5-Nils Neumann-PPT

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12/04/2019 #196400

HV Batteries for Automotive Applications -Challenges and Opportunities Beyond Cell ChemistryNils NEUMANN, Dipl.-Wirt.-Ing.


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Tension Field of Battery System Development - Efficiency, Driving Experience and Safety Influenced by Battery Systems

Slide No. 2

EFFICIENCY

SAFETY

Costs

DRIVINGEXPERIENCE

Thermal management

ModuledesignRange Assembly

Structural vehicleintegration & package

Crash & Crush

Fire protectionTightness / Corrosion

Charging infrastructure

Production process


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Key Components of a Battery SystemOverview

Battery Module Battery Cell

Battery Housing

Cell Management Controller

Floor/ Underbody protection cover

Cooling system / Thermal management

Battery housing frame

Battery tray

Lattice

Battery Junction Box (BJB)

Incl.:Battery Management System (BMS)ChargerHV connection

Imag

e So

urce

: Aud

i

Top Cover

Slide No. 3


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Tension Field of Battery System DevelopmentModule Design

Slide No. 4

EFFICIENCY

SAFETY

Costs

DRIVINGEXPERIENCE

Thermal management



Crash & Crush



Production process


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Technology Roadmap for Battery CellsAll-solid-state will not be available since 2030

Long Term 7-10+ years

Medium Term3-7 years

Short Term0-3 years

4.3 V Li-Ion4.4 V Li-Ion

Li-CompositeLi-Sulfur

Li-PolymerLi-Solid Matter

Li-Air

Challenges

Lifetime/Safety

Cycle Stability/ Lifetime

Power density/ Cycle Stability

Lifetime

Thermal Management/ Safety

LifetimeCell Chemistry/

Lifetime

§ Short-Term: Optimization of the CAM ratio (NMC), Li-Technologies: Li-Sulfur and Li-Solid-Matter most feasible for automotive application (Long-term). Lifetime is the main problem of Li-S and Li-Air batteries.

§ Battery Management: Largely similar working principle. Some software adjustments need to be done. Li-S special case as capable of deep-discharge / overcharge

§ Implications for future battery housings: Thermal management essential to solve lifetime problems and allow high C-rates § Cell type important for system design

Conclusion

Imag

e So

urce

: GM

5.0 V Li-Ion

Lithium-Ion Battery

Technologies

Slide No. 5


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§ Ensures required mechanical stability

§ Connection to the thermal management

High pack density possible

Module can not be operated on its own

Costly battery housing development

§ Ensures required mechanical stability

§ Connection to the thermal management

Easily replacement

Battery cooling and heating is being realized on

a battery system level

Loss of pack density due to additional housing

Modules can be operated as a 48 V- On-board

battery or connected to a HV-battery

Easily replacement

Costly development with respect to mechanical

and thermal characteristics

Loss of pack density due to additional housing

Types of Battery ModulesDistinct advantages and disadvantages of modules

§ Electrical or mechanical cell connections, parallel or

serial

§ If necessary apply mechanical clamping forces

§ Thermal management has to be realized on a

battery system level

§ No BMS-integration

Cell Stack

Nissan Leaf

Module-based Battery System§ Only mechanical cell connections

§ No further integrated functions within the module housing

§ Thermal management has to be realized on a battery

system level

§ Cell connector clamped, screwed together or welded

§ Integration of the BMS-Surveillance: Voltage, Power,

Temperature BMW i3

Stand-Alone-Module§ Mechanical cell integration < 60 V

§ Integration of thermal management functions: Module

cooling/heating

§ Integration of a BMS-Surveillance: Voltage, power, temperature

§ Housing seal (IP-protection class), if necessary isolation of the

housing OPTEMUS

Slide No. 6


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Europa United States China

17,5

6 37 5 24

32,5

0,01

10,0

20,0

30,027,5

2,55,07,5

12,515,0

22,525,0

Best Selling EV (2017)

Tesla Model X

Sale

s [k

uni

ts]

Renault ZOE

BMW i3

Nissan LEAF

Tesla Model SVW eGOlf

Hyundai IONIQ

14

27,5

5 237 60,0

15,0

10,0

20,0

30,0

2,55,0

22,5

7,5

12,5

17,5

25,0


Tesla Model X

Fiat 500e BMW i3

Chevrolet Bolt

Tesla Model S

Nissan LEAF

VW eGolf

7

80

3

30

6 2 10

5

4

15

20

25

35

45

40

5

10


Zhi Dou D1/D2 EV

Chery eQ EV

JAC iEV6S EV

BYD e5 EV *

BJEV EC180/200 EV *

Zotye E200 EV

Geely Emgrad EV *

Pouch Prismatic Cylindrical

* Est., due nondistinctive source information

Pouch and Prismatic Cells in favor in EU and US, Cylindrical Cells used mainly by Tesla. No clear trend for CN OEM

Slide No. 7


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Tension Field of Battery System DevelopmentAssembly and Production Process

Slide No. 8

EFFICIENCY

SAFETY

Costs

DRIVINGEXPERIENCE

Thermal management



Crash & Crush



Production process


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» Different key design issues require different solutions» Best approach is a modular toolbox that can be adapted for different use cases

Example: Joint development of fka and voestalpine AG» Several solutions have been developed to provide a tailor-made battery box that meets individual

customer needs and requirements» The result is a modular system in which desired emphases can be targeted» Exemplary concepts derived from toolbox:

Slide No. 10

Design Approach MethodologyModular toolbox as an approach for efficient individualization

