BEYOND TEARDOWN - AVL SERIES BATTERY BENCHMARKING
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1 BEYOND TEARDOWN - AVL SERIES BATTERY BENCHMARKING Getting from low level parameter to target orientation Dr. Wenzel Prochazka AVL List GmbH (Headquarters)
2 CONTENTS OVERVIEW 1. AVL Introduction Focus Series Battery Benchmarking 2. Analyzing & rating of the system Benchmarking process & metrics 3. Battery benchmark examples 4. Summary 2
3 AVL AT A GLANCE RESEARCH 10% of turnover in-house R&D INNOVATION 1500 granted patents STAFF employees 65% engineers & scientists GLOBAL FOOTPRINT 30 engineering locations >220 test beds Global customer support network GROWTH Mio SALES 1995: 0.15 billion 2015: 1.27 billion billion EXPERIENCE 65 years! ONE PARTNER 5 powertrain elements 3
4 OVERVIEW OF AVL S BATTERY ACTIVITIES: FROM CONCEPT TO START OF PRODUCTION Test equipment for pack testing turnkey solutions for battery labs + Testing & Benchmarking System validation Planning, optimization & monitoring Validation target: km cycle life 12 years calendar life EMC targets fulfilled System interaction ok Module integration Thermal Simulation Mechanical Simulation Cell Modeling Prototype build Generation 1&2 build-up Systems Engineering Electrical & Mechanical Design Engineering Design for Production BMS & MCU development (SW & HW) 4
5 8 key attributes analyzed during AVL Series Battery Benchmarking 5
6 BENCHMARKING OF BATTERIES AVL benchmarking program: approx. 4-5 vehicles (PHEV or EV) per year 10 work packages with ~240 benchmarking criteria, derived >80 objectives, evaluated in 8 attributes Attributes, targets and criteria System Design Values, Requirements, Specification Standardized reports and documentation Vehicle Level Assessment Battery Assessment Tear Down Design Concept Identification Production Concept Identification Cost study 6
7 VEHICLES IN THE BENCHMARKING PROGRAM Currently in Benchmark: Mitsubishi Outlander PHEV Model 2015 (with OBD) - finishing Q Tesla Model X P90DL (upgrade to P100DL in March 2017) vehicle arrived pretests started 12/2016 Chevrolet Bolt EV started Vehicles in Planning for 2017: BYD Tang nd half 2017 BMW i nd half 2017? Audi Q7 PHEV 2 nd half 2017? Current proposals for next vehicles: Volvo XC90 Volkswagen egolf Nissan Leaf 2017 Images: Wikipedia.com & OEM Websites 7
8 CONTENTS OVERVIEW 1. AVL Introduction Focus Series Battery Benchmarking 2. Analyzing & rating of the system Benchmarking process & metrics 3. Battery benchmark examples 4. Summary 8
9 BENCHMARK CRITERIA & PARAMETERS BENCHMARK DATA GENERATION AVL BENCHMARKING - REVERSING THE V-PROCESS Performance Driver Experience Efficiency Safety Level 0 Vehicle Level 1 Vehicle Systems (i.e. Powertrain) Level 2 Elements (i.e. Battery) Level 3 Elements Sub-Systems (i.e. Module, Cooling System) Level 4 HW Parts / SW Systems / Electronic Hardware Engineering Requirements Production Capability Serviceability Battery Benchmark Attributes Cost Global Vehicle Benchmark System & Component Benchmarking Component Testing Subsystems Teardown & Testing Single parts assessment AVL S BENCHMARK AIMS TO ASSESS HOW WELL THE BATTERY SYSTEM FULFILLS REQUIREMENTS THAT ARE CONNECTED TO 8 MAIN ATTRIBUTES 9
10 BATTERY ATTRIBUTES Number of Parameters Performance Driver Experience Efficiency Safety Engineering Requirements Production Capability Serviceability Cost General Data Power: 4 Thermal: 6 Specific:24 Energy: 15 Sum: 49 Availability ext. Temp.: 6 SOX: 5 Power Pulse rep.:2 Sum: 13 Gravimetric:8 Volumetric:9 Electric:2 Thermal:11 Sum: 30 Electrical:12 Thermal:7 Mechanical:18 Functional:10 Homologation:1 Sum:48 Mechanical:8 Electrical:12 Thermal:2 Sum:22 Assembly:5 Modularity:5 Sum: 10 Component Change: 8 Battery (dis)- mounting: 6 Nonexchangeable: 8 Diagnostics: 6 Sum: 28 Warranty:4 Service:4 Production:2 Further Use:2 Sum:12 Power to Energy P/E: 2 Driver support: 10 Sum:12 TOTAL 224 assigned criteria EACH BATTERY ATTRIBUTE IS EVALUATED VIA AVL METRIC THAT USES DIRECT MAPPING OF EVALUATED PARAMETERS 10
11 SCATTERBAND - EXPLANATION SUB-ATTRIBUTE CRITERIA EVALUIATION ALGORITHM PARAMETER SUB- PARAMETER 6.4 0,32 Power 7.6 0,15 Thermal 5.2 0,26 Specific 5.8 0,27 Energy 6.4 0,45 Specific Power 5.2 0,55 Specific Energy 6.3 f x 0,45 Gravimetric energy density battery (Wh/kg) 0,15 Gravimetric energy density module (Wh/kg) 0,05 Gravimetric energy density cell (Wh/kg) 0,20 Volumetric energy density battery (Wh/l) ,10 Volumetric energy density module (Wh/l) 410 0,05 Volumetric energy density cell(wh/l) 480 Weight, Energy, volume, 4.3 Rating 4.2 Weighting THE PARAMETERS ARE TRANSLATED TO RATED CRITERIA. THESE CRITERIA ARE RATED SUB- DIVISIONS OF ONE ATTRIBUTE WEIGHTING AND RATING DIFFER FOR SPECIFIC SEGMENTS 11
