System Engineering for Energy Storage Systems

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1 System Engineering for Energy Storage Systems Wolfgang Kriegler Guido Bartlok Erich Ramschak Rainer Schruth 7 th A3PS Conference ECO-Mobility 12 th December 2012, Tech GateVienna

2 Content Introduction Future Powertrain Options and Consequences Alternative Energy Storages Battery Systems CNG Storage Systems Hydrogen Storage Systems Integration of Energy Storage Systems Summary and Outlook 2

3 MAGNA STEYR offers Engineering Vehicle Contract Manufacturing Engineering services including complete vehicle development Flexible solutions from niche to volume production Fuel & Battery Systems Innovative fuel & battery systems Roof Systems Entire range of roof systems

4 Future Power Train Variants in the tension field of desired vehicle range & zero emission Long distance big range low emission Fuel Cell Vehicle (FCV) Range-ext ICE Plug-in Hybrid with ICE (PHEV) Hybrid Vehicles with ICE (HEV) Bi-fuel ICE CNG, H2 Efficient internal combustion engine (ICE) City emission free zones Battery AEV Battery AEV localy emission free low CO2, NOx, etc. CO2, other emissions(pm, NO x, HC, CO, O 3 ) E-Motor ICE Com mbination Diversification of power trains and fuels Alternative power trains Electrification need battery systems with high energy density CNG and hydrogen need high pressure gaseous storages 4

5 Challenges for Diversification of Power Trains driving range total cost of ownership (TCO) efficient ICE refilling time recharging hybrid transmission power / energy battery E-Motors with/without rare-earth magnets modular fuel cell systems tank systems H2 & CNG electrical axles modular power converter Smart integration of affordable systems in global vehicle platforms 5

6 Challenges 6

7 Alternative Energy Storage Systems Batteries Hydrogen Storages CNG Storage Systems 7

8 Battery Systems: Requirements and Challenges Performance Power, energy per weight and volume on system level Life Years of service Overall energy throughput No of cycles, hours of usage Cost Environment Materials used Design for recycling (eco-design) Safety EUR/kWh EUR/kW Space Available space utilization Module dimensions, mounting directions Validation for all possible situations Weight Chemistry vs. total system weight Housing 8

9 Battery Architecture Battery Energy Storage Body System CAN VEH CAN HYB LV 12V & 24V Master BMS ECU SW LIN Bus CSC CSC Cell system Cell Cellsystem Cooling cooling circuit HV Contactor switches LV Sensors Sensors HV LV HV LV Electrical Electrical interconnections PDU Low voltage connection (LV) High voltage connection (HV) Bus (CAN VEHICLE, CAN HYBRID) 9

10 Li-Ion Battery System with 36 kwh Capacity 10

11 Battery Development Process Mechanical and Thermal Integration Customer Requirements package, cooling strategy, interfaces, HV connection Battery Management BMS, CSC, wiring main fuse, contactor Cells chemistry, housing, type Algorithms and Software state algorithms (charge, power, health) Validation and Production 11

12 Battery Testing for Validation and Certification IP6K9K (Dust, High Pressure Water Jet) Test performed according ISO 20653:200 Mechanical shock test Test performed according FreedomCAR Abuse Manual Fuel Fire Test Test performed according FreedomCAR Abuse Manual 12

13 CNG Storage Systems: Requirements and Challenges Performance Kg CNG per weight and volume on system level Life Leaking Years of service Permeation No of pressure cycles Cost Environment Design for recycling (eco-design) Safety EUR/Liter Space Available space utilization Module dimensions, mounting directions Validation for all possible situations Weight Material selection vs. total system weight and cost 13

14 Gaseous Storage Systems for CNG High pressure storage vessel Filling port Compressed Natural Gas (CNG) more environmentally friendly fuel (less CO 2 ) cheaper than gasoline & diesel (up to 50%) robust & innovative technology Fuel Storage gaseous, compressed up to 200 bar Light weight-composite-technology weight reduction compared to steel up to -74% with carbon fiber up to -52% with carbon/glass fiber mix plastic inner liner as gas barrier metal end piece for valve mount Gasoline reserve tank Pressure regulator On-Tank Valve MAGNA STEYR Services Development & Production cylinder, system vehicle integration vehicle functional tests & validation 14

15 Hydrogen Storage Systems: Requirements and Challenges Performance Kg H 2 per weight and volume on system level Life Permeation, Liner-Boss Sealing No. of pressure cycles Leakage; Valve Sealing; Pressure regulation Years of service Cost Environment Design for recycling (eco-design) Selection of materials Safety EUR/Kg H 2 Package Weight Available space utilization Cylinder No, module dimensions mounting directions CFK material quality selection vs. total system weight and cost Validation for all possible situations High Volume Production Automotive processes In-Line and EoL-testing 15

