validation is performed through mechanical, thermal, and electrical tests, as well as the analysis of failure scenarios. The result is a functionally integrated cell module that combines secure cell mounting, efficient cooling, and reliable contacting in a production-ready design.

The housing plays a central role, as it must meet a wide range of requirements simultaneously. In addition to safety - the top priority for high-voltage batteries - structural and crash design, lightweight construction, suitable manufacturing technologies, as well as sealing and corrosion protection play a decisive role.

Throughout the entire development and life cycle, all relevant scenarios are considered, with a particular focus on mechanical, electrical, and thermal safety, optimal system integration, high scalability, and a functionally optimized design.

The development of high-voltage components places the highest demands on safety, reliability, performance, and electromagnetic compatibility. Drawing on many years of automotive experience and in-depth technical expertise, we create efficient, robust, and production-ready solutions.

Our engineers and technicians possess comprehensive expertise across the entire development chain - from the initial concept to the validated end-to-end solution. This knowledge enables well-informed decisions and the targeted integration of complex high-voltage systems.

By combining practical experience, simulation-based design, and extensive validation on high-voltage test benches and in the EMC laboratory, we pursue a holistic development approach. This results in high-voltage components that meet both the high technical requirements and the demanding quality and safety standards of the automotive industry.

Using state-of-the-art simulation methods, we analyze and optimize high-voltage components early in the development process. Through the strategic use of simulations, we reduce development risks, shorten iteration cycles, and establish a solid foundation for subsequent implementation.

To validate our designs, we conduct extensive testing on our own and customer-specific high-voltage test benches. Here, we test high-voltage components under realistic conditions and verify their functionality, safety, and durability. The close collaboration between simulation, development, and testing enables targeted optimization and ensures high-quality development.

In our state-of-the-art electronics laboratory, we bring together development expertise, prototyping, and testing capabilities under one roof. We develop and manufacture custom measurement and test electronics specifically tailored to support your development processes - from the initial idea to a verified solution.

Repairing and modifying sophisticated electronic components throughout the entire development process is part of our daily work. We use a variety of soldering techniques to ensure production-grade quality.

Our certified experts (IPC-A-610 experts) conduct AVT reviews in accordance with customer standards or industry standards (e.g., DIN EN 60352-x, IPC-2221 through 2223, IPC-6011 through 6013, IPC-A-610, J-STD-030, etc.) of E/E components with regard to component selection, production-friendly design and layout, manufacturing quality, and technical cleanliness to ensure the production quality of the developed electronics.​

There is a particular focus on electronics for HiL (Hardware-in-the-Loop) applications:​

Here, we develop test bench adapters for the device under test (DUT) to enable realistic, reproducible, and automated test scenarios. Our solutions ensure seamless integration of your hardware into existing test environments.

In addition, we design and build fault injection boxes that can be used to deliberately induce fault conditions - a critical component for building robust systems and verifying safety-critical functions in accordance with ISO 26262.

In the field of functional safety, we provide comprehensive support by developing and executing both automated and manual test scenarios. This enables us to establish a solid foundation for verification, validation, and compliance with standards.

Ensuring the electromagnetic compatibility of electronic systems requires a structured approach throughout the entire development and testing process. From early-stage simulation and targeted EMC testing to the validation of complete systems, we support our customers with comprehensive technical expertise and state-of-the-art testing infrastructure.

Our services cover all relevant areas of EMC - from a specialized EMC test laboratory and methodical development models to cross-industry applications and high-performance test systems for sophisticated electric drives.

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An optimized package forms the foundation for an efficient system. Using our AI-powered methods, we quickly and accurately analyze how to optimally accommodate the maximum number of cells within the available package. At the same time, necessary components such as harnesses, fuses, control units, and connectors are integrated into the layout at an early stage. Particular emphasis is placed on accounting for tolerances and on a design suitable for assembly following the specified assembly sequence.

Coordinating the assembly sequence is just as critical as consistently considering the tolerances. Through targeted tolerance analyses of the overall assembly - always in relation to the specific function of each component - we ensure a coherent and robust design. We also take complex installation scenarios into account at an early stage to ensure a smooth and reliable assembly process.

Further analyses ensure reliable and safe operation. Among other things, we verify the required protection against accidental contact during installation, compliance with clearance and creepage distances, and operational safety even under critical conditions, such as in the presence of condensation or in the event of thermal runaway.

The geometric and functional integration of the high-voltage battery system into the entire vehicle is crucial for its use as an energy storage device. Tolerances, the connectivity concept, as well as cables, connectors, and other interfaces with surrounding assemblies play a central role in ensuring a safe, robust, and functionally sound integration.