Automotive Battery Thermal Management Case Study Highlights
Challenge
- Inconsistent and inaccurate application of thermal interface material (TIM) onto cooling plates.
- Potential overheating issues that reduce battery lifespan.
- Maintaining high-quality standards while scaling production for an application requiring high volumetric flow, high throughput, a custom dispense pattern, and multiple dispense surfaces.
- TIM is highly abrasive and damaging to equipment.
Solution
- Advanced Simulation Technologies: Utilized simulation techniques to model and optimize the TIM application process.
- Automated Dispensing System: Developed a highly automated system using advanced dispensing technologies for precise and consistent TIM application onto cooling plates.
- Real-Time Monitoring: Integrated monitoring and control features to maintain performance and quality.
- Proof of Principle (POP): Validated the feasibility and effectiveness of the solution before implementation.
Results
- Achieved consistent and precise TIM application to optimize overall performance and quality of EV batteries.
- Reduced overheating risks and significantly extended battery lifespan.
- Increased production capabilities and maximized uptime and efficiency while meeting quality standards.
- Streamlined maintenance with accessible components and real-time monitoring.
Company
Major Automotive Manufacturer
Industry
Automotive
Region
Europe
Customer
A major European automotive manufacturer that produces a wide range of vehicles, including electric vehicles (EVs).
Challenge
Inconsistent Thermal Interface Material Application
The automotive manufacturer faced significant challenges in managing the thermal interface material (TIM) application onto the cooling plates for their electric vehicle (EV) batteries. Ensuring precise and consistent application of TIM is crucial for optimal thermal management and battery performance.
The manufacturer’s existing TIM process lacked the necessary accuracy and efficiency, leading to potential overheating issues and reduced battery lifespan. To meet the demand for EVs and grow its production capabilities, the automotive manufacturer needed to refine its TIM application process to ensure high-quality standards.
Solution
The ATS Industrial Automation team began by thoroughly analyzing the TIM application process and collaborating closely with the automotive manufacturer to understand their specific requirements and challenges. Using advanced simulation techniques, the team modeled the TIM application process to identify areas of improvement, enabling precise adjustments and optimizations to the final solution before implementation. This virtual simulation helped predict potential issues and refine the process to ensure accuracy and efficiency.
To meet the unique requirements of the TIM application, the team designed custom tooling for the dispensing system. A custom nozzle was developed to dispense 5 rows of TIM, precisely aligning with the main heat sources on the cooling plates. This customization was critical for accommodating the product’s specific geometry, ensuring that the TIM was applied accurately and consistently.
The decision to use 5 strips of TIM instead of one provided several advantages. It improved thermal management by ensuring even heat distribution across the cooling plates, reducing the risk of hotspots, and enhancing overall battery performance. Additionally, this approach enhanced the structural integrity of the TIM layer, contributing to improved battery reliability and a longer battery lifespan.
The ATS Industrial Automation team developed a highly automated system for applying TIM onto the EV battery cooling plates, utilizing state-of-the-art dispensing technology for consistent and precise application. Real-time monitoring and control features ensure optimal performance and quality throughout production. Furthermore, precision profilometry ensured highly accurate dispense volumes and bead termination geometry, not possibly with less sophisticated time and pressure solutions. A Proof of Principle (POP) study was also conducted to validate the solution’s feasibility and effectiveness, ensuring it met the required standards for successful implementation in the production environment.
Results
Implementing of the automated TIM application system delivered outstanding results for the automotive manufacturer. It significantly improved the TIM application’s consistency and precision, enhancing the EV batteries’ thermal management and overall performance. This advancement reduced the risk of overheating and extended the lifespan of the batteries. Additionally, it helped boost production capabilities, allowing the manufacturer to meet the growing demand for EVs while maintaining high-quality standards.
The team incorporated several optimization strategies to address common maintenance challenges such as nozzle clogging, component wear, and frequent calibration. The automated system was designed with easy-to-access components for quick maintenance and replacement. Real-time monitoring and control features helped detect and address issues promptly, minimizing downtime. Furthermore, to use of high-quality materials and advanced dispensing technology reduced the need for maintenance, ensuring efficient and reliable operation.
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