16 High Pressure Storage for Hydrogen Interface of Filling Line for High Pressure Vessel On-Tank Valve Fully wrapped composite cylinder with plastic liner (Type-IV) and system components for storage of high compressed Hydrogen (H 2 ) Storage pressure up to 70 Mpa H 2 -Supply line to FC Plastic liner as Hydrogen permeation barrier High Pressure Sensor Pressure Release Valve Pressure Regulator Low Pressure Sensor 16

17 Schematic H 2 -Systemlayout Filling receptacle P2 Pressure regulator 8+2bar and over pressure valve 16 bar P1 Filter Engine Calculation devide Excess flow limiter Filter ) ( > < ) ( > < ) ( > < Check valve Shut off valve Manual valve venting line high pressure line > 10 bar low pressure line 8+2 bar steering line housing On tank valve P1 P2 Pressure sensor 0 bar - max. pressure Pressure sensor 0-20bar 17

18 Testing for Validation and Certification Pressure and burst test Drop test Penetration test Hydraulic cycling test Leak and permeation test Bonfire test Institute for hydrogen tests with accreditation according DIN EN ISO/IEC

19 OPEL Zafira Serie (circuit diagram) Pressure regulator 8+2bar and over pressure valve 16 bar Filling receptacle P2 P1 Filter Engine Calculation devide ) ( ) ( ) ( ) ( > < > < > < > < P1 venting line high pressure line bar low pressure line 8+2 bar stearing line housing Pressure sensor bar > < > < > < > < P2 Pressure sensor 0 20 bar 19

20 Integration of Energy Storage Systems Fiat Panda E-Drive Concept Start Research Project: Hybrid System 2004 LI-ION Battery- System (LIBS) Hybrid Powertrain Development 2006 Foundation of Magna Electronics 2007 R&D Hybrid SUV (HYSUV) 4WD Full Hybrid 2008 R&D Mila EV R&D Mini PHEV 2009 SOP Heavy Duty Battery Pack 2010 R&D Fiat Panda (HICEPS) Compact city hybrid 4WD 2011 SOP Ford Focus BEV* SOP EV Battery Pack* SOP LCV EV* 2012 R&D Viano PHEV* SOP Electric Rear Axle** 27 years of experience in alternative powertrains * Magna ECar Systems **Magna Powertrain 20

21 Reference: CCH Integration Electric Rear Axle Geometrical Integration Electric Rear Axle High Voltage- Starter/Generator Integrated High Voltage-Battery Energy Management Strategy Functional Integration 21

22 R&D Project 4WD Full Hybrid Demonstrator HySUV TM Development of a complete full hybrid in cooperation with key partners to achieve enhanced driving dynamics and fuel savings. Vehicle Integration Electric 4WD module Full hybrid Li-Ion HV battery Series and parallel hybrid with unique electric 4 WD capability Unique ICE/E-Motor/Transmission integration with clutches to flexible power front or rear axle MAGNA STEYR built Lithium-Ion battery capable of powering two 50 kw electric motors Operating strategy including start/stop, load shifting for recharging battery, regenerative braking and electric driving Electric air-conditioning compressor, electric steering and other electric auxiliaries Unique AWD module integrated between ICE and AMT, designed for easy implementation in other powertrains Combining fuel savings up to 24 % with enhanced driving dynamics & electric driving 22

23 CNG Storage Integration in OPEL Zafira CNG System 200 bar 4 Vessels: Content 24kg Main Valve Block Pressure Regulator Filling receptables 4 Pcs On Tank Valves Cooling system VKM 4 Pcs Metal Ports with Temperature- Safety valves System Interface for Cost Comparison Gasoline Tank 23

24 H 2 Integration: Usual H 2 -Systemlayout H 2 System 700 bar 3 Vessels: Content 4kg Pressure regulator and pressure relief valve Fueling receptacles H 2 3x On-Tank Valves Cooling system Hydrogen Circuit FC Mounting frame Venting Line Air system Service interface with bleed valve 24

25 Vehicle Prototyping e.g. FCV Integration of Energy Storage Systems Services Vehicle prototypes up to 300 units per year Fleet maintenance and vehicle repairing (FCV, H 2 /CNG-ICE, ) Integration of FC systems, H 2 or CNG storages and components Functional testing of FC-systems and FCV or CNG vehicles H 2/ CNG safety check and verification Specifications Working areas including vehicle lifts for two fuel cell or H 2 -ICE vehicles Certified for <9kg H 2 (storages) Skilled personnel for handling with hydrogen or natural gas 25

26 Summary and Outlook Energy storages are key technologies for future green mobility and impact customer acceptance In alternative vehicles, batteries, CNG and hydrogen tank systems and their smart integration decide on cost safety driving range functionality e.g. recharging / refilling time MAGNA STEYR has long time experience in energy storage systems and offers products and engineering services for CNG, H 2 and battery vehicles We focus on Industrialization for high volume production Cost reduction incl. modularity, supply chain management System package optimization Geometrical and functional integration in global platforms 26

27 Thank your for your attention MAGNA STEYR offers mobility solutions of the future The future is ours to make. Wolfgang Kriegler, Guido Bartlok, Erich Ramschak, Rainer Schruth 27

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