Quality-Driven Resolution of Cooling System Issue in High-Voltage Battery Pack

This thesis project investigates how to manage the ePowertrain development process from the quality point of view at FPT Industrial. In particular, it is centered around the eBS 37 battery pack for the electric light commercial vehicle IVECO eDaily. The integration of quality standards (internal and external), across the entire product lifecycle, is tackled. The core of the activity is the analysis and resolution of an issue regarding the cooling system of the battery pack, which could potentially result in coolant leakage. Hence, several tests have been performed in order to understand the conditions which could lead to coolant leakage in case of incorrect mounting of cooling pipe connectors. Moreover, the consequences of such an issue are examined and the most critical components are identified. The final purpose is to improve the design of the cooling pipes as well as the mounting process in the production line in order to avoid any coolant leakage. In fact, preventing it is essential because the potential resulting short circuit would irreversibly damage the battery. This research highlights the significance of New Product Quality Support in attaining high-performance specifications and customer satisfaction, as well as the importance of cross-functional team collaboration.