Lithium Ion Batteries in E-Mobility

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1 Lithium Ion Batteries in E-Mobility Motivation Design for Manufacturing Trends Klaus Grieshofer

2 Outline Introduction of Magna Steyr Battery Systems Motivation for Electromobility Development Production Future Trends

3 MAGNA STEYR BATTERY SYSTEMS

4 Battery Systems Top Quality Storage Systems for Electric and Hybrid Vehicles Austria Graz, Zettling North America Auburn Hills China Shanghai, Changchun Li-Ion battery systems Testing services Low-voltage systems High-voltage systems Battery systems for passenger cars and commercial vehicles based on state-of-the-art lithium-ion technology State-of-the-art test labs in Europe and North America ensure the highest quality and safety standards B:LiON lightweight battery systems for automotive micro, mild and hybrid applications, as well as onboard power supply B:LiON battery systems in the high-voltage range as an energy store for fully electric or hybrid vehicle applications

5 Battery Systems Locations Europe Zettling (HQ) Austria (Europe) Employees: 171 (Status Q3 / 2013) Plant Size: 14,060 m² Functions Battery Pack Engineering Prototype Battery Builds Battery Pack Assembling

6 Battery Systems Locations North America and China Auburn Hills Changchun Michigan (USA) Employees: 48 (Status Q3 / 2013) Plant Size: 7,630 m² Functions Battery Pack Engineering Battery Testing Material Testing China, Jilin Province Expansion of existing plant Planned size: ~ m² Planned Production volume: ~35.000/(year) Functions Battery Pack Assembly (SOP: Q2/2016) Battery Pack Engineering

7 Battery Systems Portfolio Automotive Market Energy Plug-In PHEV Hybrid (HEV) 48V 12V Truck PHEV Serial Production Serial Production Serial Production Serial Production Energy Content kwh 6-18 kwh kwh kwh ~ 70 Wh 8-14 kwh Power kw kw kw 8-11 kw ~ 3 kw kw Voltage 400 V 400 V 120 / 400 V 48 V 12 V 400 / 700 V Weight kg kg kg ~ 15 kg ~ 5 kg kg Cooling liquid (optional) liquid air / liquid Manuf. Capacity AC cooling / liquid 3,000 / year > 35,000 / year 50,000 / year 100,000 / year ---- liquid < 100,000 / year 3,000 / year

8 Total Energy [kwh] Matrix of Battery Pack Applications EV* Electric Vehicle PHEV* Plug In Hybrid Vehicle HEV* Hybrid Electric Vehicle EV* ENERGY BATTERY PACKS PHEV* ENERGY BATTERY PACKS TRUCK/BUS HEV* HEAVY DUTY POWER BATTERY PACKS / 48V SYSTEMS POWER BATTERY PACKS MILD HEV* POWER BATTERY PACKS FULL HEV* POWER BATTERY PACKS Power [kw]

9 MSBS Track Record HEV Truck Gen III 12V Light Weight Li- Ion Battery PHEV / HEV Truck Gen IV 12V Light Weight Li-Ion Battery Gen II HEV Truck Gen I PHEV Battery Pack High Power HEV Battery HEV Truck Gen II BEV Battery Pack Serial Projects with SOP Development

10 Motivation for Electromobility

11 CO 2 is a Global Reference Point for Hybridization Legislative Convergence across TRIAD, China, and SK CO 2 reduction requirements by OEM in EU Source: IHS Automotive, Berlin March 2013 TODAY Legislative CO2 reduction requirements EU: -27% ( ) NA: -33% ( )

12 /%CO 2 Reduction Approach to reach the targets CO2 measures on NEDC vs. Costs Propulsion System Leightweight Improved efficiency Aerodynamiics Rolling resistance Propulsion-related measures Other measures Aerodynamics Propulsion-related CO 2 measures achieve a good cost relation

13 CO 2 Reduction requires Diversification of Powertrains Fuel cell vehicles Range extended EV emissions City Long Distance ICE optimization Light weight Energy management Aerodynamics & Friction CNG/ LPG Synthetic sun fuels BiSG & CiSG, 12V/48V Stop/start Mild hybrids Full hybrids PHEV Electric vehicles Electric vehicles relative CO 2-20 to -30% up to -40% up to -60% up to -100% EU targets: 130 gco 2 /km 95 gco 2 /km tbc: 70 gco 2 /km High powertrain diversification expected over the years For City emission free driving with PHEV and BEV

14 Functions Components Comparison EV and conventional vehicle A/B/C Segment Conventional Vehicle Electric Vehicle 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 Range >1000 km Up to 500 km Max. speed >180 1 shift Refuel/charging 3 min Fast charge <20min Energy recovery No 25-40% CO 2 emissions 140g/km 0g/km Energy efficiency <30% ~70%

