Climate change, largely caused by CO₂ emissions from road traffic, demands urgent action. Electric mobility offers a cleaner alternative, but relatively long charging times are hindering large-scale adoption. InMotion, an Eindhoven University of Technology student team, is tackling this issue with Electric Refueling: a fast-charging technology that fully charges an electric race car in under four minutes. The team consists of full-time, part-time, and intern members from various academic disciplines.
InMotion has developed a battery pack composed of eight modules, each containing 48 high-performance cells. This battery pack is integrated into the ‘Revolution’ LMP3 racing car.
“The Revolution is powered by the fastest charging battery in the world—unique in its kind,” says Coen Verkuil, Business Developer at InMotion. “We want to ensure that our team can work with this innovative battery safely.”
Safety as a priority
“Our goal was to thoroughly map the safety risks related to our battery pack,” Coen continues. “Because it’s a unique design, there are specific risks you might not encounter with standard batteries. We want to identify those as clearly as possible. Testing not only reveals where the risks lie but also how to effectively manage them.”
Arc flashes—electrical discharges between two conductors at high current, which can lead to extreme heat and fire—are a significant risk. At InMotion’s request, HyTEPS conducted arc flash calculations on the Revolution’s battery pack. Based on these analyses, a Risk Inventory & Evaluation (RI&E) was performed. This also identified which Personal Protective Equipment (PPE) is necessary to ensure worker safety during tasks involving live components.
Simulation results showed that at two locations, incident energy exceeded safe thresholds. HyTEPS recommended various measures to reduce energy levels during an arc flash. Additionally, they assessed whether distribution boxes complied with the DGUV 203-077 safety standard. The simulation model, results, and final report were validated by multiple technical engineers.
“HyTEPS’ proposals were immediately clear and applicable,” says Coen. “We got to work on their recommendations and acquired new PPE. The next step for InMotion is validating the technology on the racetrack. After a series of extensive tests, the team aims to demonstrate Electric Refueling by participating in the 24 Hours of Le Mans.”
InMotion hopes this breakthrough will inspire others to adopt electric driving more rapidly. HyTEPS is proud to contribute to this step toward the sustainability and electrification of mobility.
Electric Refueling According to InMotion
Cooling technology at the cell level is the heart of an advanced thermal management system that enables ultra-fast charging without compromising battery safety or performance. The system consists of two integrated cooling circuits:
Internal Circuit: A water-based coolant circulates directly around each individual cell. This close-contact design efficiently draws heat from the battery modules.
External Circuit: A refrigerant, similar to that used in air conditioning systems, removes the heat from the first circuit via a radiator. This ensures consistent thermal performance even at high ambient temperatures.
The dual cooling system keeps the battery cells at optimal operating temperatures. This makes it possible to charge from 10% to 80% in just four minutes. The technology supports high energy throughput while preventing thermal degradation during intensive charge cycles.