avl powertrain engineering techday #4
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AVL POWERTRAIN ENGINEERING
TECHDAY #4
Flat underfloor batteries - cheaper, faster, farther
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 2PublicBatteries are the key factor for profitability & success of BEV’s.
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 3Public
AVL BATTERY DEVELOPMENTFROM CONCEPT TO PRODUCTION
Concept development with AVL 25
battery concept points
Mechanical, electrical andthermal design
Thermal, mechanical andEMC simulation for development
Virtual and prototype based validation and
verification
Design for production
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 4Public
MARKET NEEDS FOR 4 DOORS SPORTY SEDAN?
energyload.eu
stlfinder.com
cleantechnica.com
The future fully integrated BEV battery aims at a height of just 80 mm.
… But what about the energy density and safety of this battery?
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 5Public
CHALLENGES FOR 80MM BATTERY
BEV: CHEAPER – FASTER – FARTHER
Cost
must be acceptable
(and is directly
related to range)
Time
to re-charge a BEV
must be short
Range
is the key item for
EV success
km
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 6Public
AVL CONCEPT FOR 80MM BATTERIES –TECHNICAL HIGHLIGTHS
Direct chassis
integration:
Vehicle
underfloor =
battery lid
Crash structure One-direction
assembly
Larger than 12 cell
modules
“open” modules
with structural
functions
Non-standard cells for
energy density
optimization
Stainless Steel for
intrusion
protection
Cooling plate
structurally
integrated
Cooling with
direct cell bond
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 7Public
CHALLENGES FOR 80MM BATTERY
BEV: CHEAPER – FASTER – FARTHER
Cost
must be acceptable
(and is directly
related to range)
Time
to re-charge a BEV
must be short
Range
is the key item for
EV success
km
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 8Public
www.forbes.com
www.electrek.co
www.detroitnews.com
www.bloomberg.com
NEXT GENERATION BATTERIES:
CHEAPER?...
0
100
200
300
400
2010 2013 2016 2019 2022 2025
Price in $/kWh on cell level*
*Source: Anderman Report 2016
!
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 9Public
NEXT GENERATION BATTERIES:
…AND FARTHER!
SOP Wh/kg Wh/L
2015 175 - 225 400 - 500
2020 225 - 275 500 - 600
2025 275 - 350 600 - 750
Performance Prognosis of Li-Ion Cells
Data of AVL Series Battery Benchmark program
160 Wh/kg
240 Wh/kg
350 Wh/kg
The performance of cells is significantly increasing.
Best integration is necessary to achieve highest energy density on pack level.
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 10Public
High Level Cost Analysis of a Battery PackSource: AVL Series Battery Benchmark
BATTERY PACK COST DRIVERS
Housing
Other
E/E -Systems
Module
74% 12%
9%5%
Manufacturing process AS HOUSING BOTTOM
Loading the part
Assembly Marking EOL test
Check and pack
Manufacturing process WG HOUSING BOTTOM
Spot welding Washing KTL coating Measurement
Stamping bending
Loading the part
Deburring Measurement
Underbody coating
Underbody sealing
MeasurementCheck and
pack
Production scales have grown to beyond 50.000 per year / pack
AVL has introduced different processes and lowered cost structures
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 11Public
EXAMPLE: MODULE WIRING HARNESSFLEX PRINTIED CIRCUIT
Conventional
wiring harness for
module:
€1,30 - 1,90
FPC wiring harness
for module:
€0,50 – 0,90
Source: AVL Series Battery Benchmark
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 12Public
CHALLENGES FOR 80MM BATTERY
BEV: CHEAPER – FASTER – FARTHER
Cost
must be acceptable
(and is directly
related to range)
Time
to re-charge a BEV
must be short
Range
is the key item for
EV success
km
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 13Public
Low / Medium Power
“Always on” Whenever parked
Effortless Inductive charging
Cost efficient Simple devices
Standard Charging Method
if possible at home
Fast Charging / High Power
“When in need” Mainly long dist.
Highest power Dedicated devices
Expensive Time is expensive
Necessary “Exception”, a MUST
at premium price
mainly on highways
CHARGING THE BATTERYENABLER FOR SPEED & RANGE
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 14Public
FAST CHARGINGCONVENTIONAL COOLING
Charging time
Degraded
fast charging
Temperature
limit reached
t
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 15Public
FAST CHARGINGPREDICTIVE COOLING
t
Continuous
fast charging
for reaching
higher SoC
faster
No predictive cooling
Predictive cooling
Predictive
Cooling Cell voltage
boundaries to be
regarded!!
