Webasto reveals modular battery system, thermal management, charging stations

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Use of the elements ranges from passenger cars to Class 8 trucks. (Courtesy: WEBASTO)

FENTON, Mich. — Webasto, one of the top 100 global automotive suppliers, continues to stake a claim in the rapidly expanding e-mobility segment of the commercial vehicle and automotive marketplace.

The company exhibited elements of a new modular battery system, thermal management and charging solutions in Ford Motor Co.’s booth recently at the 2019 SEMA Show in Las Vegas. Webasto won Ford’s 2019 Best of Show Stand Award for Outstanding Achievement in Design for Mustang Lithium, a one-off battery electric prototype with 1,000 ft-lbs of torque and over 900 horsepower.

Use of the elements ranges from passenger cars to Class 8 trucks.

“Webasto first entered the electric vehicle market in 2014 with the high voltage heater, as part of its strategic plan to serve its OEM customers as they moved more decisively into the e-mobility space,” said Mark Denny, president and CEO of Webasto Customized Solutions in North America. “Our expansion into battery systems, battery testing equipment, thermal management and charging systems means that both small and large manufacturers now have a respected supplier with decades of experience working within the complex vehicle manufacturing environment, as well as with dealers across North America, Europe and China.”

The Webasto CV standard battery system is designed for total scalability and configuration flexibility, Denny said.

Each battery pack has 35 kWh of energy and up to 10 packs can be used for a combined 350 kWh. With 400V and 800V versions available, the system can be easily configured via the vehicle interface box (VIB), which is the master battery management system and power distribution unit. It is truly a plug-and-play system that reduces development time and cost for the vehicle manufacturer.

Within the battery pack, the self-contained modules also include desiccant cartridges that reduce condensation, integrated thermal runaway detection sensors and state-of-the-art pressure equalization monitors for added safety. Their compact, energy-dense format makes the battery packs easy for engineers to configure for use on virtually any vehicle platform, Denny said

Using the Mustang Lithium to show their capabilities of both designing custom energy storage solutions and supplying off-the-shelf standard battery packs, Webasto set the stage for today’s revelation that its commercial vehicle (CV) Standard Battery System is available in North America. With this modular battery system, Webasto meets the requirements of several commercial vehicle manufacturers to have a cost-efficient solution even for small quantities

Conditioning the battery is essential for battery life and health. Webasto offers both off-the-shelf solutions for the CV Standard Battery and custom developments for OEM projects. Using both active and passive cooling, electric fluid heating and heat pump configurations, the Webasto thermal management keeps battery systems in optimum operating temperature which have a positive effect on performance and range.

At the Mustang Lithium display, Webasto also featured its TurboDX Level-2 charging station. The charging unit that was shown connected to the Mustang Lithium is compatible with both plug-in hybrid electric vehicles and battery electric vehicles, and perfect for home, business and multi-unit dwelling applications.

The Webasto charging solution features a slim, compact design, a durable aluminum rear enclosure and a quick-read charging status indicator.

Webasto also offers the TurboCord portable vehicle charger. The TurboCord lets users take their charger with them wherever they go. It can be plugged directly into any standard 120-volt electrical outlet, or even a 240V outlet for quicker charge times, allowing total charging flexibility and freedom.

“With the introduction of our new modular battery system, thermal management and charging technologies, Webasto has demonstrated its commitment to vertically integrate itself within the North American commercial vehicle and automotive e-mobility marketplace,” Denny said.

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