AVL SERIES BATTERY BENCHMARKING. Getting from low level parameter to target orientation

AVL SERIES BATTERY BENCHMARKING Getting from low level parameter to target orientation

CONTENTS OVERVIEW 1. AVL Introduction 2. Focus Series Battery Benchmarking 3. Benchmarking process 4. Target comparability - Analyzing & rating of the system 5. Battery benchmark example 6. Summary 3

ENTERPRISE DEVELOPMENT AUTOMOTIVE RESEARCH 10% of turnover in-house R&D INNOVATION 1500 granted patents STAFF 8.050 employees 65% engineers & scientists GLOBAL FOOTPRINT 30 engineering locations >220 test beds Global customer support network GROWTH Mio. 1.500 1.400 1.300 1.200 1.100 1.000 900 800 700 600 500 400 300 200 100 0 SALES 1995: 0.15 billion 2015: 1.25 billion prev. 2016 1.41 billion EXPERIENCE 65 years! ONE PARTNER 5 powertrain elements 4

HV-BATTERY AVL high accuracy battery state calculation algorithms: SOx and battery cell wear detection - enable increased driving range, reduced charging time and extended operability AVL algorithms developed together with AVL battery chemistry team - strategic development partner for cell manufacturers AVL control solutions for battery system from 12V to 1000V scalable for platform usage 3 rd generation integrated battery module controller and ASIC s Reduction: electronic component number, costs, size and weight Complete AVL battery control logic proven in production for several applications AVL Semiconductor based main switches R&D Project to reduced the cost, increase robustness and extend the modularity AVL HV battery EMC simulation service of full parametrized battery model for several OEMs with analog 3D model description, cell packages, SOC, aging, coupling effects of various geometrical aspects of enclosure, bus bars and battery modules AVL HV battery EMC simulation competence of H-field distribution of new batteries regarding ICNRIP requirements and exposure to human beings at various positions of the body HV battery EMC development assistance in terms of shielding, EE-box arrangement, wire routing LV, HV/LV attenuation and bus bar routing HV battery EMC full 3D and analog simulation of filters integrated within HV battery 6

OVERVIEW OF AVL S BATTERY ACTIVITIES Test equipment for pack testing turnkey solutions for battery labs + Testing & Benchmarking System validation Validation target: 300.000 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 Electrical & Mechanical Design Engineering Design for Production BMS & MCU development (SW & HW) 9

CONTENTS OVERVIEW 1. AVL Introduction 2. Focus Series Battery Benchmarking 3. Benchmarking process 4. Target comparability - Analyzing & rating of the system 5. Battery benchmark example 6. Summary 10

BENCHMARKING OF BATTERIES AVL runs a benchmarking program for xev batteries: approx. 4-5 vehicles (PHEV or EV) per year 10 work packages with benchmarking of ~240 single criteria Derivation of >80 objectives for better comparability Management view available through final evaluation in 8 attributes Attributes, objectives and criteria System Design Values, Requirements, Specification Standardized reports and documentation available Vehicle Level Assessment Battery Assessment Tear Down Design Concept Identification Production Concept Identification Cost study 11

AVL SERIES BATTERY BENCHMARKING - PROGRAM KICKED OFF JULY 2016 Vehicles in Planning for 2016/2017: Mitsubishi Outlander PHEV Model 2015 (with OBD) started finishing Q1/17 Tesla Model X P90DL (X P100DL) - vehicle arrived start within 10/2016 Chevrolet Bolt start Q1 2017 BYD Tang start Q1 2017 Audi Q7 PHEV start Q2 2017 12

AVL objective rating CONNECTING WORKING PACKAGES TO BENCHMARK ATTRIBUTES 10 Work Packages (sequential): Vehicle Powertrain Tests Vehicle Integration Battery Data Battery Testing Tear Down Module Tests Cell Tests Cost Analysis Abuse Testing Number of Criteria: ~240 Connection: How to? 8 Attributes to be assessed: 14

