avl powertrain engineering techday #4

AVL List GmbH (Headquarters)

Confidential

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


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?


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


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




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


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

!


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.


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


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




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


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


FAST CHARGINGCONVENTIONAL COOLING

Charging time

Degraded

fast charging

Temperature

limit reached

t


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!!


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




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


BATTERY IMPROVEMENTS “CONVENTIONAL MODULE”

z

y


z

y

BATTERY IMPROVEMENTSREMOVAL OF CELL CARTRIDGES

y

Cell Stack

• ~0.4mm (~3%) saving per cell

• ~150g reduction per module

• Fewer parts

z


z

y

BATTERY IMPROVEMENTSOPTIMIZED HEAT PATH

Poor thermal conductivity

Good thermal conductivity

Thermally conductive resin


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


BATTERY IMPROVEMENTS MODULE RESULTS (ALL MEASURES)

z

y

+ 20% Volumetric Energy Density

+ 25% Gravimetric Energy Density


PACKAGING DIRECTION OF CELLS IN LOWHEIGHT BATTERIES

Vertical cellVS.

Horizontal cellplacement

Both solutions possible:

Balance between available cell formats and more complicated assembly technology


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


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


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



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


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

avl powertrain engineering techday #4

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