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Battery System Development

Ricardo’s breadth of expertise ensures true vehicle optimization and real world benefits. An unsurpassed combination of battery development capability and engineering expertise provides an extension of your in-house battery pack development as well as complete, outsourced battery pack designs.

BSDC contribution to battery pack development process:


  • Up to: 250kW, 1000A, 900V
  • Module or full pack testing
  • Temperatures up to +60C
  • Li-ion, NiMH, Lead-Acid and other rechargeable chemistries
  • Hardware in the Loop (HIL) System
  • 12 ft. x 12 ft. test chamber to accommodate large packs
  • Liquid or air cooled battery packs
  • High voltage instrumentation


  • Passenger cars
  • Heavy duty vehicles
  • Military vehicles (ITAR controls in place)
  • Stationary and niche applications
  • On-road or off-road

Thermal Evaluation

  • Evaluate air flow and structure location
  • Optimize fan size and location
  • Minimize thermocouple
    count through smart sensor location
  • Integrate thermal control system with the rest of the vehicle
  • Evaluate cell-to-cell temperature variation

Battery Management System Development

  • State of charge/state of health algorithms
  • Cell balancing and instrumentation
  • Pack and vehicle communications
  • Functional testing and failure response

Vehicle System Optimization

Global Battery System Capabilities

A highly multi-disciplinary process - Ricardo has the necessary team in-house:

Battery Pack Design and Vehicle Integration

  • Structural - optimization of existing design or clean sheet design to drawing release for manufacture
  • Thermal - analysis of existing design (thermal imaging and/or CAE), suggestions for improvement
  • Electrical - sensor selection, safety system design, high voltage electrical component selection and design
  • Controls - SOC algorithm development, BMS design and development, vehicle control strategy
  • Manufacture - material selection and cost reduction, production supplier identification
  • Integration - vehicle packaging, conditioning of cooling air, vehicle performance/fuel economy optimization

Electronics and Battery Management Systems Design

  • Concept definition and specification development
  • Electronic circuit board design and development
  • State of charge/state of health algorithms
  • Battery control functions
  • Failure mode effects analysis and hazard analysis
  • Diagnostics and prognostics development
  • Hardware in the loop development including simulated failure response assessment

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