Enhanced Off-Road EV Performance with Cutting-Edge Battery Optimisation

Enhancing the performance of advanced battery technologies is pivotal in the development of high-functioning electric vehicles. In this case study, we explore how a collaboration between Rockfort Engineering, a UK based design consultancy specialising in EV powertrain integration and technologies, and IAAPS leveraged state-of-the-art testing facilities and expertise to push the boundaries of battery technology.

The Challenge
Maximising the output of a vehicle’s powertrain is a critical step in vehicle development, particularly for those designed to operate off-road and in harsh terrains. To assist Rockfort Engineering in optimising their liquid-cooled modular battery technology "Pegasus" for an off-road electric vehicle, the Ariel E-Nomad, IAAPS provided state-of-the-art development facilities and advanced technical expertise. Although the battery pack had already been tested in-vehicle on road, track and off-road conditions, achieving peak performance for the off-road EV required a full characterisation of the battery pack under controlled conditions.

The Approach
IAAPS supported Rockfort Engineering by offering engineering expertise and access to IAAPS’ cutting-edge test cell facilities. These facilities provided liquid conditioning, environmental control, and battery emulation capabilities (power, voltage, or current control) to test the pack housed in a mobile battery test framework. A single battery emulator (250 kW, 600 A, 1200 V) was used to supply and absorb current within the pack’s known limits.

The investigation focused on constant current and constant voltage charge and discharge cycles under varied conditions. Controlled parameters included coolant flow rate/temperature and test cell air temperature for thermal performance characterisation. Various test cycles were conducted at different temperatures, including preconditioning at temperatures ranging from 10°C to 50°C.

This comprehensive testing allowed Rockfort Engineering and IAAPS to further assess the pack’s performance across its full operating range, providing crucial insights for developing control strategies to manage dynamic vehicle duty loads in real-world scenarios.

The Outcome
This study led to an increased understanding of the battery pack’s performance under precise usage conditions, enabling optimisation of the pack’s current design in conjunction with the rest of the powertrain to enhance overall performance. The testing data fed into a design update for the battery pack for the production intent design, which is now undergoing an intensive vehicle based test program in the Ariel E-Nomad, which was recently unveiled to press, to validate the design and IAAPS sourced data. 

Additionally, the findings paved the way for further hardware and control software developments, which could lead to additional improvements in powertrain performance. 

“Our collaboration with Rockfort Engineering allowed us to push the boundaries of battery technology for off-road EVs. By thoroughly characterising the Pegasus battery under controlled conditions, we’ve gained valuable insights that will not only optimise the current design but also drive future advancements in powertrain performance,” says Sam Thomas, Project Lead Engineer at IAAPS. 

“Working with IAAPS was a pleasure, both in using their brand new, state-of-the-art testing facility but also their incredibly helpful and skilled engineering team. In a relatively short period of time we were able to get up and running, put the Pegasus battery through its paces and fully characterise its electrical and thermal performance, which led to improvements in the design of the pack,” says Angus Lyon, Director at Rockfort Engineering.