Electric vehicles use large batteries to store energy. The energy flows into the battery pack to power the vehicle. We all know that the flow of current causes heating in the battery cells. The higher the current flows the more the heating effect will be.
It is known that the performance of Lithium-Ion battery cells is greatly impacted by their temperature. When an Electrical Vehicle battery is too cold or too hot, it will lead to permanent and extreme damage to the cells or accelerated degradation. For example, most lithium battery cells cannot be fast-charged when they are less than 5C degrees. Plus, Lithium cells also begin to degrade quickly when their temperature is above 45C degrees.
Here we introduce you to the Best Electric Vehicle Battery Cooling System – a Compact Plate Liquid Chiller. RIGID Plate Liquid Chiller is designed to circulate chilled water or liquid throughout the tubing to get optimal local cooling performance. Effective cold plate design typically leads to a higher pressure drop across the battery pack due to the long length and narrow coolant channels required.
EV Battery cooling – Thermal fins cooling
Plate Liquid Chiller System – Plate-P Type Heat Transfer System 12V / 24V / 48V
The Plate-P type chiller module is the circulatory cooling subsystem. The plate chiller unit is not only facilitated installation but also assures end users having an excellent cooling performance with a tiny refrigerated compressor. The miniature cooling system especially applies to a microclimate cooling system and provides extraordinary cooling capacity for the extremely hot environment and confined spaces.
- 4 kgs/8.8lbs;
- Size: 330x200x150mm;
- Compact & portable water cooler;
- 12V/24V/48V mini compressor to enable peak performance.
Have you ever driven an electric vehicle? Although they still haven’t reached the peak of their popularity, more individuals and corporative users are starting to use these vehicles every day. They are the future of the industry, which is why manufacturers are trying to optimize their performance and implement innovations.
A crucial component of every electric vehicle is its battery. Since these vehicles require large batteries, that means you need to find a way to counteract overheating. RIGID Chiller System DV1910E-P is a cooling solution that can maintain the optimal temperature of the batteries to maintain their consistent performance.
DV1910E-P Liquid Chiller Module – Overview
After years of research, RIGID came up with a reliable solution that can be used throughout many industries. DV1910E-P is suitable for any application that requires a liquid loop cycling refrigeration. The great thing about this product is its ultra-compact size and high reliability. Since it is compact, it is perfect for moving around, which makes it the best thermal cooling system out there. The liquid chiller DV1910-P is ideal for small liquid cooling where space and weight are critical.
The overall size of the chiller DV1910E-P is 9.8 x 6.3 x 5.3 inches (25 x 16 x 13.5 centimeters). The compact size means that the cooling system won’t take away a lot of space, which makes it an excellent choice for electric vehicle battery cooling. It will be easy to position this chilling product the way you want so that it doesn’t affect the other installed components.
The weight of chiller DV1910E-P is only 8.8 pounds (4 kilograms), which is another important factor that contributes to mobility. DV1910E-P utilizes DC 12V voltage, which better matching many kinds of EV power supply, and that implies it is energy efficient, especially since it plays a vital role in the overall functioning of the product. You can also find the product in versions with 24V and 48V voltage.
The capacity of the RIGID’s cooling solution might vary depending on your needs. If you need modest capacity, go with the low 100W option. But some electric vehicles and other applications might require a higher capacity. That is why the company designs its liquid chiller modules with a maximum capacity of up to 500W.
You shouldn’t worry about the noise because the system utilizes a brushless inverter dc rotary compressor. The mini dc compressor’s noise level manages to stay under 40dBA, which is quite impressive. As for other specifications, the ranges of operating ambient and coolant temperatures should be between 32F and 122F (0C to 50C).
Here’s the cooling performance chart of liquid chiller DV1910E-P:
Plate Liquid Chiller DV1910E-P Cooling Performance
How Does RIGID Liquid Chiller DV1910E-P Work?