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 16Public
Charg
e P
ow
er
FAST CHARGING LIMITED BY CHARGING INTERFACE
Wallboxinductive Combo2450V350A
~2.5km/min
<0.3km/min
5km/min
5.7km/min
14
km
/m
in
3,3kW
22kW
11kW
44kW50kW
150kW
250kW
350kW
IC-CPD Combo2800V350A
Combo21000V350A
34
km
/m
in
Type 232AIEC 61851
Combo 2500V, 50kWIEC 15118IEC 61851
DC
Charging
AC Charging
23
km
/m
in
*18 kWh/100km
TESLASuper
charger
Fast ChargingSlow charging
350 A limit
13
km
/m
in
Type 263A
common
today
800 V Vehicle systems and
1000 V Charging systems will come
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 17Public
CHALLENGES FOR 80MM BATTERY
BEV: CHEAPER – FASTER – FARTHER
Cost
must be acceptable
(and is directly
related to range)
Time
to re-charge a BEV
must be short
Range
is the key item for
EV success
km
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 18Public
BATTERY IMPROVEMENTS “CONVENTIONAL MODULE”
z
y
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 19Public
BATTERY IMPROVEMENTS “CONVENTIONAL MODULE”
z
y
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 20Public
z
y
BATTERY IMPROVEMENTSREMOVAL OF CELL CARTRIDGES
y
Cell Stack
• ~0.4mm (~3%) saving per cell
• ~150g reduction per module
• Fewer parts
z
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 21Public
z
y
BATTERY IMPROVEMENTSOPTIMIZED HEAT PATH
Poor thermal conductivity
Good thermal conductivity
Thermally conductive resin
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 22Public
BATTERY IMPROVEMENTSFLEXIBLE PRINTED CIRCUITS IN MODULES
• Height Reduction
• Integration of sense line fuses and sensors
• High degree of automation
z
y
3-D FPC
Illustrative example only, source: enmech
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 23Public
BATTERY IMPROVEMENTS MODULE RESULTS (ALL MEASURES)
z
y
+ 20% Volumetric Energy Density
+ 25% Gravimetric Energy Density
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 24Public
PACKAGING DIRECTION OF CELLS IN LOWHEIGHT BATTERIES
Vertical cellVS.
Horizontal cellplacement
Both solutions possible:
Balance between available cell formats and more complicated assembly technology
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 25Public
80 MM UNDERFLOOR BATTERY:HEIGHT OPTIMIZED MODULE
No top and
bottom cover
Reduced height
pouch cells
Insulating
plastic
endplates
Package
optimized side
plates
Foil printed
circuit
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 26Public
800V IN A 80MM PACKAGE
Cost advantages expected in the future- Cost per kW-Power @ 800 V < Cost per kW-Power @ 400 V
SiC Technology (VBV 1200V) supports push into boosted voltage
Increased voltage decreases electrical current
- smaller cables, connectors, inverters
- Weight reduction (>10 kg)
- packaging improvement
- possibility to use semi-conductor
switching
Battery efficiency 350V vs 800V
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 27Public
LOW PACKAGING VOLUME FUTURE SHUT OFF CONCEPTS
Conventional SwitchgearBattery Load Solid State Switchgear LoadBattery
Conventional switchgear: Solid state switchgear:
D1
+ No power losses (no cooling necessary, except some precharge resistors)+ Widely available and established technology
+ Modular approach by parallelization+ Smaller and leight weight+ Faster switching times
Early hardware detection of current-rise, semiconductors opens (no break!)
Contactor is closed until fuse breaks and interrupts
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 28Public
CHALLENGES FOR 80MM BATTERY
BEV: AFFORDABLE - FARTHER - FASTER
Cost
is seen falling fast…
Range anxiety is a
topic of the past
The time
for BEVs is coming
now!
km
W. Prochazka, A. Harrich | Global Battery Competence Team | 07 September 2017 | 29Public
AVL CONCEPT FOR 80MM BATTERIES –TECHNICAL HIGHLIGTHS
Direct chassis
integration:
Vehicle
underfloor =
battery lid
Crash structure One-direction
assembly
Larger than 12 cell
modules
“open” modules
with structural
functions
Non-standard cells for
energy density
optimization
Stainless Steel for
intrusion
protection
Cooling plate
structurally
integrated
Cooling with
direct cell bond
www.avl.com
THANK YOU