15 Daily Tagesleistung activities in % [%] Daily activities, accumulated [%] Tagesleistung in %, kumuliert Daily Driving Range Germany 0 2,6 5,2 7, , >260 PKW-Tagesfahrleistungen in km Daily driving range [km] Source: Bundesministerium für Verkehr, Bau- und Wohnungswesen (BMVBW), % 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 At present average electrical range of electric vehicles km Batterysolution will increase costs & weight

16 Development

17 MAGNA STEYR Battery Systems Development Process Mechanical integration Thermal concept Customer tailored housing Modular concept Functional integrated (Cooler + Housing) DESIGN Thermal simulation Cooling concept for cell thermal management Liquid or air cooled Electrical integration Low cost and high integrated cell to cell connection Battery disconnect unit Interfaces Wiring of measurement circuits Cell Selection Costumized Pack Tailored cell chemistry All cell housing types and chemistries feasible Validation Mass Production Software / Battery Management Functional Safety Concept Balancing + Supervision of cells State Monitoring (State of Charge, State of Power, State of Health) Communication/ CAN Usage Logging over life Performance Transportation Mechanical Thermal and Climatic Safety Life Cycle other

18 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 Battery weight distribution Selection Topics: Mechanical design Performance design Chemical components Safety features Cylindric Cells Prismatic Cells Pouch Bag Cells

19 Specific Energy [Wh/kg] Cell Technology Lithium-Air Solid State 220 (2013) R&D stage serial after 2030 R&D stage serial after 2020 NiMH /kwh 200 (2020) R&D stage serial after 2025 Lithium-Sulfur 300 (2013) /kwh 170 (2020) Super-Capacitors Lithium-Ion Lithium-Ion-Capacitors R&D stage serial after 2018 > (2013) /kwh ~8000 (2020) Specific Power [W/kg] * 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

20 Tailored cell technologies to specific applications PHEV HEV 48V 12V Cell capacity Ah 6 10 Ah 6 10 Ah 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 Anode material Graphite Graphite, HC SC, HC, LTO Reduced particle size, thinner electrodes, high surface area Cathode material NMC, NCA, LMO, LFP Reduced particle size, thinner electrodes, high surface area, coatings NMC,LFP Electrolyte Separator Mechanical design 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

21 Thermal integration concepts - overview Energy Plug-In Hybrid 48V 12V Energy Content kwh 6-18 kwh 0,2-3 kwh 0,6-1 kwh 0,25-1 kwh Power kw kw kw 10-2 kw 3 kw Heat generated W W W < 60 W < 15W Passive cooling passive cooling should be sufficient for low C-rates applications. passive cooling should be sufficient for limited performance. Air Cooling Cost efficient air cooling option Liquid cooling For EV and PHEV applications best compromise in matter of packaging, cooling and heating performance, safety and comfort Refrigerant Cooling For HEV refrigerant cooling is an option to avoid a own liquid cooling circuit for the battery pack. 21

22 Trends in liquid cooling design Housing-integrated cooling: Thermal management Bottom cooling via cooling tubes Bottom cooling via double-wall housing Impact on: Performance, Life, Safety Cooling plate designs: Design criteria Cell operation T of ~ 35 C Homogeneous temperature distribution on cell and module level Thin sheet cooling plates Cooling plates with structural function Methods: Simulation (0d, 1d, 3d) Functional integration Verification

23 Thermal cooling design 3D Computational Fluid Dynamics (CFD) Velocities 3D Temperature distribution Temperatures

24 Mechanical integration - Overview EV PHEV / REX Hybrid (HEV) 12V / 48V Bus / Truck Serial Production Serial Production Serial Production Serial Production 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 Program, fully qualified battery pack Prototype build-up, concept validated Feasibility study, concept simulated and analyzed

25 Trends in PHEV housing design PHEV die-cast housing Material: Aluminum crash alloy +) Complex geometry possibilities +) Low cost at high volume +) crash & shock requirements - ) Limitation in size Mechanical design Package arrangement Integration of Cooling Crash performance Mechanical endurance (life time) Vibration and shock durability Temperature / humidity durability Design for manufactoring Al-Extrusion housing Material: Extruded aluminum profiles +) High mechanical strength +) crash +) For low and high volume, all sizes - ) Not suitable for complex installation space shapes

26 sensor fuse Electrical design - examples Integrated cell connection unit for battery module Automated HV connection Automated wiring to PCB Integrated temperature sensor Compact EMC Filter: Electrical design HV-Path LV-wiring Interconnections Insulation / HV Protection Battery Disconnect Units EMC Filters Compact design Easy assembly Highly effective Compact high-voltage connection board: Designed for automated assembly 2 relais

27 Battery Management System Overview Implemented Functionality BMU/ CSC functions Cell measurement -Cell voltage -cell temperature Power limit calculation Cooling control Wake up / Stop Wake up Pack measurement -pack voltage -pack temperature System measurement -Cooling media inlet and outlet temperature Wake up/ Stop control Cell balacing control HV Isolation Monitoring SOC ( Range ) Available power State of health Crash Signal SOC Estimation SOH Estimation Diagnostics CAN Communication Warning messages Diagnostics CAN Communication Vehicle Cell balancing Cooling HV contactors HV Interlock Battery

