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ADVANCED ENGINEERINGStrictly Private & Confidential

© Williams Advanced Engineering Ltd 2017

ADVANCED ENGINEERING

Strictly Private & Confidential © Williams Advanced Engineering Ltd 2017

EV MOTORSPORT DERIVED ADVANCES IN AUTOMOTIVE BATTERY SYSTEM DESIGN

AUTHOR: DR WASIM SARWARFPC 2018



CONTENTS

2

>Introduction to Williams Advanced Engineering

>The Allure of EV Motorsport

>Key Differentiators - Motorsport vs Automotive Battery Packs

>Transferring Motorsport Developments to Automotive

>Conclusions



WILLIAMS PROFILE

ABOUT US

• Williams founded in 1997

• Williams Advanced

Engineering formed in 2010

• Public Limited Company

• £150m per year turnover

• 900 employees

CORE COMPETENCIES

• Design

• Data capture and analysis

• Simulation

• Assembly

• Testing

WAE BUSINESS AWARDS

• MIA Business of the Year 2012

• Oxford Brookes Innovation Award 2013

• British Renewable Energy Pioneer 2014

• Race Tech Most Innovative New Motorsport Product Award 2015

• The IET Horizontal Innovation Award 2016

• British Engineering Excellence Award for Consultancy of the Year 2016

• MIA Business Award for Technology and Innovation

• ISO9001 awarded July 2017



BATTERY SYSTEM DEVELOPMENT AT WAE

4

Fundamental Science Multi-Scale Virtual Engineering Multi-Disciplinary Design

Battery Management System Physical Testing Manufacturing



H1PERBAT OVERVIEW

5

Flexible battery manufacturing facility in Coventry, UK

Focus on build of bespoke, high performance and low volume battery packs

Collaboration between WAE, Unipart, Warwick Manufacturing Group, Coventry University,

Productiv, MCT ReMan & the NCC



AUTOMOTIVE OEMS FLOCKING TO EV MOTORSPORT

6

Current OEM Formula E Involvement Future OEM Formula E Involvement



KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TIME

8

Hong Kong ePrix – Circuit Layout



KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TIME

9

Tesla Supercharger Network – Western Europe (Left), North America (Right)



KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TEMPERATURE

10

Monaco ePrix



KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TEMPERATURE

11

Bjorn Nyland – Model X Off-Roading in Norway



KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – DEPTH OF DISCHARGE

12



KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – DEGRADATION

13

Vehicle Period Capacity

BMW i3 8 Years / 100k Miles 70%

Chevrolet Bolt 8 Years / 100k Miles 60%

Kia Soul EV 10 Years / 100k Miles 70%

Mercedes

B250e8 Years / 100k Miles 70%

Nissan Leaf

24kWh5 Years / 60k Miles 9 Bars

Nissan Leaf

30kWh8 Years / 100k Miles 9 Bars

Tesla Model

S/XDegradation specifically excluded

Tesla Model 3

8 Years /

100k Miles (SR)

120k Miles (LR)

70%

VW e-Golf 8 Years / 100k Miles 70%



22.4

7.911.0

4.37.2

5.95.0

35.8

0.4

147.8

100

120

140

160

180

200

220

240

Ene

rgy

De

nsi

ty (

Wh

/kg)

High Performance BEV Energy Density Walk

AUTOMOTIVE BATTERY ENERGY DENSITY WALK



TRANSFERRING MOTORSPORT INNOVATIONS - OVERVIEW

Dynamic Thermal Limits

Dynamic Electrical Limits

Thermal Interface

BMS Platform Module Mechanical Design

Integrated Composite Case



DYNAMIC THERMAL LIMITS

Dynamic Thermal Limits – Requirements:

Very low pack thermal distribution

Increased temperature sensing

Sophisticated SoH observation

< -30℃ -30 to -5℃ -4 to 35℃ 36 to 55℃ > 55℃

< -30℃ -30 to -5℃ 36 to 50℃ > 62℃51 to 62℃-4 to 35℃

Static Upper Thermal Limit

Dynamic Upper Thermal Limit



DYNAMIC ELECTRICAL LIMITS

17

Advanced diagnostics techniques including Differential Thermal Voltammetry (DTV)

and Differential Resistance Analysis (DRA) enable SoH observation and electrode

capacity loss estimation

Enable dynamic voltage limits to compensate for stoichiometric drift

Y. Merla et al, Extending battery life : A low-cost practical diagnostic technique for lithium-ion batteries, 331 (2016) 224–231



DYNAMIC ELECTRICAL LIMITS

18



THERMAL INTERFACE

19

Tab CoolingMinimizing Footprint

Integrated liquid cooled cell-

to-cell bus bars

Effective Bus Bar Thermal

Mass Tuning

Conduction CoolingLow cost, package efficient

solution with low complexity

Novel interfacial materials -

↑ Thermal Conductivity &

Isolation Resistance

Combine with tab cooling

Face CoolingMaximum heat rejection

Novel interfacial materials -

↑ Thermal Conductivity &

Isolation Resistance



BMS PLATFORM

20

Flexible BMS software platform enables continuous improvement of

degradation diagnostic and suppression techniques of in-the-field batteries

Kept current with technological advances

CPU

SSD

Increased sensing

OTA updates of calibration

and functionality (without

compromising security/safety

of base code)

Futureproof

processing power

Battery Fingerprint



MODULE MECHANICAL DESIGN

21

Module mechanical components to

serve dual purpose:

Thermal Management:

Cooling components to form

mechanical ‘base’

Composite housing to contribute

‘useful’ thermal mass

Cell Compression:

Composite exoskeleton joined with

elastomer for tuneable constant

pressure solution



INTEGRATED COMPOSITE CASE

22

Stressed composite case for reduced

mass whilst maintaining structural

performance

Built in thermal event suppression &

protection

Built in EMC protectionConfidential Material

Confidential Material


Confidential Material Confidential Material



INTEGRATED COMPOSITE CASE

23

Stressed composite case for reduced

mass whilst maintaining structural

performance

Built in thermal event suppression &

protection

Built in EMC protectionConfidential Material



Confidential Material Confidential Material



CONCLUSIONS

24

Motorsport is an

excellent platform for

innovation and rapid

development

Significant scope to

transfer learning from

motorsport battery

development to

automotive batteries

Advanced BMS

computing enabling

‘smart’, adaptive and

more capable packs

Rapid cell-to-pack

engineering development

advanced engineering - futurepowertrains.co.uk · •900 employees core competencies •design...

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