Our Sectors
Automotive
BATTERY STRATEGY
MOTORSPORT
eVTOL
MOTORCYCLE
LIGHT URBAN
OFF HIGHWAY
RAIL
MARINE
CLEAN ENERGY
INDUSTRIAL
OFFSHORE
Case Studies
AUTOMOTIVE
New Battery Pack Design
ESS worked in collaboration with a world leading engineering consultancy to provide subject matter expertise in review of an update for a new battery pack design for a US Automotive OEM
ESS provided technical expertise to steer the project to meet technical requirements and timing, review of CAD design to ensure the clients guidelines were respected, review of all engineering reports to ensure robust component selection and design guideline adherence
- Successful implementation of the design update
- Readiness for battery pack to enter serial production circa 2025
Cell DVP Creation and Management
A premium high performance electric vehicle manufacturer required support for cell development & validation along with integration of the cell within the module to deliver high volume production battery pack
ESS provided reviews of all vehicle & battery system requirements to generate cell level requirements, management of the cell production development, cell design and performance specification DV of cell (electrical, thermal abuse & ageing), and test jigs for selected format
- Cell DV, test procedures and test jig design within 6 weeks
- Test progress & data collection / post processing tracked & reported
MOTORCYCLE
High Voltage Battery Functional Safety
A prestigious British motorcycle brand required high voltage battery technical expertise to develop a new battery concept
ESS provided the expertise to develop the battery concept this included battery bench-marking, functional safety concept for prototype, battery pack requirements, developed DV for pack, module and cell, and identification of production partners
- Successfully implemented functional requirements & attribute targets
- Successfully completed real world prototype testing
- Battery design is being updated with final production supplier prior to design release for mass production
BATTERY STRATEGY
Battery Pack And Cell Structure Technology
- Future cell, module design and pack design trend review (CTP, blade cells, 48xx etc.)
- 4 main OEMs (China, Europe and US) and Teir-1 suppliers included
- Assessment of the impact of cell and pack structure on thermal management system, LCA, cost and safety
Li-ion Cell Roadmap Development
- Li-ion cell roadmap development for ultra high performance application (greater than 10kW/kg)
- 50 cell companies were assessed
- Identification of potential cell development partner for the application
- Identification of companies developing anode, cathode and electrolyte materials
Technical Review for Governmental Loan Application For Cell Manufacturing Facility
- Review and validate the technology maturity
- Evaluation of performance projections
- Identification of risks and possible mitigation
EV Technology Review
Electric vehicle battery technology white paper covering the following topics:
- Abuse behaviour
- Chemistry roadmap
- Module and pack roadmap
- Battery manufacturing
- Battery pack thermal management
- Battery failure modes and root causes
- Cell balancing, etc.
INDUSTRIAL
Design Review of Forklift High Voltage Battery
- Complete high voltage battery design review
- Suggested upgrade of battery module which could double the energy of the system, with minimum engineering development effort, without negatively affecting the ageing, abuse or safety requirements
Modularity study for Marine and Off-road/Off highway
RAIL
Signal Battery Pack Upgrade
A rail client required support regarding lead-acid battery failure for a signalling back up power system, they required identification of root cause of the failure and then develop a confirmation test & modification plan
ESS reviewed all the battery system data, carried out a full 8D root cause analysis to identify & confirm the cause including full system tear-down & investigation, and provided the final step of training for the technology to maximise lifespan of the battery
- Software updates to ensure suitable voltage and temperature
- Design of battery box to improve air flow, thermocouple & hardware location
- Improved logistics process to ensure quality of components prior to assembly
OFFSHORE
Battery Design and Manufacturing Review
- Development of Li-ion high voltage battery policies
- Performed design review of the battery pack and led the implementation of the suggested changes
- Review of manufacturing documentation e.g. assembly procedures, QA test equipment, manning, manufacturing location etc…
- Development of in-house modelling capability to more accurately size battery packs for tenders
Design Review HV Battery System
A British offshore energy company required a design review of their energy storage system along with implementation of the HV battery system polices and manufacturing processes
ESS provided a Li-ion battery awareness course for all employees to ensure knowledge awareness of energy storage systems. Also performing a design review of the energy storage system bringing forward areas for improvement and lead the design changes. Also reviewing manufacturing process & provide areas of improvement for goods inward, develop HV safety guidelines, processes & polices regarding shipping, storing, handling and disposing
- All employees trained regarding Li-ion battery awareness
- Design review and change implementation performed within 4 months
- Manufacturing review leading to several improvements to quality processes
MARINE
Design of HV Battery Pack
Our client required support for the design development of a high voltage battery pack, its modular architecture, its DV test development and management as well as the evaluation of manufacturing line equipment and NRE
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- ESS Developed a model to determine the unit cost for the battery pack including the manufacturing line equipment and its depreciation
- We reviewed the high voltage battery type approval test requirements and associated test procedures and developed the complete high voltage battery pack DV and associated test procedures
- We developed the RFQ for the DV test and identified the best suited test partner in terms of capability, cost and timing
EVTOL
HV Battery System and Safety Documentation
Our client required support to create high voltage fault tree analysis covering all components, they also required support to write the required HV battery documentation for CAA approval
ESS provided fault tree analysis covering mechanical, electrical, thermal and manufacturing causes. Development of HV pack DFMEA, AR-08-32 & battery systems description documentation, and HV battery safety declaration
- Approval / acceptance of AR-08-23 & HV battery system description by CAA
- Readiness for battery pack to enter serial production circa 2025
- HV battery safety declaration internally signed off to allow for ground test
- Review of HV guidebook
- HV fault tree analysis
HV Battery System and Safety Documentation
- Development of AR-08-32 document
- Development of high voltage battery fault tree analysis
- Review of high voltage battery DFMEA
- Review of high voltage battery A-sample DVP
- High voltage battery system description document
- High voltage battery safety description document
Contact Us
UK: +44 7860 938 573
ENERGY STORAGE SPECIALISTS LTD
5 Pepper Drive,
Burgess Hill,
RH15 9UZ,
UK