28 CAN KL 30 KL 30c HVIL Cooling Vehicle HV Supply Electronics / Battery Management Hardware architecture Battery management controller CSC CSC Service Lid Lion Cell Lion Cell Lion Cell + - Current Sensor (redundant) Relay V+ Relay V- HV Fuse + - CSC CSC Pre-Charge Relay BMU Cell voltage monitoring 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

29 Software / Battery Management Cell model Requirements Development Acceptance Tests Onboard Diagnostic OBD-2 target: monitor emission relevant faults detection: defective sub-component SYSTEM LEVEL SUBSYSTEM LEVEL Design Electrics & Mechanics System Design Design System Functions Design HW Design SW SW Integration Test (HiL) SW HW System Integration Test (System Testbench) Subsystem Integration Test (System Testbench) SW Test (HiL) Design Verification (DV) Electronics, Mechanics & Electrics Safety System target: monitor safety relevant faults detection: hazard / non-hazard Tooling construction Create production data Detailed Design Detailed Design SW Software SW Implementation Implementation Electronics Production Module Test SW SW Module test Module test Set into operation, HW Component test Electrics & Mechanics monitoring of system current COMPONENT LEVEL Component Production (Electrics & Mechanics) monitoring of cell temperature monitoring of cell voltage advanced diagnostics monitoring of cell temperature monitoring of high voltage fuses monitoring of system voltage monitoring of high voltage relay monitoring of cell voltage monitoring of high voltage plugs and service lid Cell Modeling Cell characterization Battery algorithm monitoring of system current battery management functionality monitoring of coolant temperature Application Software cell voltage balancing insulation monitor System functions Application software Basic Software AUTOSAR configuration Driver development

30 Safe Operation of Li-Ion Batteries 4 Level Concept Safety Risk minimization by a 4 Level Safety Concept 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 Level 1 Level 2 Level 3 Level 4 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 selfextinguishing 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

31 Production

32 Serial Production of Lithium Ion Batteries 5 4 PHEV serial production line Module 1. Check / Preparation 2. Glueing 3. Welding Pack 4. Assembly/Wiring 5. EOL Testing

33 Process: Check / Preparation / Glueing Plasma Cleaning of Cooler 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 Glue application to cooler Laser cleaning of the cells electrically isolated stacked together Glueing of cell stack to cooler Laser Cleaning of Cell stack

34 Process: Welding Module Connector board Connector board for cell connection is pre assembled Aluminium busbars are cliped into a polymer carrier Welding of busbars to the cell measuring system Assembled modules 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

35 Process: Assembly / Wiring / EOL Test Assembly of 3 modules in bottom housing 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. Wiring of modules High Voltage End of Line Test performing Safety, Capacity Tests and Charging Operation Battery complies with an absolute contact protection 3/13/2015

36 Future Trends

37 Gravimetric Energy / Wh/kg air liquid air liquid liquid air liquid liquid Mechanical Design & Integration Wh/kg on cell level ~79 ~88 ~80 65,5 78,7 88, Ford M C346 GM Volt Mitsubishi i-miev Magna E- Car serial program 2010 Magna E- Car concept 2010 Magna E- Car concept 2011 Magna Steyr concept 2013 Magna Steyr concept 2014 Pouch housing Steel metal can housing Al can housing Pouch housing Weight: 110 kg (10,5 kg/ kwh) Dimensions: 1000 x 250 x 600mm (b x h x t) mm Self supporting module structure Cell is used as mechanical structural part Reduced weight of cooling air cooled system Package based on Standard Modules Functionally combined Housing and cooling Crash resistent Al housing

38 price in % Battery price* development / kwh estimation** 100% 80% 60% 40% % % % 200-5% % 2009 optimization of productions (mass production, cell power) new materials standardization cell material price 2018 * supplier to OEM ** source: Continental AG

39 Cost target Standardization is the Enabler Standardization potential Standardization on sub module/component level is a feasible approach to fulfill OEM requests and shows quality & economy of scale effects on component level.

40 Battery Systems Product Roadmap From 12V systems up to high energy BEV applications Product diversification driven by matching market needs PHEV / HEV Truck Gen IV New Products PHEV Battery Pack Gen II Innovation Fields PHEV/EV Systems based on: Improved Battery management Integrated sub components Next generation cell technologies Current Products HEV Truck Gen I BEV Battery Pack 12V Light Weight Li-Ion Battery HEV Truck Gen II HEV Truck Gen III PHEV Battery Pack 12V Light Weight Li-Ion Battery Gen II 48 V System Gen I High Power HEV Battery 48 V System Gen II (specific cells) Diversification of product portfolio beyond vehicle industry

41

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