BENCHMARK CRITERIA & PARAMETERS BENCHMARK CRITERIA & PARAMETERS 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 AVL S BENCHMARK AIMS TO ASSESS HOW WELL THE BATTERY SYSTEM FULFILLS REQUIREMENTS THAT ARE CONNECTED TO 8 MAIN ATTRIBUTES 15

BATTERY ATTRIBUTES Number of Parameters Performance Power: 4 Thermal: 6 Specific:24 Energy: 15 Sum: 49 Driver Experience Availability ext. Temp.: 6 SOX: 5 Power Pulse rep.:2 Sum: 13 Efficiency Gravimetric:8 Volumetric:9 Electric:2 Thermal:11 Sum: 30 Safety Electrical:12 Thermal:7 Mechanical:18 Functional:10 Homologation:1 Sum:48 Engineering Requirements Mechanical:8 Electrical:12 Thermal:2 Sum:22 Production Capability Assembly:5 Modularity:5 Sum: 10 TOTAL 224 assigned criteria Serviceability Cost General Data 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 EACH BATTERY ATTRIBUTE IS EVALUATED VIA AVL METRIC THAT USES DIRECT MAPPING OF EVALUATED PARAMETERS 17

BATTERY ATTRIBUTES DETAIL VIEW Parameters Weighting Gravimetric energy density battery (Wh/kg) 0,45 Gravimetric energy density module (Wh/kg) 0,15 Gravimetric energy density cell (Wh/kg) 0,05 Volumetric energy density battery (Wh/l) 0,20 Volumetric energy density module (Wh/l) 0,10 Volumetric energy density cell(wh/l) 0,05 Sum 1 EACH BATTERY ATTRIBUTE IS EVALUATED VIA AVL METRIC THAT USES DIRECT MAPPING OF EVALUATED PARAMETERS 18

SCATTERBAND - EXPLANATION SUB-ATTRIBUTE CRITERIA 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) 130 170 250 360 0,10 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 19

RENAULT ZOE BATTERY BENCHMARK VEHICLE Official Vehicle Data Power peak: Power continuous: Torque: Speed: Acceleration: 0-100 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 2015 21

CLOSED AIR COOLING - ASSESSMENT ON ROAD MEASUREMENT Test Conditions: Driving in 3 segments After each segment charging Results interpretation: Air cooling is needed only during charging in 20 C ambient conditions Temperatures are not equalized during driving Temperature spread between modules is rising due to a metal crash protection profile halfway through pack Driving Battery cooling only active during charging Increasing temperature difference between modules 22

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 Central air distribution duct Detail: structural aluminum profile in side view 23

TESLA MODEL S BATTERY BENCHMARK VEHICLE Official Vehicle Data Power: 270 kw Torque: 440 Nm Speed: 201 kph Acceleration: 0-100 kph 5,6 sec Range: 482 km (NEDC) Weight: 2108 kg 15, 16 Official Battery Data Energy: Voltage Nominal: Voltage Max: 400V Cell number: 7104 Configuration: Cooling: Weight: 85kWh 355V 96s74p Liquid 618 kg Source: Official product and website information, Tesla 24

PACK TESTING COOLING SYSTEM EVALUATION Test conditions: Start temperature +20 C Symmetric rectangular current profile e.g. ±100/200/250A, 0.05Hz Coolant flow rate e.g. 3/4/5Lt/min (+20 C) Result interpretation: Pack temperature spread up to 9.8K module temperature spread up to 8.0K module number legend T 1 [ C] T 2 [ C] Temperature data just after end of test 25

SUMMARY AVL BENCHMARK ADDS VALUE TO YOUR BENCHMARKING AND DEVELOPMENT ACTIVITIES: Vehicle to screw analysis Functions and performance on vehicle level is brought into context of design and parts Building functional understanding AVL developed test program clearly shows function principles and their limits Orientation in the target system Comparable evaluation via AVLs rating system transparently shows strengths and weaknesses Comparable evaluation supports positioning your future products in the market 27

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