Fast charging problems

Modern electric cars should have systems that control the temperature in the battery cells. It is important for performance, for the batteries to take a fast charge, for range and for the life of the batteries. The factory numbers only apply when the batteries are at the correct temperature. The batteries prefer the same room temperature as us humans. Not all electric car models have satisfactory solutions. We have tried to find out which solutions are used in the most popular models. It's no easy task, even for car geeks.

How many kWh does the Tesla 3 lose in the blast cold?

preheating tesla 3
Battery loss in the cold

Electric car owners in cold regions certainly have good access to electricity where they park. But what happens if you are visiting and have to leave the electric car overnight in the freezing cold without access to electricity?

 

Looking for the cold

It was reported -16 degrees, but already after Lillehammer I saw that the degrees crept down to -18. It looked promising for a cold test. In Gudbrandsdalen, temperatures can vary with local conditions. I was on my way to check the holiday home before the winter holidays. Thawing water pipes, turning on the heat, shoveling, putting up firewood, chasing away mice, as well as other necessary caretaker tasks. It takes time to fire up a house with an inside temperature of 4 degrees. The cold did not disappoint. During the evening and night, the outside temperature dropped to -24,9 degrees.

The cold steals kilowatt-hours

I parked the Tesla with 80% on the batteries after charging on Øyer. The remaining battery capacity decreased in line with the falling outside temperature, but stabilized at 73% when the thermometer stopped at -24 degrees. During the night, 7% of the batteries had evaporated in the cold - of Tesla's 75 kwh, this amounts to 5,25 kwh.

preheating the batteries
Cold degrees

Lightning-fast heating of the compartment

Ready to leave, I started heating the cabin by preheating the batteries at the same time as scraping the windows. Scraping wasn't really necessary. The car warmed up long before I expected - much faster than in modern petrol cars. After I had turned off the water in the laundry cellar, loaded the luggage into the car and locked the house, the car was wonderfully warm and ice-free. Almost 15 minutes had passed.

Just driving?

The heating had taken another 2% of the batteries. They were now down to 71%. In total, the night had cost 9% of the battery capacity (6,75 kwh). But I was a little too quick on my feet to get off. The app that heats up the car shows a battery symbol with an ice rose when it preheats the batteries. It switches off when the temperature in the batteries is 19 degrees. I preheated for 15 minutes. Ideally, I should have continued preheating until the battery symbol went out. Preheating the batteries is not only for comfort, but to make the best use of the remaining battery capacity. If the batteries are too cold, they will not accept charging from regenerative energy. It therefore pays to preheat the batteries even if the car is not plugged in. I could have preheated for maybe 30-60 minutes. All monners leave. 15-20 minutes drains maybe 2 percent of the batteries, but makes the batteries give more range when you start driving.

Preheating the batteries

The pre-heating in the Tesla 3 uses the electric motors to produce the heat. The heating of the batteries is water-based – coolant that passes through all the cells. The pre-heating does not drain more power from the batteries than quiet driving, so you can start the pre-heating in good time. When you come from petrol and diesel cars, you are set on getting off as soon as the routes are ice-free. But preheating electric cars does not generate any toxic gases or noise. You can optionally start pre-heating without the air conditioning - or low temperature in the passenger compartment and gradually turn up the heat to save the batteries.

preheating tesla
Tesla Supercharger on Øyer. -16 and wind made it colder than it looks.

Slow charging in the cold

Although the batteries had not reached ideal temperature, they worked fine from the first kilometer. Consumption was the same as the day before. After 1 mile of driving, I set my destination to a charging station to buy coffee and sausage - and test charging. Tesla preheats the batteries before arrival, which in my case was calculated for 10 minutes. The batteries thus received additional preheating to cope with the cold. But the batteries were probably not quite ready to receive electricity. It took a few minutes before charging started, and then with low power. Although I was the only customer at Tesla's Supercharger facility, the maximum charging power did not reach more than 27 Kw during my little lunch break. The day before, the batteries received 87 Kw. But I didn't really need much power, so when the break was over, I moved on.

No big increase in consumption

The experts warn against higher electricity consumption in the cold - up to 41% higher than in summer. My winter consumption on the section Oslo - Øyer this trip was 25% higher than the lowest record measurement from September last year - and about the same level as other measurements made in warmer temperatures under alternating driving and driving conditions. Nor did the trip up offer any surprises in terms of range. I don't know if it is of great importance, but I drive with a thick sweater and an indoor temperature between 19-20 degrees. It is possible T-shirt and 25 degrees could have given other experiences.

