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High-Voltage Batteries

Development of High-Voltage Batteries Suitable for Series Production for our Customers

As an engineering service provider, invenio offers the holistic development of high-voltage batteries suitable for series production for BEVs and PHEVs. The scope of services can be realised in support of an existing development team or as outsourced system development for partial scopes. If required, on-site support is also possible.

Our services include:

Concept

Installation space analyses

Manufacturing-
suitable
construction

Drawing-
creation
(GD and T)

Simulation (FEM, Crush, Crash, CFD)

Optimisation (weight and costs)

Supplier-
support

Concept development includes analysis, goal description, application of concept methods, and evaluation. Through internal production locations for component scopes and partnerships with numerous suppliers, our developers can offer production-oriented development, drawing creation and supplier support.

Mobility
Dynamic Analyses

The optimisation of assemblies, the reduction of component costs, topology optimisations or simulations of static or dynamic scopes round off our internal development scope of high-voltage batteries.

Your Added Value Thanks to invenio

Intelligent invenio software (VT-DMU) for checking derivatives, distances and assemblies

Short-term production of prototypes to secure your test set-up

Independent technically sound second opinion on one's own specialist area

Standard-compliant drawings and specifications for enquiries with suppliers

From Individual Components to the Overall Development of High-Voltage Batteries

Our development scope includes the architecture selection of the battery cell, its contacting and storage. In addition, the connection of several modules – if modules still exist – and the control system to form an overall electrical system.

Depending on the concept, cooling plates or cooling lines can be integrated between the cells, modules or housings, or immersion cooling can be used for direct cooling. In a sealed housing, as a load-bearing or non-load-bearing structure of the vehicle, the energy storage system becomes a crash-relevant overall system.

We provide support in all development batches of high-voltage batteries up to series production and also with series production support.

Our expertise in the individual components:

  • Cooling plates

  • Immersion cooling

  • Cooling distribution

  • Contact

  • Expansion tank

  • Fastening

  • Special components with e.g. VDA or SAE coupling

  • Filling analyses and emptying

  • Volume determination and optimisation

  • Modular system for derivatives

  • Cast, extruded and deep-drawn components

  • Integrated cooling

  • Optimised for Crash and Crush

  • Weight-optimised

  • Consideration of EMC specifications

  • Waterproofing concepts

  • Assembly sequences

  • Cell contacting ZKS

  • Cell storage

  • Cooling of the cells

  • Tolerance analysis

  • Assembly

  • Waterproofing

  • Bursting and venting

  • Busbars / busbars (bent, twisted)

  • Cooling

  • Touch protection according to IP

  • Arrangement of relays, sensors and contactor

  • Tolerance calculation

  • Holder

  • Plastic housing

  • Wiring harnesses

  • Connection plates for LV and HV connectors

  • Rupture discs

  • Venting path

  • Sealing with solid and liquid seals

  • Design of O-rings

  • Moulded seals

  • Measures for Crash and Crush

  • Holder made of sheet metal, cast iron and plasticac

  • Weight optimisation

  • Holder for cooling, S-Box and cable sets

Manufacturing Process

Benefit from our independent opinion, concept development, evaluation, selection and constructive implementation of components. We can take over the preparation of enquiry documents, as well as the implementation of the enquiry and evaluation for decision documents and the coordination of suppliers.

Manufacturing processes and example scopes for traction batteries:

  • Aluminium extrusion for e.g. housings, modules and crash subjects

  • Sheet metal forming and stamped parts for e.g. enclosures, cell contact systems (CCS), holders and busbars

  • Plastic injection moulded parts for e.g. cooling lines, insulation components, plugs, housings and holders

  • Machining for e.g. contact pins, castings and spacer sleeves

  • Plastic pipes for e.g. cooling lines

  • Welding for e.g. cell contacts, housings and spacer sleeves

  • Sealing with e.g. liquid seals, moulded seals or O-rings

  • Aluminium die casting, chill casting and sand casting for e.g. holders, housings, connector interfaces and crash themes

YOU WOULD LIKE TO CONTACT US?

We will be happy to answer any questions you may have!

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