12 CONTENTS OVERVIEW 1. AVL Introduction Focus Series Battery Benchmarking 2. Analyzing & rating of the system Benchmarking process & metrics 3. Battery benchmark examples 4. Summary 12
13 VEHICLES CURRENTLY ON THE MARKET Already benchmarked vehicles Nissan Leaf Tesla Model S Smart EV Chevrolet Bolt Vehicles in work / planned for 2017 Mitsubishi Outlander PHEV BYD e6 Current proposals for next vehicles Denza Yutong Electric City Bus Tesla Model 3 (2018) VW Passat GTE Renault Kangoo ZE Audi Q7 PHEV Tesla Model X Nissan NV200 Renault Zoe 2015 Volvo XC90 VW eup BMW i8 Images: Wikipedia.com & OEM Websites BYD Tang Renault Zoe 2017 BMW i3 VW egolf 13
14 BATTERY BENCHMARK VEHICLE RENAULT ZOE Official Vehicle Data Power peak: Power continuous: Torque: Speed: Acceleration: kph Range: Weight: 65 kw 43 kw 220 Nm 135 kph 13,5 sec 210 km (NEDC) 1468 kg Official Battery Data Energy total: 25,9 kwh (battery label) Voltage Nominal: 360V Cell number: 192 Configuration: 96s2p Cooling: closed air cooling Weight: 279 kg (incl. side profiles) Source: Official product and website information, Renault, own picture Best sold BEV in Europe
15 CLOSED AIR COOLING - ASSESSMENT ON ROAD MEASUREMENT Driving Charging Driving Charging Driving Charging Module temperatures during demanding driving and charging Continuous operation leads to ΔT > 10 C Battery cooling only active during charging Increasing temperature difference between modules * * Outside air temperature 15
16 COOLING SYSTEM AIRFLOW DESCRIPTION Air path in the battery: central channel -> gaps between the cell housings -> to outer sides -> back to the outlets. To cooling air return duct right Cooling air inlet duct To cooling air return duct left Cooling air distribution is disturbed by structural profile used for crush safety! Central air distribution duct Detail: structural aluminum profile in side view 16
17 Pack Volume Efficiency (%) Cell/Pack PACK WEIGHT AND VOLUME EFFICIENCY BROUGHT INTO CONTEXT Renault Zoe Pack Weight Efficiency (%) Cell/Pack Renault Zoe cooling system volume included refrigerant cooling water/glycol cooling air cooling 17
18 BATTERY BENCHMARK VEHICLE TESLA MODEL S Official Vehicle Data Power: Torque: Speed: Acceleration: kph Range: Weight: 270 kw 440 Nm 201 kph 5,6 sec 482 km (NEDC) 2108 kg Official Battery Data Energy: 85kWh Voltage Nominal: 355V Voltage Max: 400V Cell number: 7104 Configuration: 96s74p Cooling: Liquid Weight: 618 kg Source: Official product and website information, Tesla 18
19 BATTERY CRASH PROTECTION TESLA MODEL S Battery housing mainly Aluminum parts (rectangular profiles, casted parts and sheets), rather massively constructed In case of side crash, protection only in combination with the special vehicle side structure Shield is added to the front underfloor for impact protection Explicit view of Mountingprofile side in detail in mm battery housing side structure Mounting profile front small (including outer profile) in detail in mm 19
20 BATTERY BENCHMARK VEHICLE MITSUBISHI OUTLANDER PHEV MODEL 2015 Official Vehicle Data Power peak (electric): Power cont. (electric): Torque (electric - front): Torque (electric - rear): Speed: Acceleration: kph Range: Weight: 76 kw 50 kw 137 Nm 195 Nm 170 kph 10,3 sec 52 km (NEDC) 1969 kg Official Battery Data Energy total: 12 kwh (battery label) Voltage Nominal: 300V Cell number: 80 Configuration: 80s1p Cooling: closed air cooling Weight: 183 kg (incl. mounting) Best sold SUV-PHEV worldwide in 2015 Source: Official product and website information, Mitsubishi, Own picture 20
21 GLOBAL VEHICLE BENCHMARKING EXAMPLE GIVEN - PREMIUM PHEV SUV AVL scatter band BMW X5 xdrive40e Gasoline, AWD, 1997 ccm Volvo XC90 T8 Gasoline, AWD, 1969 ccm Mitsubishi Outlander (III) Plug-In Hybrid Gasoline, AWD, 1998 ccm Economy Technology Vehicle Attributes Driving experience 21
22 CONTENTS OVERVIEW 1. AVL Introduction Focus Series Battery Benchmarking 2. Analyzing & rating of the system Benchmarking process & metrics 3. Battery benchmark examples 4. Summary 22
23 SUMMARY AVL BENCHMARK ADDED VALUE Vehicle benchmark knowledge extended to sub-system and component level Advanced component testing and analysis (e.g.: abuse testing) Assessment of overall component interaction to fulfill vehicle targets Evaluation of requirements and achievement from system to component level Methodical approach to objectively compare battery system metrics 23
24 THANK YOU
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