 

Don't forget to preheat the batteries in the cold!

 

thaw thirteen
Water vapor looks dramatic in the cold. From here The Tine plant at Tretten.

Tesla Owners Club Norway: Battery heating

See

Tesla Model 3 Long Range
terjes cars
Life with Tesla 3
Temperature control of electric car batteries
Active battery cooling?

 

Active cooling of the batteries?

battery cooling
Cars dissected in the interest of consumers.

Did you know that the Nissan Leaf and Volkswagen e-Golf lack active cooling of the batteries? Nissan has put restrictions on fast charging. Volkswagen dampens engine power if you drive too hard. It does not matter which solution is chosen to control the temperature. Read why!


 

The quality that is rarely mentioned

Modern electric cars should have systems that control the temperature in the battery cells. It is important for performance, for the batteries to take a fast charge, for range and for the life of the batteries. The factory numbers only apply when the batteries are at the correct temperature. The batteries prefer the same room temperature as us humans. Not all electric car models have satisfactory solutions. We have tried to find out which solutions are used in the most popular models. It's no easy task, even for car geeks.

Reverse Engineering

Car manufacturers prefer to present battery packs as black boxes. They are generally reluctant to provide detailed information. Even simple questions like “Who manufactured the battery cells?” can be deeply ingrained. It will then be much more difficult to find out how excess heat is conducted from the batteries under load, or how efficiently heat can be added on cold days. Fortunately, there are actors who make a living by picking things apart to document how they are actually constructed – the unvarnished truth. Cars like the Tesla 3, BMW i3, Opel Ampera (Chevrolet Bolt) and Renault Zoe have already been dissected.

Passive or active cooling?

battery cooling
Tesla 3 is the benchmark.
Passive cooling cannot control the temperature in the batteries, but can capture and dissipate a good deal of heat through the metal in the battery case and surrounding air. Active air cooling can consist of something as banal as a thermostatically controlled fan. One liquid cooled system is far better, where the glycol mixture (coolant) is led in channels around the batteries. It is ideal if the temperature changes in the batteries can contribute to heating the passenger compartment via a heat exchanger. In the future, perhaps the battery cells will be mounted in thermally insulated boxes.

battery cooling
Tesla 3 with round battery cells (ebay.com).

Flat or round cells?

Worldwide, there are only a handful of manufacturers that supply the entire world with battery cells. The best known are LG Chem, SK Innovation and Samsung SDI in South Korea, BYD and CATL in China and Panasonic, originally from Japan. The battery manufacturers only supply cells and let the car manufacturers build their own battery packs. The following types of battery cells are used:

Pouch cells

Almost all new battery packs today are based on flat cells wrapped in plastic – so-called pouch cells (also referred to as pocket cells or purse cells ). These can be stacked closely together (but not too closely) – and most often vertically.

Prismatic cells

Here, the cells are wrapped in more solid material, such as aluminium, which absorbs more heat than the plastic in the bag cells. The BMW i3 and Volkswagen e-Golf use this.

Round cells

Round cells are reminiscent of flashlight batteries. Used by Tesla, but Toyota uses/will use round cells as well. These can also absorb more heat than the bag cells.

 

Liquid cooling

Tesla 3

battery cooling
Cooling between the cells. Clippings from YouTube. See Jalopnik's YouTube feature at the bottom of the post.
Upright round/sleeve-shaped cells from Panasonic. Between the cell rows, coolant is led through channels in flat cooling belts at full height. The cooling tape is attached to each cell with a type of adhesive that conducts heat. Each cell is surrounded by cooling from two sides. The system consists of several loops to dissipate heat. In cool conditions, the system is used to heat the batteries.

Opel Ampera/Chevrolet Bolt

Vertical bag cells from LG Chem. Separate cooling frame under the batteries with coolant channels controls temperature. For reasons of space, the battery cells are stacked with two layers at the back - as an extra elevation. It is uncertain whether the topmost cells get as good cooling as the cells closest to the cooling frame.

Audi e-tron

e-tron battery cooling
Battery cooling (audi.com)
Vertical bag cells from LG Chem. A network of coolant channels under the batteries ensures that heat is transported away - or added heat if required. When cooling, the liquid passes through a cooling element. The car's radiator is used for heating. The system is connected to a heat pump. Audi claims that their cooling should be more efficient than Tesla's solution.

