Battery Fast-Charging Thermal Control

A major European OEM needed to extend their EV platform with fast-charging capabilities while preserving thermal system stability. The challenge was to integrate battery cooling control logic into an existing thermal management controller – originally developed for a different vehicle model – without introducing regressions or disturbing validated behaviors. Time to market was tight, and the project had to go from integration to series production-ready in record time.

Having previously developed the original thermal control platform, Synchrotek was tasked with adapting and extending the software to support battery thermal management during fast charging. This involved:

• Extending existing control logic with battery-specific charging scenarios
• Ensuring smooth integration into the existing software and calibration environment
• Supporting full system validation, both in simulation and on prototype vehicles

Collaborating closely with vehicle integration teams to ensure no side effects were introduced

Our deep familiarity with the platform enabled rapid implementation, precise testing, and a stable release process.

Stable integration: Battery fast-charging thermal management was added without disrupting existing control logic or requiring rework.

Smooth launch: The software entered serial production and is running successfully in production vehicles.

End-to-end support: Synchrotek provided full integration, testing, and validation support from concept to SOP.