Electric Vehicle Battery Cooling - LG Chem Lithium Ion

We are now to the point where we are addressing electrical vehicle battery cooling. The LG Chem Lithium Ion batteries have an aluminum plate that we will utilize for cooling. New cooling plates are added with thermal paste. The rear battery box also starts to take shape.
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[@JerryRigEverything]

This is awesome. Super pumped to see this thing in action. You explain things very well.

[@ElectricSuperCar]

Thanks!!! Super big fan of yours!

[@offapparatus365]

Your progress is impressive. Starting to think your day job might have "engineer" in the title ;) Excellent choice of battery btw.

[@ElectricSuperCar]

Thanks friend!

[@Sanjayadon]

This where I first stumble across your channel! You did shiploads of work for the past 3 years!

[@ElectricSuperCar]

Welcome to my channel!

[@speedracer8367]

Time to complete the second trimester, we want to see this running!

[@gladegordon3624]

Such a great project! I've been considering battery cooling options for my own EV conversion and thinking of doing something similar. Thanks for sharing.

[@ElectricSuperCar]

Thanks Friend!

[@matthewtaylor3351]

Watching from Australia. We get very hot days in parts, over 40 degrees C. Cooling matters.

[@ElectricSuperCar]

Thanks for watching!

[@nickhannay4090]

I’ve an ex-Army ‘89 110 Landrover, looking forward to seeing your solutions.

[@mitchhodge5903]

Nice system, where did you get the cooling plates fabricated?

[@ElectricSuperCar]

I had a machine shop make them. I also put the CAD files in GrabCad

[@suntzu6122]

Its been a hot minute since this video. Has battery cooling gone anywhere?

[@rogercrier]

Are you going to monitor every thermistor, or just a few like Zeroev are doing on their LG chem powered MX5? I need to monitor 64 thermistors in 32 LG Chem modules☹️ what monitoring system will you be using?

[@ElectricSuperCar]

Hey Roger, the LG Chem modules that I have state that they have 4 thermistors per module (16 cells). After trying things out, they only have 2 working thermistors per module. I am monitoring one thermistor per module. I figure if there is a bad cell in the module the whole module will heat up pretty quick. I am using the dilithium design BMS which also monitors the thermistors. Good luck with your application.

[@thermalinterfacematerialsm2755]

I wonder if the graphite sheet or silicone thermal pad can be used for the battery cooling.

[@aiev5545]

Hi! Nice build! What are those LG modules? Where did You got them?

[@ElectricSuperCar]

lg chem lithium ion battery - 60.8v, 2.6kwh. They are used in the Chrysler Pacifica. You can order from Thunderstruck EV or EV West.

[@ArthurTheLibraryDetective]

@@ElectricSuperCar 😎..is.This LG...like 'Life is Good'...the phone??

[@qckslvrslash]

Curious where you ordered the cooling plates from. I have lg chem batteries going into my build and have been wanting to actively cool them but nothing exists off the cheslf and I haven't been able to find a place to make plates like you have.

[@ElectricSuperCar]

Same story here. I designed them and had a machine shop make them.

[@qckslvrslash]

@@ElectricSuperCar May I ask what shop. I have been trying to find a shop to machine the ones I have designed an locally I have been struggling to find a company.

[@ElectricSuperCar]

@@qckslvrslash I used www.ztltech.com They quoted and delivered quite a bit less than I could find locally.

[@anshumanparhi5963]

Nice build!! Can I know where did you get the silver cooling plates?

[@ElectricSuperCar]

They are custom machined

[@anshumanparhi5963]

@@ElectricSuperCar from where did you customise it?

[@ElectricSuperCar]

@@anshumanparhi5963 I designed it and had a local machine shop fabricate it.

[@bawfuls]

Checking in from a couple years in the future, how did this cooling solution work out for you? Was it adequate to manage heat at high discharge rates for extended periods?

