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Volker HennigeMike Parsons

AVL List GmbH AVL UK Ltd

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NEXT GENERATION BATTERIES -CHEAPER, FASTER, FURTHERADVANCING THROUGH DEVELOPMENT & TEST

| V. Hennige – AVL Global Battery Competence Team | Mike Parsons – AVL UK Ltd | 28 November 2017 | 2Public

WHO ARE AVL?AN AUTOMOTIVE DEVELOPMENT ENTERPRISE

5 powertrain elements

EXPERIENCE65 years !

GLOBAL FOOTPRINT

30 engineering locations• >220 testbeds• Global customer support network

ONEPARTNER

INNOVATION 1500 granted patents

RESEARCH 10% of turnover in-house R&D

GROWTHSALES

1995:0.15 billion €

2016:1.40 billion €

Plan 2017:1.52 billion €

STAFF 8.600 employees65% engineers and scientists

0200400600800

1,0001,2001,4001,600

| V. Hennige – AVL Global Battery Competence Team | Mike Parsons – AVL UK Ltd | 28 November 2017 | 3PublicBatteries are the key factor for profitability & success of BEVs


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


HOW TO DESIGN THE FUTURE EV BATTERY?

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 – FURTHER

Costmust be acceptable

(and is directly related to range)

Timeto re-charge a BEV

must be short

Rangeis the key item for

EV success

km

ADVANCING THROUGH DEVELOPMENT & TEST


AVL CONCEPT FOR 80mm BATTERIES –TECHNICAL HIGHLIGHTS

Direct chassis integration:

Vehicle underfloor = battery lid

Crash structure

“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

Larger than 12 cell modules

One-direction assembly







must be short


EV success

km



High Level Cost Analysis of a Battery PackSource: AVL Series Battery Benchmark

BATTERY PACK COST DRIVERS

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 Measurement

Check and pack

Production scales have grown to beyond 50,000 per year / packAVL has introduced different processes and lowered cost structures

Diagramm1

Housing

Other

E/E - Systems

Module

Battery Pack - Cost Drivers

[]

0.09

0.05

0.12

0.74

Tabelle1

Battery Pack - Cost Drivers

Housing9%

Other5%

E/E - Systems12%

Module74%


EXAMPLE: MODULE WIRING HARNESSFLEXIBLE PRINTED CIRCUIT (FPC)

Conventional wiring harness for

module:

€1,30 - 1,90

FPC wiring harness for module:

€0,50 – 0,90Source: AVL Series Battery Benchmark







must be short


EV success

km



Cha

rge

Pow

erFAST CHARGING 1: 800V REQUIRED!BUT LIMITED BY CHARGING INTERFACE

Wallboxinductive Combo2450V350A

~2.5km/min


Powernet

AVL E-Motor

P_out: 210 kW (10 s) 140 kW (S1)

T_out: 750 Nm @2700 rpmDimensions:

Ø 245 x 390 mmWeight: 104 kgDirect fluid cooling

R&D: 2012 COUP-E VEHICLE TECHNICAL DATA

AVL HV-Battery

180s/1p pouch cells: 41 Ah Energy usable: 22 kWh Energy installed: 27,6 kWh Gravimetric energy density:

108Wh/kg Weight (cells/pack):

180 / 250 kg

Liquid cooling system Foamed frames for cell

protection Self carrying module blocks Cell tab clinching AVL MCU and BCU controls Serviceable E/E box

Battery Powertrain

AVL Inverter

Operating voltage:250 – 980 V

Continuous power: 250 kW

Peak current: 600 A Dimensions:

472 x 280 x 182 mm


FAST CHARGING 2: PUSHING THE LIMITS

Cell

Pack

VehicleCharger

Infra-structure

Fast charging defines the thermal system requirements in cooling power and also lag time!


FAST CHARGINGCONVENTIONAL COOLING

Charging time

Degraded fast charging

Temperature limit reached

t


FAST CHARGINGPREDICTIVE COOLING

t

Continuousfast charging for reaching higher SoC

faster

No predictive coolingPredictive cooling

PredictiveCooling Cell voltage

boundaries to be regarded!!







must be short


EV success

km



80mm UNDERFLOOR BATTERY:HEIGHT OPTIMIZED MODULE

No top and bottom cover

Pouch cells with reduced height

Insulating plastic

endplates

Package optimized side

plates

Flexible printed circuit


BATTERY IMPROVEMENTS MODULE RESULTS (ALL MEASURES)

+ 20% Volumetric Energy Density

+ 25% Gravimetric Energy DensityConventional module Advanced AVL module


80mm UNDERFLOOR BATTERY

Overall achievements when

integrating AVL’s advanced

module into a smart pack design:

• 80 mm height of the pack

• ~10% weight saving

~60kg weight saving @ 96kWh

• ~5% package density increase







must be short


EV success

km



PART 2 – BATTERY TESTING

1. Test systems (cell/module/pack) 2. Facility engineering3. Modular test beds4. Simulated & emulated test environments


INTRO: ELECTRIFICATION TEST SOLUTIONS

Design and supply of test facilities Facility design & implementation Containerised test cells

