Lithium Ion Batteries in E-Mobility · Lithium Ion Batteries in E-Mobility Motivation Design for Manufacturing Trends Klaus Grieshofer 04.03.2015 . Outline Introduction of Magna Steyr

Lithium Ion Batteries in E-Mobility

Motivation

Design for Manufacturing

Trends

Klaus Grieshofer

04.03.2015

Outline

Introduction of Magna Steyr Battery Systems

Motivation for Electromobility

Development

Production

Future Trends

MAGNA STEYR BATTERY SYSTEMS

Battery systems for passenger

cars and commercial vehicles

based on state-of-the-art

lithium-ion technology

Li-Ion

battery systems Testing services

State-of-the-art test labs

in Europe and North

America ensure the

highest quality and safety

standards

Low-voltage

systems

B:LiON lightweight

battery systems for

automotive micro, mild

and hybrid applications,

as well as onboard power

supply

High-voltage

systems

B:LiON battery systems in

the high-voltage range as

an energy store for fully

electric or hybrid vehicle

applications

China Shanghai,

Changchun

Austria Graz, Zettling

North America Auburn Hills

Battery Systems

Top Quality Storage Systems for Electric and Hybrid Vehicles

13 March 2015 Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited

Battery Systems Locations Europe

• Austria (Europe)

Employees: 171 (Status Q3 / 2013)

Plant Size: 14,060 m²

• Functions

Battery Pack Engineering

Prototype Battery Builds

Battery Pack Assembling

Zettling (HQ)

Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015

• Michigan (USA)

Employees: 48 (Status Q3 / 2013)

Plant Size: 7,630 m²

• Functions


Battery Testing

Material Testing

Battery Systems Locations North America and China

Auburn Hills

• China, Jilin Province

• Expansion of existing plant

Planned size: ~10.000 m²

Planned Production volume: ~35.000/(year)

• Functions

Battery Pack Assembly (SOP: Q2/2016)


Changchun


Battery Systems Portfolio Automotive Market

Energy Plug-In PHEV Hybrid (HEV) 48V 12V Truck PHEV

Energy

Content 16 - 36 kWh 6 - 18 kWh 0.2 - 3 kWh 0.25 - 1 kWh ~ 70 Wh 8 - 14 kWh

Power 50 - 120 kW 50 - 120 kW 10 - 50 kW 8 - 11 kW ~ 3 kW 100 - 170 kW

Voltage 400 V 400 V 120 / 400 V 48 V 12 V 400 / 700 V

Weight 180 - 400 kg 80 - 200 kg 10 - 40 kg ~ 15 kg ~ 5 kg 120 - 220 kg

Cooling liquid (optional) liquid air / liquid AC cooling /

liquid ---- liquid

Manuf.

Capacity 3,000 / year > 35,000 / year 50,000 / year 100,000 / year

< 100,000 /

year 3,000 / year

Serial Production Serial Production Serial Production Serial Production


Matrix of Battery Pack Applications

TRUCK/BUS HEV*

HEAVY DUTY

POWER BATTERY PACKS

50

Tota

l E

nerg

y [k

Wh]

0

1

10

Power [kW]

1 10 100 1000

EV* Electric Vehicle

PHEV* Plug In Hybrid Vehicle

HEV* Hybrid Electric Vehicle

12 / 48V SYSTEMS

POWER BATTERY

PACKS

EV*

ENERGY

BATTERY PACKS

MILD HEV*

POWER

BATTERY PACKS

FULL HEV*

POWER BATTERY

PACKS

PHEV*

ENERGY BATTERY

PACKS


MSBS Track Record

2013

2010

BEV

Battery Pack

HEV Truck Gen II

HEV Truck Gen III

12V Light Weight Li-

Ion Battery

PHEV Battery Pack

Serial Projects with SOP Development

2009

2010 2011

2013

2014

2015 2016

High Power HEV Battery

12V Light Weight

Li-Ion Battery Gen II

HEV Truck Gen I

PHEV / HEV

Truck Gen IV


Motivation for Electromobility

CO2 is a Global Reference Point for Hybridization

Legislative CO2 reduction requirements

EU: -27% (2012-2020)

NA: -33% (2012-2020)