Tray Design

Ø Maximum safety & tightness

St-Al Hybrid Design

Ø Maximum weight savings

Frame Design

Ø Maximum modularity


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Benchmarking of HV-Battery HousingsNew Releases/Concept Cars Europe (Excerpt)

§ General: Frame mode construction

§ Frame: Extruded aluminum profiles

§ Cooling: Water-Glycol Liquid, Radiator & AC

§ Tray/Floor: Reinforced floor

§ Lattice: Aluminum

§ Top Cover: Aluminum Sheet

§ Cell Arrangement: Pouch Cell (432, 36 modules)

Jaguar I-PACE

§ General: Deep draw/ Bended tray

§ Frame: Extruded aluminum profiles

§ Cooling: Water-Glycol Liquid

§ Tray/Floor: Tray with floor reinforcement

§ Lattice: Aluminum

§ Top Cover: Aluminum sheet

§ Cell Arrangement: Pouch Cell (432, 36 modules)

Audi e-tron

90 kWh

95 kWh

Slide No. 11


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Benchmarking of HV-Battery HousingsSupplier Concepts (Excerpt)

§ General: Bended constructed tray(Al or Steel possible)

§ Frame: Steel Rollforming (UHSS)§ Cooling: Liquid§ Tray/Floor: Tray with floor reinforcement§ Lattice: Hybrid§ Top Cover: Sheet based Al/St§ Cell Arrangement: N/A

Benteler

§ General: Frame mode construction§ Frame: Extruded aluminum profiles§ Cooling: N/A§ Tray/Floor: N/A§ Lattice: Hybrid HSS, Aluminum§ Top Cover: N/A§ Cell Arrangement: N/A

Gestamp

Slide No. 12


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Tension Field of Battery System DevelopmentCrash and Crush Safety

Slide No. 13

EFFICIENCY

SAFETY

Costs

DRIVINGEXPERIENCE

Thermal management



Crash & CrushFire protection

Tightness / Corrosion


Production process


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Safety is a basic requirement, but still critical to the quality of future EV battery systems – even beyond existing standards

Slide No. 14


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Crash / Crush Standards and Exemplary Validation

Slide No. 15

Regulatory standards Customer requirements§ Detailed testing of regulatory crush and shock

tests

§ GB/T 31467.3

§ ECE R100

§ . . .

§ Fulfilling of customer specific requirements

leads to modular battery

box system

§ e.g. 20 kN bottom impact


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Tension Field of Battery System DevelopmentThermal Management

Slide No. 16

EFFICIENCY

SAFETY

Costs

DRIVINGEXPERIENCE

Thermal management



Crash & Crush



Production process


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Effective thermal management can have a direct impact on customer satisfaction

Slide No. 17


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Comparison of Battery Cooling Concepts – Main differentiation is the heat sink

Slide No. 18

§ Coolant directly flows through

battery heat exchanger

§ Coolant exchanges heat with ambient air or via chiller, depending on ambient

conditions and cooling power

demand

Coolant cooling

§ Air is actively routed

through ducts within housing

§ Separate HVAC for battery box including evaporator

and heater

§ Possibility to re-use cabin air due to similar thermal

needs

Air cooling

§ No active thermal management, only driving

temperature difference between

ambient air and housing

§ Issues with high current DC

charging

Ø#rapidgate

Passive cooling

§ Evaporator directly integrated into battery housing

§ In parallel to HVAC evaporator

§ Active cooling only when

electric compressor is active

Direct refrigerant cooling


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Framework Conditions for Battery Thermal ManagementCoolant-based concepts seem to be most feasible

Slide No. 19

Common Li-Ion cell types Cooling Concept by Heatsink

Joule heating Q̇#$%&' = )* + ,-./

Entropy effect Q̇0 = ) + 1-./ + 234526789

Enthalpy flow Q̇$%/ = ℎ + ; + (1= − 1?)

Cell heat balance

cylindrical prismatic pouch

Heatsink: direct ambient air or refrigerant cycle

Coolant Refrigerant

Heatsink: refr. cycle

Current industry focus High effortAir

Limited heat transfer

Complexity, costs, thermal performance

Chevrolet Bolt

BMW i3

Renault Zoe


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Battery system

Most design parameters linked to the thermal management systems are influenced by the battery system

Slide No. 20

BoundaryConditions

Minimal pressuredrop

Maximum heattransfer

Maximum dynamic forTransient Operation

Channel size

Flow speeds

Channel geometry

Volume flow rates

Package Costs InterfacesManufacturing Weight

Heat transfercoefficient

Thermal conductivity

Wall thickness

Surface [m²]

RequiredPumping Power Type and potency of Heat Sink


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» Battery system engineering finds itself in a tension field between driving experience, safety and efficiency

» Battery cells are an important design factor, but requirements of Lithium-Ion cell types are similar, while game changing all-solid-state will not be available since 2030

» Battery system concepts have very different advantages and disadvantages – a technology toolbox might be a solution for an efficient design approach for individual design solutions

» Safety is a basic requirement, but still critical to the quality and customer acceptance of future EV battery systems – even beyond existing standards

» Thermal management turns out to be a key differentiation factor in future battery systems. However, current suppliers mostly do not have a sufficient design competence to provide cutting edge solutions.

Slide No. 21

Summary


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fka GmbHSteinbachstr. 752074 AachenGermany

Hinweis: Kontaktfolie Variante AUTO/CAR alternativ STRASSE/STREET

Nils NEUMANN

phone +49 241 8861 127e-mail [email protected] www.fka.de

5-Nils Neumann-PPT

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