DV1910E-P is a plate and frame evaporator cooling solution. That means it utilizes a heat exchanger that contains metal plates. Their task is to divert the heat away from one fluid to another. It is a huge benefit and an important advantage that this heat exchanger has over conventional units.
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Furthermore, the liquid chiller works by utilizing the proven R134A coolant. You can find that compound in many other refrigerating solutions as it is frequently used throughout many industries. That means RIGID goes with a proven formula packed in an innovative new design that brings even better results.
RIGID chiller modules also contain a brushless mini DC compressor, as well as a driver board, filter drier, condenser, and other required components. The important thing to note is that all these cooling parts are built-in-one together, which means that you will receive a complete cooling unit including R134a refrigerant. Users only need to connect a dc power supply and run it. No piping, no engineering. RIGID experienced engineers spent years working on the design to come up with an innovative solution that maintains maximum performance while keeping size and weight as low as possible.
Small Mini BLDC COMPRESSOR – RIGID HVAC CO., LTD
That particular construction is what makes this chiller system perfect for battery pack cooling in electric vehicles and other applications. The unique design of skilled engineers is a guarantee that battery cooling will be solved efficiently.
Although it is compact-sized, this chiller system manages to be extremely efficient and does its job above expectations. The reason is the brushless inverter compressor, which enables liquid circulation. RIGID liquid chiller is fully charged R134a coolant to circulate through the system, which is connected to the battery pack or another application.
DV1910E-P plate liquid chiller offers significant benefits. It prevents a temperature gradient from developing between the layers of the cell, furthermore, the chilled liquid in the loop keeps the battery maintain a nice temperature constantly.
The refrigerant goes through the system and diverts the heat away from the battery. Once it removes heat, it continues circulating and returns to the base of the cooling device. That is where it cools down while continuing to circulate. That is how these cooling systems secure constant performance and maintain battery temperature at an optimal range at all times.
Why Choose RIGID – Cooling Specialist?
Want to know all RIGID compact cooling modules, Click Here!
RIGID has been in the business of designing compact-sized cooling solutions for a long time. We’ve gathered experienced engineers skilled in refrigerating systems and ready to revolutionize the market by offering innovative products. That enabled RIGID to become an industry leader when it comes to groundbreaking solutions and technology development.
Besides standard compact cooling systems, RIGID also focuses on delivering chilling solutions tailored to the customer’s needs. It is why RIGID Chiller System DV1910E-P comes with adjustable cooling capacity, and multiple DC inputs available. These are only some of the features that can be tailored to your application. The compact cooling system designed by RIGID is hermetically sealed, and it can be both portable and stationary. Its benefits are also a low noise level, small footprint, and minimal weight.
Customers can rest assured that each cooling solution is tested because RIGID applies strict quality control during every step of the manufacturing process. That is the best way of achieving the company’s high standards and ensuring maximum reliability, durability, and performance. The great thing about RIGID is that the sales team listens to the requirements of the consumers. We invest plenty of time, effort, and other resources into research and development. Combined with the user feedback, that allows us to come up with improvements and update our products constantly. It is that approach that established the company as one of the most reliable in the industry.
RIGID makes sure to use high-quality components in its chilling systems. One of those components is the brushless dc compressor, then we adopt coolant R134A, arguably the most popular refrigerant in the world. You can see this refrigerant in a large number of air-conditioning and refrigeration applications, including both domestic and corporative use. The reason why it has become a favorite among manufacturers and users is that it has a far less damaging effect on the ozone layer than CFC refrigerants, and its cooling capabilities are admirable.
The full name of the compound is tetrafluoromethane, and it comes from the HFC refrigerant family. R134A is capable of answering medium and high cooling demands, and it can help to reduce the temperature in various applications. You will often find the compound in air-conditioning in homes and cars, but also centrifugal and other industry chillers.
Why Is the RIGID Chiller System the Best Choice for EV Battery Cooling?
