Sounds like fun. Diet EE (EET) here, repairing electronics for the DoD. My initial observations after owning a Gen 1 volt for 6 months is that it was well though out, and designed to last. Robust. Liquid cooled battery is a win.
I do wonder, have you worked with Prius Prime (European PHEV), or the North American Ford Fusion Energi or cMax Energi? Do any of these use dexcool to control the battery temp? Only when plugged in? Thermal management does wonders for battery life.
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