ITB / Overview of our references / Our expertise / electric mobility

Components of battery storage systems

Battery storage systems are essential for enabling the operation of electrical systems independently of a permanent stationary power supply. A battery storage can be a single battery cell or an entire module in which many hundreds of battery cells are electrically connected to provide sufficient electrical power. Modules, in turn, can be combined. Following this concept, battery storage systems are designed for electrically powered vehicles.

These modules consist of many sub-assemblies, such as:

  • Housing
  • Cell contacting systems
  • Busbars
  • Sensors
  • Cells, etc.

Depending on the system’s concept (the type of battery cell), various requirements arise, which can be divided into different physical disciplines, such as:

  • Electrical requirements (resistances, voltage measurements, current densities, etc.)
  • Thermal requirements arising from electrical conditions (temperatures due to transient current flow; simulation of fuse melting)
  • Mechanical requirements, such as vibration loads, mounting loads, operating loads, shock loads, or thermal loads (see above)
  • Requirements for sensors, such as reaction times or component-dependent electrical voltage differences


Your advantage through simulation

Using the Finite Element Method, the aforementioned requirements can be simulated and tested in a time- and cost-efficient manner. This helps to easily locate critical areas and optimize them already in the development phase. We can assist in:

  • Designing fuses
  • Optimizing components regarding their current flow
  • Determining thermal loads due to current and cooling profiles
  • Determining mechanical stresses due to thermal loads
  • Determining operational durability due to vibration loads or other cyclic loads

The production of prototypes is minimized through these preliminary investigations.


Documentation of calculation results

The documentation of calculation results is provided according to customer preferences as an auditable calculation report in German and English or in the form of a PowerPoint presentation.