At Ion Lab, we are proud to have supported Modul System in the development of the Modul E-Power, an advanced energy storage solution designed to meet the demands of modern commercial vehicles. This project highlights our expertise in battery design, battery management systems, and thermal management technologies, ensuring the E-Power system performs reliably in extreme climates and challenging environments.
Modul E-Power
The Modul E-Power system is a cutting-edge energy storage solution that is integral to the performance of commercial vehicles. Ion Lab played a key role in supporting Modul System throughout the development process, providing expert input and custom solutions that ensured the battery system met all functional requirements.
Battery Design
Our involvement in the Modul E-Power project began with the crucial task of battery design. We were responsible for several key elements of the system, including:
- Sizing the Battery: We ensured that the battery capacity was optimally sized to meet the energy requirements of the vehicle while maintaining efficiency and longevity.
- Battery Chemistry: Selecting the right battery chemistry was essential to ensure maximum energy density, performance, and safety under all operating conditions.
- Battery Retaining Structure: We designed the structural elements required to securely house the battery within the system, ensuring stability and protection from external forces during operation.
- Battery Busbar Design: The busbars, which connect the individual cells in the battery, were carefully designed for minimal resistance and safe operation, optimising power flow within the system.
- Packaging of the Battery and Associated Components: We designed the overall layout, ensuring that all critical components, including contactors, current sensors, and fuses, were integrated into a compact and efficient package.
Battery Management System
The next vital component of the project was the development of the Battery Management System (BMS). Ion Lab designed and developed the hardware for the BMS, ensuring it could safely monitor and control the energy storage system. This involved creating both the control system and the firmware that managed the operation of the BMS, which plays a key role in balancing the cells, monitoring temperature, and providing real-time data about the battery’s performance.
Extreme Climate System
One of the key challenges with energy storage systems, particularly in commercial applications, is ensuring reliable performance in extreme temperatures. The Modul E-Power system was designed to operate in ambient temperatures ranging from -30°C to +50°C, a range that would challenge most systems.
To address this, Ion Lab designed and developed the heating and cooling elements necessary to maintain optimal operating conditions for the battery in these extreme climates. This included an integrated thermal management system, which helped regulate the temperature of the battery, preventing overheating or freezing, and ensuring the system could operate efficiently regardless of external weather conditions.