TODAY

CO2 reduction requirements by OEM in EU

Source: IHS Automotive, Berlin March 2013

Legislative Convergence across TRIAD,

China, and SK


Approach to reach the targets

Aero-

dynamics Propulsion-related CO2 measures achieve a good cost relation

Propulsion-related measures

Other measures

€/%

CO

2 R

ed

ucti

on

CO2 measures on NEDC vs. Costs

Propulsion

System

Improved

efficiency

Rolling

resistance

Aero-

dynamiics

Leightweight


CO2 Reduction requires Diversification of Powertrains

Fuel cell vehicles

Range extended EV

Electric vehicles

High powertrain diversification expected over the years

For City emission free driving with PHEV and BEV

EU targets: 130 gCO2/km 95 gCO2/km tbc: 70 gCO2/km

rela

tive C

O2

em

issio

ns

up to -100%

up to -40%

up to -60%

Mild hybrids

Full hybrids

CNG/ LPG

Synthetic sun fuels

BiSG & CiSG, 12V/48V

Stop/start

ICE optimization

Light weight

Energy management

Aerodynamics &

Friction

PHEV

Cit

y

Lo

ng

Dis

tan

ce

-20 to -30%

Electric vehicles


A/B/C Segment Conventional

Vehicle

Electric

Vehicle

Co

mp

on

en

ts

Propulsion system Combustion engine

Gear box (6 gear)

Electric motor

Gear box (1 gear)

Converter

Inverter

Energy storage system Tank ~70l Battery pack ~ 350l

Onboard charger

Fu

nc

tio

ns

Range >1000 km Up to 500 km

Max. speed >180 >180 @ 1 shift

Refuel/charging 3 min Fast charge <20min

Energy recovery No 25-40%

CO2 emissions 140g/km 0g/km

Energy efficiency <30% ~70%

Comparison EV and conventional vehicle


Germany

0

10

20

30

40

50

60

70

80

90

100

0

2

4

6

8

10

12

14

16

0 2,6 5,2 7,8 13 20,8 26 39 52 78 130 260 >260

Tage

sle

istu

ng

in %

, ku

mu

liert

Tage

sle

istu

ng

in %

PKW-Tagesfahrleistungen in kmSource: Bundesministerium für Verkehr,

Bau- und Wohnungswesen (BMVBW), 2002

At present average electrical

range of electric vehicles

120 150 km

• 90% of all trips are

shorter than 130km

• 70% of all Germans

drive less than

35km per day

• PHEV allows pure

electric drive up to

50km + full

conventional range Daily driving range [km]

Dail

y a

cti

vit

ies

[%

]

Da

ily a

cti

vit

ies

,

ac

cu

mu

late

d [

%]

Batterysolution

will increase

costs & weight

Daily Driving Range


Development

MAGNA STEYR Battery Systems

Development Process

Electrical integration

Cell Selection

Software / Battery Management

Validation

Mechanical integration

• Customer tailored housing

• Modular concept

• Functional integrated

(Cooler + Housing)

• Low cost and high

integrated cell to cell

connection

• Battery disconnect

unit

• Interfaces

• Wiring of measure-

ment circuits

• Functional Safety Concept

• Balancing + Supervision of cells

• State Monitoring (State of Charge,

State of Power, State of Health)

• Communication/ CAN

• Usage Logging over life

• Tailored cell chemistry

• All cell housing types

and chemistries

feasible

Thermal concept

• Thermal simulation

• Cooling concept for cell

thermal management

• Liquid or air cooled

DESIGN

• Performance

• Transportation

• Mechanical

• Thermal and

Climatic

• Safety

• Life Cycle

• other

Costumized Pack

Mass Production


Cell Selection - overview

• “Cell”? – (Galvanic) Cells are Accumulators (Secondary

Batteries or Rechargeable Cells) • the electrochemical process is reversible

– In an Energy Storage System (ESS), several cells are connected in series and parallel configuration

• Selection Topics: – Mechanical design

– Performance design

– Chemical components

– Safety features

Cylindric Cells Prismatic Cells Pouch Bag Cells

Battery weight distribution


Cell Technology

10

10

100

1.000

100 1.000 10.000

Sp

ecific

Energ

y [

Wh/k

g]

Specific Power [W/kg]