[@ElectricSuperCar]

Thanks for the comment! Always good to check after a few years. For my particular application the cooling was overkill. I can drive my system pretty hard and my battery temps do not very high at all. I think I would drain my batteries before I am in danger of overheating. It is always good to know that I am being overly cautious. To answer your question...yes this system works well

[@HavokBWR]

@@ElectricSuperCar does the cooling system allow for fast charging?

[@ElectricSuperCar]

@@HavokBWR It could, but I do not have my system set up for fast charging

[@tahoe9813]

You need to run your cooling lines in parallel. If you do it in series, your batteries at the end of the loop will not cool properly.

[@ElectricSuperCar]

Yep! I re-ran the lines. Thanks for the comment!

[@kingersgarage]

What temp are you aiming to keep the batteries at? How about heating in cooler weather? How has this system worked for you?

[@ElectricSuperCar]

Ideally 5⁰-20⁰C. Operationally fine 0⁰-45⁰C. For my application (open air roadster) I wasn't too worried about the colder temperatures, as I would not want the car out when it is cold anyway, so I wasn't looking too closely at heating options. For me this system worked great, and probably overkill as it proved hard to elevate the battery Temps with aggressive driving.

[@kingersgarage]

@@ElectricSuperCar awesome! Thanks for the info. Hard to find proper cooling information for these batteries.

[@kingersgarage]

@@ElectricSuperCar just curious on your track days or charging what’s the highest temp you have seen? They seem more robust and less sensitive then the Tesla cells.

[@ElectricSuperCar]

@kingersgarage I would say it is like running your cordless drill non-stop until the battery runs out. Then feel the battery. It is barely above ambient temperature. 5⁰-10⁰C above ambient is the highest I have seen

[@kingersgarage]

@@ElectricSuperCar super helpful. I like the new project! OE interior will be so nice and you can just worry about getting it to fly…silently of course! I might reconvert my Rx7 from a v8 monster to dual MS motor set up so I’ll be watching!

[@FranciscoAlves-om2kj]

Great job. What is the overall distance that you'd think you'd make in one charge? I have a similar project in mind btw. Cheers.

[@ElectricSuperCar]

Francisco, good to hear from you! I expect around 100 miles.

[@FranciscoAlves-om2kj]

@@ElectricSuperCar Thank you! Last question: would it be realistic to achieve a minimum of 600 miles, and ideally 800 miles, if you have enough space and volume, (5 feet width by 7 feet length by 14 inches in height), to accommodate the batteries, cooling plates, etc? I guess fire is a risk though, right?

[@ElectricSuperCar]

Anything is possible. Tesla model S use a 100kWh battery pack and can go ~300 miles with a ~4000 lb car. You would need to balance the equation to either have a much lighter car or a much larger battery pack. I am using a ~32kWh battery pack and ~2000 lb car.

[@FranciscoAlves-om2kj]

@@ElectricSuperCar I want to open a new KZbin channel where I showcase some architectural and design-based projects of mine as well sketching lessons soon and have a few videos ready. One of these projects is the design of an electric motorhome, which I would love to actually build some day. The idea is to buy a second hand Mercedes Vario and convert it. Now this specific Mercedes has a tare of roughly 10500 to 16500 lbs. However I should probably take that information with a grain of salt, as I got this information straight from a website with technical information of the truck: www.trucklocator.co.uk/blog/truck-and-trailer-news/2013/10/the-mercedes-vario-a-trucklocator-review So I'm not too worried about space for battery storage. Also, I realize that because this won't take many live loads in the form of people, which is what it was meant for, it will take quite a bit of static loads such as the bed, the couch kitchen stuff, etc. So what I'm worried about, like "The Tyranny of the Rocket Equation", I realise that I have to put the weight of the batteries, (which will undoubtedly be a lot of them), the weight of people and the weight of the entire bus into the equation. My other worry is fire. As there would probably be a lot of these batteries in one place, (or maybe I can place them in two separate locations), I want to ensure these are cooled appropriately and make sure there is a Fire-Resistant barrier all around them in case there is a short circuit of some kind. The last thing I'd like to include, but it would be the least of my worries is to research on the cooling system for super-charging. Don't want to boondock on a charging station overnight every time I hit the road. It's really something that I'd like to build. I've purchased the Technical CAD drawings for the Mercedes and just after I'm done preparing and editing a few videos, I will begin draughting the project. In any case, thanks for any tips and your project is going from strength to strength it seems. Stay well buddy.