Now that you are familiar with the basic specifications of the RIGID Chiller System DV1910E-P, you might already be aware of the product’s potential. The careful design, and taking care of every detail is what makes this small cooler stand out from the competition. However, you might be wondering if it is the best choice for electric vehicle battery cooling.
The important thing to note is that electric cars and other vehicles use plenty of energy. That is why they need huge batteries because that energy needs to be stored somewhere. Now, the energy that powers the vehicles comes from the battery pack that discharges it. We measure this energy by using voltage and electrical current.
Once the current flows, the battery cells and the systems that connect them become heated. The heat increases proportionally to the square of the current that is multiplied by the interconnection systems and internal cell resistance. If that’s confusing, just think that the more current flows through the battery cells, the more their temperature increases.
The problem is that heat affects the performance of the batteries. If they are heated too much, and the temperature goes over the optimal range, the battery performance will drop. It is interesting to note that the same happens if the temperature goes below the recommended range, which implies batteries are also affected by the cold. Extreme temperatures can affect both the performance and durability of the battery cells because they can shorten their lifespan and cause damage that compromises optimal functioning. For example, if the batteries are made from lithium, you can’t charge them under 0C, and they start deteriorating if the ambient temperature is over 45C.The biggest challenges for battery design are energy density, power density, charging time, life, cost, and sustainability
Now, electric vehicles are a fairly new occurrence on the market. Although they have been around for a while, manufacturers are still perfecting their performance and improving overall quality. That is true for all-electric vehicle components, and that includes battery packs.
As we already established, the performance quality of the battery packs depends on maintaining the optimal temperature. Even the biggest batteries used a couple of decades ago didn’t require additional cooling. That is because the current flow and the pack size were not too big when compared to the pack’s overall capacity. However, battery size and performance increased over time. That lead to higher requirements in terms of cooling, which led to a discussion of special thermal management techniques. It is why manufacturers now use different methods to keep the battery pack at optimal temperatures the entire time.
Now, you will find three techniques used to cool down batteries:
Forced or passive air convection:
* Using dielectric oil to flood the battery, and pump it out to a system for exchanging heat
* Using a water-based coolant or special liquid to go throughout the passages in the battery structure and remove the heat
The temperature affects the battery pack performance, but recent research proved that the cooling method could also affect whether the battery cells will perform well.
While air cooling is the simplest method, this basic chilling technique is not a smart choice for advanced applications, such as electric vehicles. The truth is that you might get some passive air cooling while using the vehicle because of the airflow while driving. However, that is far from enough to meet the cooling requirements of a battery that generates that much power. Even if you are using an air cooling system, the chances are you won’t get adequate results for electric vehicles.
The experts conclude that the chilling system for an electric vehicle battery needs to be highly targeted. That is because a temperature gradient might develop between cell layers, and that is something that the cooler needs to prevent. It is the only way to preserve the battery’s lifespan and maintain optimal performance. That was the main consideration RIGID had when designing their DV1910E-P chiller system.
The idea is simple – connecting the product to the battery pack in your electric vehicle allows a special refrigerant to extract heat from the battery. Since the liquid is circulating, it drives the heat away into the heat exchanger. That is where the liquid gets cool again, and the process is repeated to extract heat consistently. It is how these coolers manage to maintain the optimal temperature of the battery at all times. That implies that chilling systems won’t compromise the battery pack’s performance for a second, which will maximize its longevity.
Some manufacturers already use a medium in their cooling plates. For example, Chevy went with a water-glycol mixture, while BMW utilizes a refrigerant. However, testing proves that RIGID Chiller System DV1910E-P is more reliable than these solutions. That is why companies like Workhorse have already decided to apply this cooler to their new delivery trucks to ensure optimal thermal battery management.
