BESS sensor increaes battery safety and performance
Case study
Key challenges and obstacles faced by our customer:
Precise monitoring needs
More precise battery monitoring – that was the goal of a leading North American provider of scalable energy storage systems. The solution needed to complement existing thermistor temperature data with high-resolution measurements taken in real-time directly at cell level.
Real-time data
This real operational data allows maximum utilization of the temperature limits specified by the cell manufacturer. Warranty claims remain intact while increasing usable cell capacity without changing cell size or pack costs.
Data management
Robust data management and BMS connectivity for reliable communication.
Scalability
Scalable and adaptable solution that integrates into existing product lines.
Physical integration
Physical integration of on-cell sensors into existing battery pack design.
FLEXOO’s approach: precision meets scalability
Concept & Design
Created a sensor matrix that simultaneously measures cell-level pressure and temperature, transmitting real-time data to the BMS via defined interfaces.
Tailored integration
Engineered exact positioning of sensors, connectors, and FFC cables for integration into automated battery pack production.
Prototype & Production
Manufactured prototypes for functional testing and engineered the sensor matrix for series production using high-volume roll-to-roll printing processes.
Custom in-situ cell sensors that maximize battery capacity without compromising pack design
Precise positioning
Positioning is achieved through alignment with cell geometry. The sensors are positioned on the film to match the cell-to-cell spacing, while the number of temperature and pressure sensors corresponds to the pack width. The length of the sensor flaps is designed to match the pack depth, ensuring proper positioning of the measurement points.
BMS integration
The connector position and layout are designed to align with the BMS connection grid spacing, ensuring proper interface compatibility between the sensor system and the battery management system.
Reliable real-time data
Substrate and ink selection are designed for long service life, ensuring consistent performance throughout the operational period.
Most precise printed sensor
For pressure measurement, FLEXOO's Prime Mode Sensor was selected. This printed sensor is currently the most precise worldwide, making it the right choice for high demands on accuracy and response time for enhanced safety.
The sensors are calibrated to the precompression in the battery pack, ensuring optimal performance under real operating conditions.
Benefits delivered
Let’s start to work on your challenge!
Ready to take the next step? Reach out to our sales team today and discover how we can tailor our solutions to meet your needs.
