conference perspectives for e-mobility in brazil€¦ · power – (discharge/charge) – 315 w/...

CONFERENCEPERSPECTIVES FOR E-MOBILITY IN BRAZIL

AUGUST 21 – 23, 2019, São Paulo

Dr. Roland PlatzFraunhofer Institute for Structural Durability and System Reliability LBFwww.lbf.fraunhofer.de

Test and reliability research for e-mobility at Fraunhofer LBF

FUTURE MOBILITY – BATTERY TECHNOLOGY FOR ELECTRIC VEHICLES

[FEV Europe GmbH]

[Foster, 2011]

[Hergersberg, 2011]

ice drilling core

Temporal evolution of CO2 and climate forcing

[Foster, 2017 ]

[Boden, 2015]

Annual global fossil-fuel carbon emissions

[BP-Report, 2018]

World primary energy consumption

modern renewables: e.g. solar, hydro, wind, and biofuels (canola)

modern renewables other than electricity, e.g. geothermal

[Zervos, 2018]

transportation

powerheat

sector 1 sector 2 sector 3

Renewable energy in total final energy consumption

ben [Sterner, 2017]

over-ground, 100% renewable

under-ground, predominantly

fossil

over-ground, 100% renewable

global primary energy consumption in EJ/a *

*E = Exa, 1018

1 J = 1 Nm = 1 kg·m 2/s 2

Biomass Water

Biomass

Energy efficiency

Time frame primary energy consumption

[Sterner, 2017]

Examples of basic electric energy storing technology

primary batteries – discharging only once secondary batteries – multiple charging/ discharging (≥ 1.000 cycles)

Primary and secondary batteries

Understanding today’s basic electric car concepts

[electrikcars.in]ICE – internal combustion engine

Areas of e-mobility – pursued mix

[General Electric]

reliability check at

- Li-ion chemistry

- Performance

- Degradation

- Packaging and cooling

- Reliability testing

- Conclusion

- Li-ion chemistry

- Performance

- Degradation

- Conclusion

Brief history

*from the frog

[Wikipedia]

Element Lithium

[Wikipedia]

Element Lithium

Li-ion cell – set up and function, discharging condition

[IKT, 2015]

electron applianceanode cathode

LiMO2 layergraphite layer Li+-ions

Li-Ion battery design

[IKT, VDE, DKE]

cell module

pack/system

- temperature

- voltage

- current

- cooling temp.

battery management

system

Li-Ion battery design

- Li-ion chemistry

- Performance

- Degradation

- Conclusion

Technical criteria

[Buchmann, The Battery University]

Power tools vs. kitchen clock

[Sterner, 2017]

composite anode (-)

current collector (-)

micro porous separator, electrolyte

composite cathode (+)

current collector (+)

Layers of electrodes in Li-ion cells

Technical criteria

[IKT, 2015]

time for 2000 mA (theor.) current per hour

example: Li-Ion cell with nominal capacity of 2000 mAh

C-rate in relation with time and current

Technical criteria

charging cycles

cell phone, MP3

medicine devices

stationary batteries

emergency systems

SOC 20 -90 %

[IKT, 2015]

Lifetime for different applications without and with restriction of SOC

[IKT, 2015]

charging cycles

ity in

Decrease of residual capacity for different currents

[IKT, 2015]

remaining residual capacity of 70% after 500 cycles if fully used (1.000 cycles if restricted to DOD 80%)

Cycles if restricted to state of charge (SOC) and depth of discharge (DOD) to a residual capacity of 70%

[IKT, 2015]

Properties of different cell types for Li-ion batteries, material combination with respect to the cathode

- Li-ion chemistry

- Performance

- Degradation

- Conclusion

[Broussely,2005]

Degradation and aging

[barre2013]

Illustration of aging effects on battery negative electrode: the capacity fade and the SEI raise

