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1© Ricardo plc 2015
Benchmarking Overview
2014MY BMW i3 w/ REX
Version 1.2©Ricardo 2015
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 2
Disclaimer
[email protected] +01‐734‐394‐3939
Ricardo Inc. has taken all reasonable care in compiling the analyses and recommendations provided in this report. Information contained in this report is based on limited data available to Ricardo believed correct
on the date of publication. Ricardo does not assume any liability, nor provide any warranty to activities based on the contents of this report.
This report is restricted and may not be distributed, re-published, sold or exchanged outside use by purchased companies.
INTRODUCTION
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 3
Executive Summary
Ricardo and partner A2Mac1 conducted a benchmarking teardown and analysis review of a 2014MY BMW i3 with range extender vehicle. This report provides an overview of:
– Selected vehicle features
– High voltage battery pack design
• Enclosures
• Thermal system
• Battery module
• Battery cell
• Battery management system
– Traction motor and eMachine electronics (inverter/ DC‐DC converter)
– Charging system
– Range extender system
Most imagery is courtesy of A2Mac1 and Ricardo, and is available through A2Mac1.com subscription services and may be purchased by contacting A2Mac1.com or [email protected]. This report provides a review of selected vehicle and component features, suppliers and patents.
Additional information is provided in the Appendix of this document including public domain resources and patent files.
INTRODUCTION
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 4
1. Vehicle……………………………………………………….……………..4
2. Battery Pack…………………………………………………………….11
3. Battery Module………..……………………………………………..20
4. Battery Management System…………………………………..34
5. Traction Motor………………..………..…………………………….40
6. Gearbox…………………..…………………..………………………….52
7. eMachine Electronics……………………………………............54
8. On‐Board Charger………………………………..…………………..60
9. Charging Station……………………………………………..………..65
10. Range Extender System………………………….......………..…68
a. Generator eMachine……………………………….…………..71
b. REX eMachine Electronics…………………………….……..76
c. Combustion Engine……………………………………….…….82
d. REX Engine ECU……………………………………………..…….85
11. Appendix……………………………………………...…………….……88
Table of Contents
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 5
Vehicle Model Year 2014 Vehicle Market (as purch.) USA
Vehicle Price as Purchased $47,025 Vehicle Mass (as weighed) 1,404 kg
Powertrain ArchitectureBattery electric vehicle with range extender
Fuel Tank Capacity1 1.9 gallons
All Electric Range (label) 72 milesGasoline Only Range (label)
78 miles
Battery Location Under vehicle floor Battery Cooling Refrigerant (R134a)
Battery Pack Capacity (stated)
22 kWhBattery, Number of Modules
8
Battery Configuration XXX Battery, Number of Cells XX (1X per module)
Battery Voltage (label) 3XXVDCBattery Pack Capacity (label)
XXAh
Battery Cell Type Rigid Prismatic Battery Cathode Chemistry NMC
Motor Architecture 3- phase, AC hybrid sync. Motor Max Speed XX,X00
Motor Peak Torque 2XX Nm Gearbox Single-speed fixed gear
Motor Peak Power XX5 kW Final Drive Ratio X.X:1
Engine Configuration (REX) 4-stroke, Inline 2 cylinder Engine Displacement (REX) 647 cc
Engine Power (REX) XX kW @ XX00 RPM Engine Torque (REX) XX Nm @ 4300 RPM
AC Charging Capacity XX kWDC Charging*(Not included in purchased vehicle)
XXkW
1775mm 3999mm
1578mm
Source: http://www.bmwusa.com/Standard/Content/Vehicles/2014/i3/BMWi3RangeExtender/
Benchmarked Vehicle Overview
VEHICLE
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 14
2014MY BMW i3 Battery PackBattery Pack – Parameter Summary
BATTERY PACK
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 21
2014MY BMW i3 Battery ModuleBattery Module Overview
BATTERY MODULE
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 31
Battery Module Sense Controller Circuit Board Major Components (Bottom)
BATTERY MODULE
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 53
1-spd Gearbox – Internal Assembly
GEARBOX
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 79
REX eMachine Electronics (REME) Interfaces
11 9a
12
9b
12
11
9a 9b
Connection: XXXManufacturer: XXXMaterial: XXX
Connection: XXXMaterial: XXX
Connection: XXXManufacturer: XXX
5a
5a
Connection: XXX
15
15Connection: XXXManufacturer: XXX
REX EMACHINE ELECTRONICS
2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 90
Contact Information
Ricardo Strategic Consulting (RSC) is the global management consulting subsidiary of RicardoPLC and is a natural extension of Ricardo's high value‐added engineering services. We serve abroad range of clients in both the Automotive & Transportation sectors.
Coupling Ricardo’s significant work in the xEV sector product development and strategyconsulting with A2Mac1, the industry’s most recognized provider of web‐accessible automotivebenchmarking services, provides a unique toolset that supports companies efforts to deliverinnovative, high‐value services to their global automotive clients.
The following vehicles have been benchmarked:
Hands‐on workshops, interactive benchmarking tools, and battery CAD models are available forpurchase.
+01‐734‐394‐3939
http://estore.ricardo.com/
Ricardo Benchmarking
CONTACT US TO LEARN MORE ABOUT OUR xEV BENCHMARKING ACTIVITES
Workshops CAD ModelsEV/Hybrid Analysis
• 2015 VW e‐Golf• 2014 BMW i3 w/ Range Extender• 2014 VW Jetta Hybrid• 2014 Chevrolet Spark EV• 2013 Tesla Model S 60• 2013 Ford Fusion Hybrid
• 2013 Ford C‐Max Energi• 2013 Chevrolet Malibu Eco• 2012 Toyota Prius Plug‐in Hybrid• 2011 Chevrolet Volt• 2011 Nissan LEAF• 2011 Mitsubishi i‐MiEV
APPENDIX