Workhorse Inc. USA Selected RIGID Chiller System for Electric Vehicle Cooling
Workhorse, a US-based company EV C1000 delivery truck
Workhorse Group Inc. (NASDAQ: WKHS), is an American technology company focused on providing sustainable and cost-effective electric mobility solutions to the transportation sector.
“Original Equipment Manufacturer (OEM) of Class 3-6 Workhorse brand medium-duty truck chassis. Its 200,000 sq. ft. assembly plant enables it to build the tried and true W62 chassis and the new, narrower-track W88 chassis at price points and performance specifications sure to be attractive to fleet purchasers.”
“The Delivery system is a custom-built, high-efficiency octocopter-based delivery UAV that is fully integrated with our line of electric/hybrid delivery trucks. The HorseFly system is designed to conform to the FAA guidelines for UAV operation in the U.S. Most notably, being fully integrated with delivery trucks, the system is designed such that a driver or driver’s assistant can maintain the line-of-sight operation of the UAV delivery process.”
RIGID is proud that an increased number of companies are showing interest in their cooling systems. We are privileged to work with Workhorse, a US-based company that is working on its new C1000 delivery truck. These vehicles will be powered by electricity and built with composites to provide maximum value for the users.
The delivery trucks will utilize RIGID DV1910E-P for thermal battery management. The task of the chilling system will be to keep the batteries cool and ensure their consistent performance and maximum durability. It is a crucial feature because a delivery truck is a vehicle that requires a high-performing battery to run. That is why it was crucial for Workhorse to implement a reliable chiller system to get the performance they want. The company succeeded with RIGID’s cooling solution.
EV C1000 is an electric delivery truck that features a low floor with a 6,000-pound payload, and adjustable shelving options. The vehicle features LED lighting, as well as independent front and rear suspensions. The product is also equipped with modern safety systems and driver feedback that comes with telematics.
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The construction of Workhorse C1000 is admirable. The frame is resistant to rust, and the manufacturer also implemented an aerodynamic body. The driver has excellent sightlines, which is important to prevent potential accidents while on the road.
The important thing for drivers is also that C1000 is easy to maintain. For example, you can detach the electric motor and rear suspension assembly in seconds, as it only takes moving a few bolts. Once you remove the assembly from the vehicle, it will be easier to perform the necessary repairs. You can even keep the truck on the road when installing the replacement cradle.
Workhorse is set to revolutionize the market with its new electric vehicle. The huge interest that the market already expressed in the Workhorse’s delivery truck is a clear indicator of that. United Parcel Service (UPC) is the world’s largest delivery company, and they recently announced a plan for purchasing 950 electric vehicles from Workhorse. Although Workhorse is a startup in the electric vehicle industry, that proves their delivery truck is highly anticipated among users. It is interesting to note that this should be the biggest order of Class 5 electric delivery trucks in the United States.
According to some estimations, it will take about $6 to pass 100 miles with this electric delivery truck. Thanks to the high-performing battery packs, you can travel a large distance before the battery needs to recharge.
During that travel, RIGID Chiller System DV1910E-P will be in charge of keeping the batteries at an optimal temperature. That reliable cooling solution will ensure the maximum performance of the product. It is a demanding task, but one that this chiller system can fulfill because it is made of the highest quality components.
Final Thoughts
The electric vehicle industry is coming up with innovative solutions every day. However, the performance of these vehicles is directly related to battery packs. If you want to keep the batteries working properly, it is vital to prevent overheating and maintain the temperature at optimal ranges.
That is why RIGID designed a DV1910E-P cooling system that extracts heat and maintains electric vehicle performance. The chilling system has many other potential applications because compact sizes ensure a high level of versatility.
If you are interested in using a cooling solution for your upcoming product, do not hesitate to contact RIGID. We offer compact cooling systems that are highly customizable and can be tailored to various applications. You can reach RIGID by sending an e-mail to info@rigidhvac.com or giving them a call at +86 579 8837-9768 to check out why partners and customers working with the company are delighted with their work!