Electrochemical Impedance Spectroscopy (EIS)

inductive behavior

ohmic internal resistance

SEI-layer

charge transfer

diffusion

lowest frequency:

highest frequency: 4 kHz

impedance spectrum: T = 25° C, SOC = 3%, Idc = 200mA, Iac=400mA

[Keil, 2012]

Identifying physical and electrochemical effects –characteristic areas in the electrochemical impedance spectroscopy (EIS)

SOC increasing

impedance spectra to 10 mHz when charging with Idc = 500 mA and Iac=400mA

[Keil, 2012]

Modelling dynamic behavior for battery characteristics

[CEA, 2017]

Aging – cyclic

- Li-ion chemistry

- Performance

- Degradation

- Conclusion

cylindrical cell

prismatic cell

pouch cell

Cell types

[IKT, 2015]

Cell types

Connecting in series and parallel

Packaging and cooling in a HV-battery systemexample: development of a HV-battery system for a trailer at Fraunhofer LBF

[evTrailer – self-sufficient electric cooperative driving system for trailers, funded by the GERMAN FEDERAL MINISTRY FOR ECONOMIC AFFAIRS AND ENERGY]

Specifications for HV-battery

basic idea

specifications, set by Fraunhofer LBF

LG NMC (INR- 18650 HG2)

3000 mAh | 3,6 V | 213 Wh/kg | 1,3 C

module

224 cells | 8s28p | 84 Ah | 28,8 V | 2,42 kWh

module housing: thermoplastic resin (Polyamide PA-1200)

system

21 modules

4704 cells | 168s28p | 84 Ah | 604,8 V | 50,08 kWh

system housing: carbon-fiber-sandwich-compound

drag at kingpin, electric support, discharging

sensorickingpin

pressure at kingpin, recuperation, charging

Auxiliary electric powerUsable capacity

consumption reductionlifetime

redemption time < 4 years

Cooling – with water-glycol

forward and backward flow

Cooling – with water-glycol

Module

Module – spot welding for cell contact und busbars

Module

Modules

Modules – system pack

Module – integration and wiring

Modules – cell sensor circuit (CSC)

Module – high voltage wiring

Battery Management System BMS

Battery system – mechanical integration

Lindapter®-Trägerklemmverbindungen

Battery system – startup at FRAMO, May 27. – 29, 2019

Helping hands

- Li-ion chemistry

- Performance

- Degradation

- Conclusion

Fraunhofer LBF – car pool battery electric vehicles (BEV)

Mechanical + thermal + electrical loading on high voltage battery

high voltage battery pack

Mechanical + thermal + electrical loading data

high voltage battery pack

Test rig for cell cyclization of cells at Fraunhofer LBF

Cell Cyclization device

Voltage – up to 6 V DC

Current – +20 A/ -40A

Power – (discharge/charge) – 315 W/ 160 W

Cell temperature measurement (cylindrical cells)

Climatic Chamber

Temperature range: -40 °C – 180 °C

Cooling down / heating up rate : 5 K/min / 3 K/min

Humidity : 10 - 98% (max) (Temp - +10 °C - +95 °C )

Dimensions: 0.5 x 0.5 x 0.4 m

Mechanical, thermal and electrical testing at Fraunhofer LBF HF HST : High Frequency Hydraulic Simulation Table

Max. specimen weight :1000 kg

Frequency control band : 2 – 200 Hz (m < 350 kg)

Max. displacement: 100 – 120 mm (x,y,z)

Max. acceleration : 12 g (@1t)

Climatic Chamber

Temperature range: -40 °C – 80 °C

Cooling down / heating up rate : 4 K/min

Humidity : 95% (max)

Dimensions: 4 x 4 x 3.5 m (width depth high)

VES : Vehicle Energy System

Voltage range: 8 – 800 (DC)

