Battery Thermal Management System (BTMS)

With the rapid growth of electric vehicles, the continuous advancement of powertrain systems demands higher battery performance and modularity. Heat generation from batteries has become an increasingly critical issue, directly impacting performance and lifespan. Effective thermal management is essential, making the Battery Thermal Management System (BTMS) a core component of electric vehicles.

Our BTMS is widely applied in various sectors, including electric buses, heavy-duty trucks, and mining trucks, ensuring optimal battery performance and longevity.

Whatsapp: +8619352173376

Email: contact@brogenevsolution.com

What is a Battery Thermal Management System (BTMS)?

A Battery Thermal Management System (BTMS) is an integrated cooling and heating system designed to regulate the temperature of onboard batteries. It consists of key components such as a compressor, condenser, expansion valve, evaporator, water pump, expansion tank, PTC liquid heater, and essential control units.

The primary goal of BTMS is to keep the battery pack within an optimal temperature range, ensuring peak performance and longevity. By managing thermal energy across the vehicle, the system effectively reduces waste heat emissions, enhances energy efficiency, and minimizes environmental impact.

Functions of the Battery Thermal Management System (BTMS)

Monitoring: Accurately measures and tracks battery temperature in real time.
Cooling: Effectively dissipates heat when battery temperature is high, preventing thermal runaway.
Preheating: Warms the battery in low temperatures to ensure safe and efficient charging and discharging.
Temperature Balancing: Reduces temperature differences within the battery pack, preventing localized overheating and extending overall battery lifespan.

Solutions

Roof Mounted Battery Thermal Management System (BTMS)

Integrated drying system ensures system cleanliness and enhances reliability.
Top-mounted design saves space and allows easy maintenance.
Integratable expansion tank and heating system (≤14 kW)
Lightweight aluminum alloy structure, streamlined appearance design

Our Roof Mounted BTMS Features

The unit is designed on the roof, which can meet the thermal management requirements of 6-meter to 18-meter buses and electric locomotive batteries;
Lightweight aluminum alloy is used in the bottom shell. RTM material is used in the outer cover. The double waistline design is internally formed;
Optional PTC liquid heater allows for selection of standby, with cooling, heating, and self-cycling working modes;
The adoption of CAN bus communication enables it to have the function of fault self-diagnosis and real-time uploading of operating status and fault information;
EMC can meet Level III requirements;
Strong environmental adaptability to harsh operating conditions such as high and low temperatures, high corrosion, and high altitude.

Our Roof Mounted BTMS Offerings

Model	OETLE105	OETLE108	OEEDDR-01	OEEDDR-02	OEEDDR-03	OEEDDR-04
Cooling capacity	5 kW	8 kW	3 kW	5 kW	8 kW	13 kW
Low voltage power consumption	300 W	500 W	300 W	300 W	450 W	700 W
High voltage input	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V
Low voltage input	DC 24 V	DC 24 V	DC 24 V	DC 24 V	DC 24 V	DC 24 V
Control power	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal
Low voltage power supply	Vehicle provided	Vehicle provided	DC-DC (standard configuration) / Vehicle provided	DC-DC (standard configuration) / Vehicle provided	DC-DC (standard configuration) / Vehicle provided	DC-DC (standard configuration) / Vehicle provided
Size	L1029W1369H280 mm	L1029W1369H280 mm	L1300W1920H256 mm	L1300W1920H256 mm	L1300W1920H256 mm	L1300W1920H256 mm
Refrigerant	R134a	R134a	R134a	R134a	R407c/R134a	R407c
Water pump	External	External	For selection	For selection	For selection	For selection
Pipe diameter	25 mm	25 mm	25 mm	25 mm	25 mm	25 mm
PTC heater	Can be integrated, <14 kW	Can be integrated, <14 kW	Reserve 5 kW / 10 kW / 14 kW / 24 kW for selection	Reserve 5 kW / 10 kW / 14 kW / 24 kW for selection	Reserve 5 kW / 10 kW / 14 kW / 24 kW for selection	Reserve 5 kW / 10 kW / 14 kW / 24 kW for selection

Solutions

Bottom / Skirt Mounted Battery Thermal Management System (BTMS)

It’s mainly used for power exchange/charging of logistics transportation vehicles such as trucks and sanitation vehicles.
Thee unit adopts an aluminum alloy fame structure, which can meet the needs of weight reduction and efficiency improvement.
Optional PTC liquid heater allows for selection of standby, with cooling, heating, and self-cycling working modes.
The adoption of CAN bus communication enables it to have the function of fault self-diagnosis and real-time uploading of operating status and fault information.
EMC can meet Level III requirements.
Optional configuration: tube-fin condenser, DC-DC, expansion tank.