1

10.000

NiMH Lithium-Ion

Super-Capacitors

Lithium-Ion-Capacitors

Lithium-Sulfur

Lithium-Air

Solid State R&D stage

serial after 2025 R&D stage

serial after 2020

R&D stage

serial after 2030

€/kWh 170

(2020)

300

(2013)

€/kWh 200

(2020)

220

(2013)

€/kWh ~8000

(2020)

>10.000

(2013)

R&D stage

serial after 2018

* Cost indication based on cell level

** Source: Magna-internal information based on 10 market studies as well as cost indications from serial production requests

*** Specification based on reachable energies


PHEV HEV 48V 12V

Cell capacity 22 - 40 Ah 6 – 10 Ah 6 – 10 Ah 10 - 20 Ah

Peak Power / Cell 1000 W 700 W 800 W 1200 W (crank)

Grav. Energy > 170 Wh/kg > 80 Wh/kg > 80 Wh/kg >100 Wh/kg

Thermal Active cooling Active cooling Reduced thermal

control passive cooling

Life 10 years of service life

Tailored cell technologies to specific applications

Anode material

Cathode material

Electrolyte

Separator

Mechanical design

NMC, NCA, LMO, LFP NMC,LFP

Graphite Graphite, HC SC, HC, LTO

Reduced particle size, thinner electrodes, high surface area

Reduced particle size, thinner electrodes, high surface area, coatings

voltage stability thermal stability, low T performance

Solvent mix, functional additives, salt concentration

+ thermal stability, no shrinkage ceramic modified PE/PP

Low transport resistance tailored to mod. electrolyte

Metal can pouch type cells


Thermal integration concepts - overview

21

Energy Plug-In Hybrid 48V 12V

Energy Content 16-36 kWh 6-18 kWh 0,2-3 kWh 0,6 -1 kWh 0,25 -1 kWh

Power 50-120 kW 50-120 kW 10-50 kW 10-2 kW 3 kW

Heat generated 200-300 W 200-300 W 200-300 W < 60 W < 15W

Passive cooling

Air Cooling

Liquid cooling

Refrigerant

Cooling

passive cooling should be sufficient for

limited performance.

Cost efficient air cooling option

For EV and PHEV applications best compromise in matter of packaging,

cooling and heating performance, safety and comfort

For HEV refrigerant cooling is an

option to avoid a own liquid cooling

circuit for the battery pack.

passive cooling should

be sufficient for low

C-rates applications.


Trends in liquid cooling design

• Bottom cooling via cooling tubes • Bottom cooling via double-wall housing

Housing-integrated cooling:

Cooling plate designs:

• Thin sheet cooling plates

• Cooling plates with structural function

• Impact on:

Performance, Life, Safety

• Design criteria

• Cell operation T of ~ 35°C

• Homogeneous

temperature distribution on

cell and module level

• Methods:

• Simulation (0d, 1d, 3d)

• Functional integration

• Verification

Thermal management


Thermal cooling design

3D Computational Fluid Dynamics (CFD)

3D – Temperature distribution

Temperatures

Velocities


Mechanical integration - Overview

Serial Production Program, fully qualified battery pack

Prototype build-up, concept validated

Feasibility study, concept simulated and analyzed

EV PHEV / REX Hybrid (HEV) 12V / 48V Bus / Truck

Steel deep drawn Concept Serial Concept PT Concept

Steel welded Serial PT PT - Serial

AL-deep drawn - Serial (cover) Concept (cover) Concept PT (Cover)

Al Casting - Serial PT Concept PT

Al extrusion profile - Concept - Concept -

Polymer Serial (Cover) Concept (Cover) - Serial -

Serial Production Serial Production Serial Production Serial Production


Trends in PHEV housing design

• Package arrangement

• Integration of Cooling

• Crash performance

• Mechanical endurance (life

time)

• Vibration and shock durability

• Temperature / humidity

durability

• Design for manufactoring

Mechanical design PHEV die-cast housing

Material: Aluminum crash alloy

+) Complex geometry possibilities

+) Low cost at high volume

+) crash & shock requirements

- ) Limitation in size

Material: Extruded aluminum profiles

+) High mechanical strength

+) crash

+) For low and high volume, all sizes

- ) Not suitable for complex installation space shapes

Al-Extrusion housing


Electrical design - examples

• HV-Path

• LV-wiring

• Interconnections

• Insulation / HV Protection

• Battery Disconnect Units

• EMC Filters

Electrical design

Compact EMC Filter:

• Compact design

• Easy assembly

• Highly effective

• Automated HV connection

• Automated wiring to PCB

• Integrated temperature sensor

Compact high-voltage connection board:

• Designed for automated

assembly

Integrated cell connection unit for battery module

sen

so

r

fuse

2 relais


Implemented Functionality

Battery Management System Overview

BMU/ CSC functions

Cell measurement

-Cell voltage

-cell temperature

Pack measurement

-pack voltage

-pack temperature

System measurement

-Cooling media inlet and

outlet temperature

SOC Estimation

SOH Estimation

Power limit calculation

Cooling control

Wake up/ Stop control

Cell balacing control

HV Isolation Monitoring

Diagnostics

CAN Communication

SOC („Range“)

Available power

State of health

Warning

messages

Diagnostics

Wake up / Stop

CAN

Communication Vehicle

Cell

balancing Cooling

HV

contactors

HV

Interlock

Wake up

Crash Signal

Battery


Electronics / Battery Management

• Main components: – Battery Management Controller (also unit)

• Data treatment/analysis

• Functional/safety algorithms

• Vehicle communication

– Cell Voltage Monitoring • LV measurement of cells

• Temperature measurement

• Balancing components

– HV components: • Relais

• Fuse

Cell voltage monitoring

Battery management controller

CSCCSC

Lion

Cell

Ve

hic

le H

V

Su

pp

ly+

-

+

-

Service Lid

Co

oli

ng HV Fuse

Relay V-

Relay V+

BMU

Current Sensor

(redundant)

Lion

Cell

Lion

Cell

KL

30

KL

30

c

HV

IL

CA

N

CSC CSC

Pre-Charge Relay

Hardware architecture


Software / Battery Management Cell model

Deta

iled D

esig

n S

W SW

Module

test

SW Implementation

Design

SW

Design

HW

System Integration Test

(System Testbench)

SW Integration

Test

(HiL)

Requirements Development

System Design

Acceptance Tests

SW HW

Component Production

(Electrics & Mechanics)

Com

ponent te

st

Ele

ctr

ics &

Mechanic

s

SYSTEM LEVEL

SUBSYSTEM LEVEL

COMPONENT LEVELT

oolin

g c

onstru

ctio

n

Cre

ate

pro

ductio

n d

ata

Electronics Production

Set in

to o

pera

tion, H

W

Module

test

Deta

iled D

esig

n

Software

Implementation

Module

Test S

W

Subsystem Integration Test

(System Testbench)

SW Test

(HiL)

Desig

n V

erification (

DV

)

Ele

ctr

onic

s, M

echanic

s &

E

lectr

ics

Desig

n E

lectric

s &

Mechanic

s

Design

System Functions

Onboard Diagnostic OBD-2target: monitor emission relevant faults

detection: defective sub-component

monitoring of cellvoltage

monitoring of systemcurrent

monitoring of celltemperature

monitoring of celltemperature

monitoring of cellvoltage

monitoring of systemcurrent

monitoring of systemvoltage

monitoring of coolanttemperature

insulation monitor

monitoring of high voltage plugs and

service lid

monitoring of high voltage fuses

monitoring of high voltage relay

cell voltage balancing

battery management functionality

Safety Systemtarget: monitor safety relevant faults

detection: hazard / non-hazard

advanced diagnostics

Basic Software

ApplicationSoftware

Cell Modeling

• Cell characterization

• Battery algorithm

• System functions

• Application software

• AUTOSAR configuration

•Driver development


Safe Operation of Li-Ion Batteries

4 Level Concept

Cells Pack Design Pack Functions Application

• Qualified to Hazard

Level <= 3

• coated separator

• Pure and safe cathode

and anode material

• integrated safety

devices

• Robust and qualified

mechanic and electric

design

• Usage of self-

extinguishing materials

• Safe gas release to

ambient

• Safe Battery Mgmt.