Turn-key automated test systems Battery cell / module / pack Fuel cell / module / stack E-motor, E-drive, E-Axle Inverters, charging systems e-Integration Powertrain / chassis dyno EMC and NVH

Test beds driven by simulation models• Road load / vehicle dynamics / ADAS

Data acquisition, analysis & host systems• Compatibility across all test beds


Validate performance: power, capacity, ageing & life Front-load testing for fewer test vehicles Decrease time to market Avoid recall actions

BATTERY LAB TESTING GOALS


• Effective facility layout & safety• Scalable data management• Repeatable test cycles• Realistic test conditions• Future-proof ratings• Adequate site power• Trained operators• Future support

ROUTE TO PRODUCTIVE TESTING


BATTERY TESTING – TYPICAL SETUPBattery testerAVL E-Storage

Test Automation AVL LYNX

Climatic Chamber

IR Camera

Measurement systemVolt / Amps / Temperature

Scalable data host AVL Santorin

Data analysis/reportsAVL Concerto

Vehicle simulation AVL InMotion

Safety Systems

Coolant Conditioning

LV Power Supply

Restbus Simulation

Battery cells / module / pack

BMS


Base Option

Power rating 160 or 250kW 1MW (parallel)

DC output voltage 8 – 800V 10 - 1,200VDC output current ±600A ± 2,400A

Current rise time (10%...90%) < 2ms

< 0.4ms for 800V< 1.0ms for 1,200V

Voltage and current accuracy ± 0.1% FS ± 0.01% FS

Dimensions 800V: 2,007 x 610 x 2,478 mm1,200V: 2,800 x 610 x 2,478 mm (incl. 200 mm plinth)

HIGH PERFORMANCE BATTERY TESTERS

Example: E-Storage BT


FAST CURRENT RISE TIME WITH LOW OVERSHOOT & RIPPLE ARE IMPORTANT

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0Zeit [ms]

Cur

rent

[A]

-100

-50

0

50

100

150

200

250

300

350

400

450

500

550

600

650

700

750

Volta

ge [V

]

-50

0

50

100

150

t90 < 0.4 ms

Step response: 0A - 600A


FACILITY ENGINEERING- FROM CONCEPT TO IMPLEMENTATION

AVL has planned and implemented over 30 engineering centres for customers worldwide


BESPOKE MODULAR TEST BEDS

• Simplify final site installation with a modular containerised test bed

1. Design2. Build & Pre-commission

3. Deliver & Commission


Inside Testing Room

Climate Chamber with UUT

Drawings of complete Test Beds

MODULAR BATTERY TEST LAB EXAMPLES


GET CLOSER TO REAL WORLD CONDITIONS- TEST WITH SIMULATED VEHICLE & ENVIRONMENT


SPEED UP DEVELOPMENT BY TESTING WITH EMULATION BEFORE REAL HARDWARE EXISTS

Emulated battery and BMS

Real battery and BMS + climatic

conditioning

E-integration Test Bed


CONCLUSION -NEXT GENERATION BATTERIES

Advancing through …• Development

• Challenges: Cheaper, faster, further • Progress with 80mm underfloor battery

• Test - Systems & facilities • Front-load testing for fewer test vehicles• Decrease time to market• Avoid recall actions

www.avl.com

THANK YOU

For more details please visit the AVL stand, or contact:[email protected]@avl.com

Next generation batteries -Cheaper, faster, furtherWHO are AVL?�AN AUTOMOTIVE DEVELOPMENT ENTERPRISESlide Number 3AVL Battery Development�From Concept to ProductionHow to design the future EV battery?Challenges for 80mm batteryAVL concept for 80mm batteries – technical highlightsChallenges for 80mm batteryBattery Pack Cost driversEXAMPLE: MODULE WIRING HARNESS�Flexible PRINTED CIRCUIT (FPC)Challenges for 80mm batteryFast Charging 1: 800V required!�But limited by Charging InterfaceR&D: 2012 COUP-E VEHICLE TECHNICAL DATAFast Charging 2: �Pushing the limits Fast Charging�Conventional coolingFast Charging�Predictive coolingChallenges for 80mm battery80mm underfloor Battery:�Height Optimized ModuleBattery Improvements �Module Results (All measures)80mm underfloor batteryChallenges for 80mm batteryPart 2 – battery testingIntro: electrification test solutionsSlide Number 24Route to productive testingbattery testing – typical setuphigh performance battery testers Fast current Rise time with low �overshoot & ripple are importantfacility engineering� - from concept to implementationBespoke Modular test bedsSlide Number 31Get closer to real world conditions�- test with simulated vehicle & environmentSpeed up development by testing with emulation before real hardware exists Conclusion - �Next generation batteriesSlide Number 35

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