I-Detekt

Intelligent battery protection system for electric vehicles for detection of undesired mechanical damage

The project I-Detekt focused on the development of an intelligent battery protection part for electric vehicles in a sandwich-structured design with made glass-fiber reinforced plastics cover layers and a thermoplastic foam core. This structure can be used to automatically detect and classify relevant damages to the overlaying battery module, thanks to an integrated sensor system. As a result, service visits or component replacements will only take place when demonstrably necessary.

Based on a detailed requirements profile, the ILK developed potential manufacturing technologies for the fiber composite compatible integration of electronic components, which are suitable for the detection, processing and evaluation of damage events. Furthermore, the contacting of components with printed conductive tracks was investigated. An additional goal was the widely automated production of a product demonstrator within a wet compression moulding process chain. The demonstrator structures allowed extensive mechanical characterisation through adapted test scenarios and enabled validation as well as iterative adaptation of evaluation algorithms for damage analysis.