Jaguar I-Pace

Vertical bag cells from LG Chem. Liquid-cooled temperature control. Unknown how the channels run, but it is assumed that they are located under the battery pack and consist of several loops. Jaguar is reticent to publish detailed information.

Hyundai Kona

Bag cells from LG Chem. Active thermal management with liquid-cooled channels in a cooling plate under the batteries that transports away heat when needed. The system has several loops and its own cooler. The system can also produce heat when needed. NB! Only cars for the Nordic markets have a battery heater.

KIA e Niro

Bag cells from SK Innovation. Liquid cooling. Same system for thermal management of the batteries as the Hyundai Kona.

 

Models that have been upgraded from air to liquid cooling

Hyundai Ioniq

ioniq battery ventilation
Ventilation for the batteries in the Ioniq series 1.
Bag cells from LG Chem. Hyundai states that models from 2020 with a 38,3 kwh battery have liquid cooling. There is no information material on how the system is built, but it is assumed to be of the same type that the Hyundai Kona uses, - and which from 2020 will also be rolled out in the new KIA e-Soul. The outgoing model of the Ioniq, series 1 produced before 2020, has ventilation ducts from the passenger compartment with a thermostatically controlled fan that draws interior air towards the battery pack.

KIA e-Soul 64 kwh

Models from 2020+ have pouch cells from SK Innovation. Uses the same system for battery cooling and heating as the Hyundai Kona. The first series of KIA e-Soul – before 2020 – ventilates the batteries based on air from the car's air conditioning. They have their own fan to draw air if needed.

 

Active battery cooling with air

Renault Zoe

New 2020+ models with 52 kwh have vertical bag cells from LG Chem. All models (also older ones) have active air cooling that uses air from the car's air conditioning to supply cooled air directly into the battery box - one hole for intake and two for venting. During charging, the car can therefore start the air conditioning if necessary. The system can also use warm air from the heating system, for example during preheating.

BMW i3

battery cooling
BMW i3 battery pack (bmw.com)
Prismatic battery packs from Samsung are mounted over a frame with cooling channels. It is not air, but cooling gas that is sent out under the battery packs when needed. There are also heating wires that produce electrical heat under the batteries.

 

Without active battery cooling

Nissan Leaf

Lying pouch cells from Chinese AESCs. Nissan claims that there is no need for active battery cooling, even for 62 kw batteries. Leaf has put a limitation in the software to limit fast charging several times in a row - on the same day. The phenomenon is hashtagged #rapidgate. This is probably done to prevent damage to the battery due to a lack of active battery cooling. Cars that are delivered to cold regions have battery heaters that are primarily intended to protect the batteries from being destroyed in extreme cold - not to provide an optimal operating temperature.

Volkswagen e-Golf

Prismatic cells from Panasonic. Volkswagen claims that the batteries do not need an external source for battery cooling and heating. In addition to passive cooling, the e-Golf has a function that automatically reduces the current when you press the gas too hard for a long time. The official reason is to reduce consumption. The real reason is probably to reduce the possibility of the battery overheating. Similarly, the charging power is limited if the battery is too hot. This is common on all electric cars, but is rarely a problem on cars with active battery cooling. Volkswagen has recommended that the e-Golf should not be fast-charged more than every other charge.

Conclusion

It is not surprising that premium cars such as the Tesla 3 and Audi e-tron have proper temperature control of the battery cells. Although performance degradation has been demonstrated in the Tesla after repeated accelerations due to the battery cooling not being efficient enough. If it is not the world's best, it is a benchmark for the other electric cars.

I am impressed that even affordable electric cars have active, liquid-based cooling of the batteries. I'm thinking in particular of the new KIA e-Soul and Hyundai Ioniq. Mentions on the fly also the Renault Zoe passenger car with separate air ducts from the air conditioning directly into the battery box.

It's about what we get for our money. If you use an electric car in temperate environments with quiet charging, you can certainly save a few kroner by choosing a model without active battery cooling. The most important thing is that you make conscious choices.


The car manufacturers must then explain how they ensure that the battery cells reach the optimum working temperature. Please mention it in the brochures!


 

See

Jalopnik visited Munro & Associates , who have taken apart three leading electric cars. Jalopnik characterizes the three cars as a “conventional approach,” a “weird approach,” and a “blank sheet.” Guess who’s who!

tesla3 battery
Tesla 3 Long Range
i3 battery
BMW i3