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

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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

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Test and reliability research for e-mobility at Fraunhofer LBF

FUTURE MOBILITY – BATTERY TECHNOLOGY FOR ELECTRIC VEHICLES

[FEV Europe GmbH]

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[Foster, 2011]

[Hergersberg, 2011]

ice drilling core

Temporal evolution of CO2 and climate forcing

[Foster, 2017 ]

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[Boden, 2015]

Annual global fossil-fuel carbon emissions

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[BP-Report, 2018]

World primary energy consumption

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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

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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

Water

Biomass

Energy efficiency

year

Time frame primary energy consumption

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[Sterner, 2017]

Examples of basic electric energy storing technology

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

Primary and secondary batteries

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Understanding today’s basic electric car concepts

[electrikcars.in]ICE – internal combustion engine

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Areas of e-mobility – pursued mix

[General Electric]

reliability check at

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Scope

- Li-ion chemistry

- Performance

- Degradation

- Packaging and cooling

- Reliability testing

- Conclusion

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Brief history

*from the frog

*

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[Wikipedia]

Element Lithium

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

[IKT, 2015]

electron applianceanode cathode

LiMO2 layergraphite layer Li+-ions

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Li-Ion battery design

[IKT, VDE, DKE]

cell module

pack/system

- temperature

- voltage

- current

- cooling temp.

battery management

system

BMS

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Li-Ion battery design

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Scope

- Li-ion chemistry

- Performance

- Degradation



- Conclusion

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Technical criteria

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[Buchmann, The Battery University]

Power tools vs. kitchen clock

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[Sterner, 2017]

composite anode (-)

current collector (-)

micro porous separator, electrolyte

composite cathode (+)

current collector (+)

Layers of electrodes in Li-ion cells

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Technical criteria

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[IKT, 2015]

h

h

min.

min.

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

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Technical criteria

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charging cycles

lifet

ime

in y

ears

long

rath

er sh

ort

cell phone, MP3

medicine devices

BEV

stationary batteries

emergency systems

SOC 20 -90 %

[IKT, 2015]

Lifetime for different applications without and with restriction of SOC

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[IKT, 2015]

charging cycles

resid

ual c

apac

ity in

mAh

Decrease of residual capacity for different currents

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[IKT, 2015]

char

ging

cyc

les

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]

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[IKT, 2015]

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

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Scope

- Li-ion chemistry

- Performance

- Degradation



- Conclusion

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[Broussely,2005]

Degradation and aging

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[barre2013]

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

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Electrochemical Impedance Spectroscopy (EIS)

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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)

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SOC increasing

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

[Keil, 2012]

Modelling dynamic behavior for battery characteristics

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[CEA, 2017]

Aging – cyclic

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Scope

- Li-ion chemistry

- Performance

- Degradation



- Conclusion

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cylindrical cell

prismatic cell

pouch cell

Cell types

[IKT, 2015]

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Cell types

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Connecting in series and parallel

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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]

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Specifications for HV-battery

basic idea

specifications, set by Fraunhofer LBF

cell

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

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Cooling – with water-glycol

view

view

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forward and backward flow

Cooling – with water-glycol

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Module

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Module – spot welding for cell contact und busbars

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Module

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Modules

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Modules – system pack

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Module – integration and wiring

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Modules – cell sensor circuit (CSC)

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Module – high voltage wiring

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Battery Management System BMS

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Battery system – mechanical integration

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Battery system – mechanical integration

Lindapter®-Trägerklemmverbindungen

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

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Helping hands

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Scope

- Li-ion chemistry

- Performance

- Degradation



- Conclusion

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Fraunhofer LBF – car pool battery electric vehicles (BEV)

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Mechanical + thermal + electrical loading on high voltage battery

high voltage battery pack

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Mechanical + thermal + electrical loading data

high voltage battery pack

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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

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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

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Example test profile for battery systemte

mp

erat

ure

in °

C

time in min

stat

e o

f ch

arg

e SO

C in

%

time | temp.

time | temp.

temperature

cooling water

SOC

flow rate cooling water 8 l/min

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

load power spectrum density load class limit exceedance

specified (target) load

realized load

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Scope

- Li-ion chemistry

- Performance

- Degradation



- Conclusion

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[Albemarle, 2019]

Li-Ion Battery Technology Evolution

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[BP-Report, 2018]

Lithium and Cobalt: reserves and production

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from left to right: material cost decrease

CopperLithium usability

Iron

Graphiteother electrode Materials

other Polymers

others

perc

ent o

f bat

tery

wei

ght

[IKT, 2015]

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

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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]

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[Sterner, 2017]

biomass Heat

year

gas from wind, solar

windwind

solar heat

solar power (PV, CSP)

geothermic (power, heat)

biomass power

water power

natural gas

nuclear power

coal

mineral oil

energy saving

energy efficiency

electro-mobility

heat pump

wind, solar, water

glob

al p

rimar

y en

ergy

cons

umpt

ion

in E

J/a

Time frame primary energy consumption prediction

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Li-Ion battery principle

[battery university]

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[IKT, 2015]

Element Lithium

[IKT, 2015]

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[Keil, 2012]

time in h

volta

ge in

V

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

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terminal voltage

open-circuit voltage

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

[Keil, 2012]

state of charge (SOC) in %

volta

ge in

V

charging steps

discharging steps

Performance check

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

[Keil, 2012]

state of charge (SOC) in %

volta

ge in

V

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

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[Sterner, 2017]

active material potential

vs. Li/Li+ [V]

max. useful spec. capacity [Ah/kg]

notes

Redox potential and maximum useful capacity

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potential vs. Li/Li+ [V]

Electrode potential of different active materials

[IKT, 2015]

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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

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[Vetter, 2005]

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

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isolator

positive plate

positive temp. coeff. comp.

seal

housing

positive electrode

negative electrode

negative tab

separator

positive tab

pressure relief valve

safety device short circuit

[Sterner, 2017]

Properties cylindrical cell

AAA

18650

large size

large size

type diameter in mm

height in mm

nominal capacity in Ah

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

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

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