Our Bottom / Skirt Mounted BTMS Offerings

Model	OETLE205	OETLE207	OETLE208	OEEFDR-01	OEEFDR-02	OEEFDR-03	OEEFDR-04
Cooling capacity	5 kW	7 kW	8 kW	3 kW	5 kW	8 kW	10 kW
Low voltage power consumption	500 W	700 W	700 W	450 W	800 W	800 W	1000 W
High voltage input	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V	DC 400-750 V
Low voltage input	DC 24 V	DC 24 V	DC 24 V	DC 24 V	DC 24 V	DC 24 V	DC 24 V
Low voltage power supply	Vehicle provided	DC conversion	Vehicle provided	DC-DC (standard configuration) / Vehicle provided	DC-DC (standard configuration) / Vehicle provided	DC-DC (standard configuration) / Vehicle provided	DC-DC (standard configuration) / Vehicle provided
Control power	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal	DC 24 V ON/OFF signal
Size	L643W599H3863 mm	L835W560H310 mm	L669W621H461 mm	L685W600H280 mm	L685W600H280 mm	L818W600H280 mm	L1005W557H280 mm
Refrigerant	R134a	R410a	R134a	R134a	R134a	R407C/ R134a	R407C
Water pump	Q=1200L/h, H>10m	Q=2400L/h, H>13m	Q=2800L/h, H>16m	100 W	180 W	240 W	240 W
Pipe diameter	25 mm	25 mm	25 mm	25 mm	25 mm	25 mm	25 mm
Expansion tank	No	No	No	Can be integrated
PTC heater	No	No	No	Reserve 5 kW / 10 kW / 14 kW / 24 kW for selection

Case Study - BTMS Solution for Electric Mining Trucks

Why should we use a BTMS for electric heavy trucks?

Cabin climate control
- Maintain a comfortable temperature and airflow for the driver.
- Defrost and defog the windshield for clear visibility.
- Control cabin humidity and air outlet temperature to ensure a clear driving view.
Battery temperature regulation
- Prevent extreme temperatures from affecting charging/discharging rates and battery lifespan.
Motor cooling
- Maintain optimal coolant temperature for efficient motor operation.
Limited space constraints
- Electric commercial vehicles require additional battery cooling, but lack waste heat from an engine.
- Complex vehicle layout with multiple components.

Our BTMS solution

We provide an integrated battery thermal management system that regulates air and equipment temperature and humidity through a shared condenser and compressor module, ensuring stable and reliable vehicle operation.

Solution Features

Modular Design
- Simplifies vehicle integration, assembly, and debugging.
- Improves overall system efficiency.
Advanced Refrigeration System
- Uses a high-efficiency DC inverter compressor with PID automatic adjustment for dynamic temperature control.
- Supports automatic variable frequency operation for both high and low temperatures.
Efficient Heating System
- Equipped with a power-adjustable PTC heater to handle defrosting, defogging, and cabin heating.
- Built-in temperature protection ensures automatic shutdown in case of overheating or abnormal conditions, enhancing safety.
Smart Liquid Cooling System
- Embedded intelligent modules optimize cooling performance while minimizing power consumption in low temperatures.
- Adaptive flow and water temperature control ensure efficient heat dissipation.
Seamless Vehicle Integration
- CAN communication enables real-time interaction with the vehicle system.
- User-friendly control panel displays cabin and ambient temperatures for easy monitoring.
Adaptive Environmental Control
- Designed to function effectively in high-altitude regions and extreme weather conditions.