[@FranciscoAlves-om2kj]

P.S. I guess with something that heavy it would be more important to take the potency of the motor into question more so than battery quantity? It is the powerhouse of the machine and it is what will move the whole thing.

[@Moppemannen_mattias]

Nice!. But I think that its better too connect the front battery parallel. You connected it in serie, but then the first battery will heat up next battery.....

[@ElectricSuperCar]

Mattias, good to hear from you again. I have not yet connected any batteries.

[@Moppemannen_mattias]

@@ElectricSuperCar I mean the cooling hoses.

[@ElectricSuperCar]

@@Moppemannen_mattias Ahh, that makes more sense. Thanks

[@rich8669]

Where did you pick up that cooling plate from?

[@ElectricSuperCar]

It is custom

[@dieselphiend]

Is it not possible that we are demanding too much current from these batteries for EV usage? They use midtier high drain cells for EV's. Why not use high drain cells? They'd sacrifice some capacity, but shouldn't need cooling. Keeping them warm in the winter, however, is a different story.

[@InspireCNC]

thats not a good design for coolant. You dont have an effective amount of track in the plate to disperse heat. Also it should have been designed with a channel around the tracks for an o-ring to seal the coolant in. It will leak for sure.

[@ElectricSuperCar]

You may be right. If (when) it leaks, I will have to give your suggestion a try. Thanks for the insight.

[@niffrig]

@@ElectricSuperCar Just test the plate with an open loop to the radiator and pump with everything unmounted. If its low enough pressure you might get away with it.

[@ElectricSuperCar]

You read my mind. 👍

[@InspireCNC]

​@@niffrig thats a very simple test that doesn't ensure much. you have to consider the pressure from a closed loop system, vibrations and stresses applied to the plate while the car is in operation.

[@InspireCNC]

a better more reliable design would be running copper tubing as coils, encapsulated with epoxy, or just filled with thermal paste inside an aluminum housing.

[@santoshmariguddi7263]

You can uses vacuum brazing cold plate for Cooling

[@ElectricSuperCar]

Thanks for the comment

[@santoshmariguddi7263]

In india our company is manufacturer vaccum brazed cold plate

[@indrajithn7094]

Which is the best way for cooling ev battery

[@santoshmariguddi7263]

@Mohana Kumara ML Thermovac aerospace Pvt Ltd

[@Ryukachoo]

Considering the thermal paste was the cause of all your battery was, I imagine you look back on this video and scream at yourself

[@ElectricSuperCar]

If I would have known about the thermal pads...yes it would have saved so much time and heartache 🥴

[@Ryukachoo]

@@ElectricSuperCar so, if you could do it again what would you do? Stick on thermal transfer pads instead of paste? Redesign the chill plate? And if so into what?

[@ElectricSuperCar]

@@Ryukachoo do the thermal pads. They conduct heat but not electricity

[@nicholaslandolina]

How are you cooling this

[@ElectricSuperCar]

These cooling plates, a pump, coolant, and tubes to connect them all

[@kimolai9206]

is this the battery of Renault Zoe bro ?

[@ElectricSuperCar]

This is an LG chem from a Chrysler Pacifica (hybrid minivan)

[@polyteky]

what coolant did you use

[@ElectricSuperCar]

Probably best to use something made for EVs. Zerex G48

[@lijitao7153]

This Dana make .

[@tommac5411]

Introductory graphics suck and run too long.

[@ElectricSuperCar]

Yes. Comments like yours helped me improve. Recent videos are better kzbin.info/www/bejne/m3XVl5d3fdafpLc