An efficient energy storage unit is regarded as key technology for future-proof electric vehicles. ElringKlinger offers components, modules, and complete battery systems – intelligent, flexible, tested under practical conditions.
Among our core competences is the capacity to bring together a wide range of components as assemblies, while also ensuring end-to-end process reliability. This is a compelling advantage within the area of battery technology in particular. We are a development partner and supplier of separate components as well as complete systems.
Since 2011, ElringKlinger has been mass-producing various highly cost-effective components for lithium-ion batteries, such as cell contact systems and cell connectors. Moreover, we also produce complete battery modules based on different cell formats. Thanks to other high-end products such as cell housings, module connectors, and pressure equalizing elements, we are capable of developing entire battery systems according to individual customer requirements and putting them into serial production.
Lightweight components, sealing systems, shielding technology, and dynamic precision parts from ElringKlinger are also fitted in electric cars and commercial vehicles.
Battery modules and energy storage systems
In compliance with LV 123, our standard battery modules can be connected to complete systems with voltage levels of up to 800 V. Thanks to the modular approach, they can be used in various configurations with storage system sizes between 2.2 and 60 kWh and beyond. At the same time, we develop and manufacture modules with a wide range of cell formats to meet the specific requirements of customers. Thanks to integrated sensors and conformity with UN 38.3, our modules are intelligent and safe elements for battery systems.
ElringKlinger battery modules and systems can be used in a wide range of applications, including those outside the automotive sector.
The exceptional reliability of our cell housings, achieved in combination with substantial throughput, is a tribute to our experience in large-scale production and our expertise in the field of sealing and forming technology.
High-current-capable joining processes and optimized sealing concepts help to ensure a long service life of the cells. We also incorporate highly efficient safety features for excess pressure, current, and temperature in order to provide the very best in reliability at cell level.
Cell connectors are responsible for the conduction of current between the individual cells within a module. They have to be as flexible and thin as possible in order to compensate for the tolerances between the cells. At the same time, it is essential that they have a large cross section so that very high currents can be transmitted. The specific lightweight connectors developed by ElringKlinger excel in both areas.
Displaying a very high degree of thermal and physical strength, they ensure that temperature fluctuations are compensated to the largest extent possible. Ultimately, these features translate into a longer service life for the cells.
Cell contact systems
ElringKlinger cell contact systems for lithium-ion batteries in various configurations are tailored precisely to customer requirements; they can be fitted directly onto the cell combination and welded together accordingly. Cell contact systems consist of a plastic carrier frame that accommodates the cell connectors and ensures installability in all tolerance positions.
The required voltage and temperature sensors are already included, while the electronic cell supervision circuit can be integrated by the customer. Approved or newly developed automotive connector systems are used at the interfaces (Plug & Play).
ElringKlinger cell contact systems can be used both in hybrid vehicles and in all-electric cars.
In order to create an energy storage unit, module connectors are required as interfaces between the individual modules and the cell contact systems. The modules are connected not only with each other but also with the power electronics of the vehicle. As an optional feature, ElringKlinger module connectors can also be directly integrated into the cell contact system. In this context, both plugged and bolted solutions – or combinations thereof – are possible.
All approved contact systems can be used. Alternatively, newly developed systems tailored to specific requirements can be implemented – in collaboration with partners if needed.
Battery management systems
The battery management system (BMS) from ElringKlinger allows cell and overall system monitoring as well as protection of the system from voltage fluctuations, overcurrent and temperature fluctuations; it also designed to make power predictions. Depending on customer requirements, an ASIL B or ASIL C safety level can be implemented. The basis for this is a reverse isoSPI BUS system.
Pressure equalizing elements
The energy storage unit housing must be able to compensate for different pressures between the interior of the storage unit and its environment. These may result, for example, from driving uphill and downhill, temperature differences, and from transportation of battery modules or electric vehicles in airfreight compartments without pressure equalization.
ElringKlinger pressure equalizing elements with an integrated safety function compensate for such differences in pressure. On account of permeability to water vapor, condensation in the energy storage unit is also reduced. An emergency degassing function that is also integrated into the pressure equalizing element opens up a port with a large cross section in the event of gas emission from a battery cell; this brings about controlled pressure equalization in the storage unit housing as quickly as possible.
For further details, please refer to our brochures and fact sheets.
Electromobility: series production at ElringKlinger
Within a short space of time and to a very high standard, ElringKlinger produces samples and small batches at its in-house prototyping facility, the equipment of which is very close to that of full-scale production. We have resources available for all the manufacturing processes that are also used in series production, e.g., ultrasonic welding and laser welding systems. In this way, we achieve continuity in all processes from prototyping to series production – only the degree of automation has to be adjusted. At an early stage, during prototype construction, it is possible to ensure seamless 100% traceability, as in subsequent series production.
ElringKlinger also operates high-performance production lines for manufacturing the various components in series. Adapted to specific customer requests and product requirements, we implement highly flexible, scalable or fully automated production solutions – integrated in a continuous quality concept. Our mission is to achieve competitive series production geared to specific product requirements. Efficiently, safely, and reliably. Worldwide.
An all-embracing approach is essential when it comes to achieving smart solutions at the highest technological level possible. At our purpose-built E-Mobility Development Centers all the necessary test and validation facilities are brought together under one roof.
Be it a cell test, a module inspection, or a component validation test – we handle the full range of procedures. In taking this approach, we can offer our customers the very best conditions when it comes to pursuing new routes and achieving goals sooner; this also applies to small batches and prototypes.
Other automotive suppliers also take advantage of our expertise and have tests performed by us. Reliable, economical, comprehensive.