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This article is part of an archived collection from Nikolay Shishkov's blog about first-generation electric vehicles, battery maintenance, modifications, and repairs. Nikolay was an EV pioneer who passed away in 2025. His technical knowledge and generous sharing of information continues to help the EV community.

EV95 Modules testing

By Nikolay Shishkov • June 03, 2017

batterybattery sensing ecuchargingEV95NiMHravrav4 evtestingthermal imaging

I have been testing some old EV95 modules with my new test setup and noticed something very interesting: the temperature of different points on an EV95 battery module can vary by as much as 21C (70F) during the end phase of the charge.

This is a bit scary and I started wondering - what does it mean when specialists talk about battery temperatures - where is that temperature measured?

Here is a screenshot -

During that particular cycle cell #7 (this is 8th cell) has been overcharged, and has unacceptable high temperature on the battery pole of 58.3C (137F)(!!!), while the temperature on the side of the battery is around 40C.

What is not visible on this screenshot is that the module is put on top of 3 fans that blow air upwards.

There is also two bigger fans blowing from the side of the module, so there is plenty of air circulation.

This is an extreme situation - most of the modules I see do not go nuts like this... but isn't it enough that one such module is in your battery pack, and starts heating up not only the module but even neighboring modules?

Edit:
List of equipment I use for testing:
 - 2 floor standing fans
 - 30V 20A regulated power supply
 - icharger 4010Duo running @30A charging and @34A discharging
 - 2x 1kW 1 Ohm resistors in series
 - 3x 120mm fans 24V 0.5A each
 - 24V power supply
 - C2 FLIR camera
 - 2x Powerlog 6s
 - 1x Laptop running custom software for the powerlog units, and FLIR program

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Comments (7)

gosh

September 04, 2017 at 05:16 AM

Nikolay, я написал Вам письмо по указанному адресу.

Nikolay

July 15, 2017 at 09:47 AM

Gosh, find my contact info on http://uppladdning.nu/About.aspx and send me an e-mail.

gosh

June 21, 2017 at 11:38 PM

он не заряжается,TIS выдаёт три ошибки
c2913 "Abnormally Large Variation Among Traction Battery"
c2956 "Traction Battery Voltage Detection Circuit"
C2946 "Battery Sensor ECU Abnormally"
я подозреваю, что проблема с Battery Sensor ECU, но хотел бы спросить у Вас в какую сторону копать? Можно ли её заменить или обойти/сэмулировать, насколько сложен протокол взаимодействия ECU на этом автомобиле? Насколько я понял из схемы, "BATTERY SENSOR ECU" по трём проводам сообщает "BATTERY ECU" состояние батареи и "BATTERY ECU" с помощью "EV CONTROL ECU" соединяет батарею с "EV MOTOR INVERTER". Т.е. если сообщать нужную информацию о состоянии батареи "BATTERY ECU", минуя "Battery Sensor ECU", от последнего можно избавиться. Или в будущем заменить батарею на LiPo или LTO.
Сейчас, думаю зарядить, батарею по-блочно внешними зарядным устройством, но не знаю как лучше это сделать, какие параметры зарядки и прочее.

Nikolay

June 20, 2017 at 10:27 AM

Sure, what is the problem with your RAV4 EV?

gosh

June 18, 2017 at 11:12 PM

Спасибо, что ответили.
К сожалению, я плохо говорю по английски. У меня есть проблема с моим RAV4 EV 2002, хотел бы задать Вам несколько вопросов, если это возможно. (My English is very bad, so may I write in Russian?)

Nikolay

June 09, 2017 at 07:48 AM

Thanks for the question! I updated the post with list of equipment I use for the testing. I did speak Russian, but have not done it in 15 years... why?

gosh

June 03, 2017 at 11:07 PM

Hi Nikolay, what kind of charger do you use?
(Can you speak Russian?)