On 2 Aug 2014 at 14:47, Ben Goren via EV wrote:

>  _should_ I be worried about active cooling for
> batteries? And, if so, what're good ways to go about it?

I'm pretty weak on lithium; the Li experts here should be able to give you 
specific heat resistance information.  I'm more familiar with lead, and I 
can tell you that lead batteries suffer mightily in the heat.

Again taking Solectria as an example, the early Forces (1992-1993) they 
delivered to APS (Arizona Public Service) had 12v flooded marine batteries 
by Johnson Controls. Their AC induction inverters had a modest 180 amp 
current limit,  I think even 150a in the really early cars.  So while they 
were running well above their design load of around 25a, they weren't 
stressed as much as they are in 400-600a DC EVs.

In a temperate climates, those batteries typically gave 1-3 years of 
service, depending on use and maintenance.  In Airzona, even with apparently 
decent care from APS mechanics, they were lucky to make it through even one 
summer.

As another data point, it seems to me that GM's EV engineers decided to not 
even offer the NiMH EV-1 in AZ. In CA, they routed the aircon into the 
battery tunnel, which knocked down its Wh/mi numbers.  (Battery ventilation 
on that car apparently wasn't too well designed.)  

 
> On Aug 2, 2014, at 1:18 PM, EVDL Administrator via EV <[email protected]>
> wrote:
> 
> > Solectria vehicles retained the factory Geo Metro aircon system, and drove
> > the compressor with a small (1hp?) DC brushless motor and controller.  The
> > system seems to have been robust and reliable, if somewhat noisy.  It used
> > about 1500 watts from the traction battery.
> 
> 
> That's an interesting thought. If I have the math right, that's all of 7 - 10
> amps at the 144 volts I'm planning on for the traction battery. 

That's exactly what the early Solectria Force aircon used - 7 to 10 amps at 
144 volts.

However, the Geo Metro aircon it was based on was a pretty efficient design 
to begin with.  In those days, GM was battling Honda for top billing in the 
DOE fuel efficiency rankings (if you can imagine that), so they worked 
pretty hard at making the Metro an efficient car overall.  That's part of 
the reason that an early Force can do 150-160 Wh/mi at the battery, though 
not with the aircon running. ;-)

I have no idea whether you could find an aftermarket aircon as efficient as 
that, but starting with components salvaged from a high-mpg modern car might 
give you a leg up.

David Roden - Akron, Ohio, USA
EVDL Administrator

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