Electronics and SW

• Monitoring of all safety

relevant operation

parameters

• Safe shutdown

• Thermal management

• Integration area

• Vent gas management

• Crash reaction

Level 1 Level 2 Level 3 Level 4

• Cell Design Qualified to Hazard Level <= 3

• Robust and qualified mechanic and electric pack design

• Safe Battery Management Electronics and SW

• Integration into vehicle safety concept

• Extensive Validation

Safety Risk minimization by a 4 Level Safety Concept


Production

Serial Production of Lithium Ion Batteries

PHEV serial production line

Module

1. Check / Preparation

2. Glueing

3. Welding

Pack

4. Assembly/Wiring

5. EOL Testing

1

2 3

4

5


Process: Check / Preparation / Glueing

• Plasma cleaning of the cooling plates

• Adhesive application on the cooling plates

• Adhesive needs to be thermally conductive, electrically

insulating, providing highest strength, process friendly

• Laser cleaning of the cells electrically isolated stacked

together

• Glueing of cell stack to cooler

Plasma Cleaning of Cooler

Laser Cleaning of Cell stack

Glue application to cooler


Process: Welding

• Connector board for cell connection is pre

assembled

• Aluminium busbars are cliped into a

polymer carrier

• Welding of busbars to the cell measuring

system

• Connector board is attached on top of the

cell stack which is glued on the cooling plate

• Aluminium busbars are laser welded onto

the cell terminals.

• All weld beads are controlled optically by

a surface scanner

Assembled modules

Module Connector board


Process: Assembly / Wiring / EOL Test

• Assembly and screwing of the cell

modules in pack housing.

• Wiring of module electronics to battery

management unit

• Wiring of modules and conectors

• Mounting the cover and end of line test.

• High Voltage End of Line Test performing

Safety, Capacity

Tests and Charging Operation

• Battery complies with an absolute contact

protection

3/13/2015

Assembly of 3 modules in bottom housing

Wiring of modules

Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited

Future Trends

Pouch housing

0

20

40

60

80

100

120

140

160

Ford MC346

GM Volt Mitsubishii-MiEV

Magna E-Car

serialprogram

2010

Magna E-Car

concept2010

Magna E-Car

concept2011

MagnaSteyr

concept2013

MagnaSteyr

concept2014

~79 ~88 ~80 65,5 78,7 88,7 95 110

Gra

vim

etr

ic E

nerg

y /

Wh

/kg

Mechanical Design & Integration

Self supporting module structure

Cell is used as mechanical structural part

Reduced weight of cooling air cooled system

Weight: 110 kg (10,5 kg/ kWh)

Dimensions: 1000 x 250 x 600mm (b x h x t) mm

Wh/kg on cell level

liq

uid

liq

uid

air

air

Pouch housing Steel metal can housing Al can housing li

qu

id

liq

uid

air

Package based on Standard Modules

Functionally combined Housing and cooling

Crash resistent Al housing 20

11

20

15

liq

uid


Battery price* development / kWh – estimation**

€ 315

€ 250

€ 200 € 180

€ 450

2009 optimization ofproductions (mass

production, cell power)

new materials cell standard material pricestandardization

2018

-30%

-15%

-10%

-5%

-60%

100%

80%

60%

40%

pri

ce

in

%

* supplier to OEM

** source: Continental AG Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015

Standardization on sub module/component level is a feasible approach to fulfill OEM

requests and shows quality & economy of scale effects on component level.

Cost target Standardization is the Enabler

Sta

nd

ard

izatio

n p

ote

ntia

l


Current Products

Innovation Fields

New Products

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2020

From 12V systems up to high energy BEV applications Product diversification driven by matching market needs

BEV

Battery Pack

Battery Systems Product Roadmap

HEV Truck

Gen I

12V Light Weight

Li-Ion Battery

PHEV

Battery Pack HEV Truck

Gen III

PHEV / HEV

Truck Gen IV

48 V System

Gen I

High Power

HEV Battery

12V Light

Weight Li-Ion

Battery Gen II

PHEV Battery

Pack Gen II

48 V System

Gen II (specific cells)

PHEV/EV

Systems based on:

• Improved Battery management

• Integrated sub components

• Next generation cell technologies

HEV Truck

Gen II

Diversification of product portfolio beyond vehicle industry


Documents

Lithium Ion Batteries in E-Mobility · Lithium Ion Batteries in E-Mobility Motivation Design for Manufacturing Trends Klaus Grieshofer 04.03.2015 . Outline Introduction of Magna Steyr