Current range: -600 up to +600 A

Max.Power : 250 kW

Current output speed : -540 A to 540 A in 2 ms

Coolant device

Temperature range : -30 up to +120 °C

Resolution accurateness : ± 0.3 °C

Max. coolant flow : 60 l/min-ca

Example test profile for battery systemte

time in min

time | temp.

temperature

cooling water

flow rate cooling water 8 l/min

Matching between specified and realized load spectra at Fraunhofer LBF – example

load power spectrum density load class limit exceedance

specified (target) load

realized load

- Li-ion chemistry

- Performance

- Degradation

- Conclusion

[Albemarle, 2019]

Li-Ion Battery Technology Evolution

[BP-Report, 2018]

Lithium and Cobalt: reserves and production

from left to right: material cost decrease

CopperLithium usability

Graphiteother electrode Materials

other Polymers

others

[IKT, 2015]

Usability of parts in a Li-ion battery with weight proportion in % each

Summarizing notes

- 90% cell production in Asia

- Cell with 70% cost share in battery

- 90% recycling ratio Li

- Moor’s low is not valid, batteries with limited minimization

- 25% C02 by transport sector, highest potential for reduction

- 30% cost of BEV because of battery

- Next two years critical in Germany for cell production

- Digital and electrical transformation highest challenge

- Solid state not before 2025, 80% of liquid Li-Ion techniques are usable

- 55 EUR / kWh profitable

- 35 Mio t Li sources worldwide, 1 Mio t p. a. 35 years exploitation recycling

- 800 V charging voltage is goal to be similar to fueling ICE-cars today less current necessary that needs high cooling

- Remanufacturing (like in aerospace engineering during repair and maintenance) not as good due to difficult separation of cell components

[Notes from 7. Batterieforum Berlin, 2019]

Literature

Thank You.

[Sterner, 2017]

biomass Heat

gas from wind, solar

windwind

solar heat

solar power (PV, CSP)

geothermic (power, heat)

biomass power

water power

natural gas

nuclear power

mineral oil

energy saving

energy efficiency

electro-mobility

heat pump

wind, solar, water

Time frame primary energy consumption prediction

Li-Ion battery principle

[battery university]

[IKT, 2015]

Element Lithium

[IKT, 2015]

[Keil, 2012]

time in h

Open-circuit voltage for Li-ion cell, discharging and charging in 25 steps each with 4h waiting time after each discharging or charging

Performance check

terminal voltage

open-circuit voltage

Open-circuit voltage for Li-ion cell with respect to SOC

[Keil, 2012]

state of charge (SOC) in %

charging steps

discharging steps

Performance check

Open-circuit voltage for Li-ion cell, with respect to different C-rate and averaging

[Keil, 2012]

state of charge (SOC) in %

charging 1,00 Cdischarging 1,00 Ccalculated open-circuit voltage 1,00 Ccharging 0,01 Cdischarging 0,01 calculated open-circuit voltage 0,01 C

Performance check

[Sterner, 2017]

active material potential

vs. Li/Li+ [V]

max. useful spec. capacity [Ah/kg]

Redox potential and maximum useful capacity

potential vs. Li/Li+ [V]

Electrode potential of different active materials

[IKT, 2015]

environmentsafety

nominal voltage in V

volumetric energy density in Wh/l

gravimetric energy density in Wh/kg

discharge current

lifetime (cycles)

costs for 18560 €/kg in (2014)

rel. costs for €/kg per cycle

application

[IKT, 2015]

Properties of different cell types for Li-ion batteries, material combination with respect to the cathode

[Vetter, 2005]

Lithium-ion anode aging—causes, effects, and influences

isolator

positive plate

positive temp. coeff. comp.

housing

positive electrode

negative electrode

negative tab

separator

positive tab

pressure relief valve

safety device short circuit

[Sterner, 2017]

Properties cylindrical cell

large size

type diameter in mm

height in mm

nominal capacity in Ah

conference perspectives for e-mobility in brazil€¦ · power – (discharge/charge) – 315 w/...

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