PROGRESS OF BATTERY SYSTEMS AT GENERAL MOTORS Manfred Herrmann Roland Matthé World Mobility Summit Munich October 2016
AGENDA DEVELOPMENT OF ELECTRIFICATION ELECTRIFICATION BATTERY SYSTEMS PROGRESS OF BATTERY SYSTEMS EREV BATTERIES BEV BATTERIES
GM Milestones in Electric Propulsion From the first fuel cell vehicle to EREV and BEV 1966 Electrovan with fuel cell 2000 HydroGen1 2007 HydroGen4 Space technology New materials for FC membranes 1968 1972 1987 1991 1996 2010/11 1966 2000 2007 2017 Ampera-e 1968 Electrovair 1972 Electro-Vette 1987 Sunraycer 1991 Impuls 1996 EV1 2010 Volt 2011 Ampera 1972 Lunar Rover AG-Zn primary battery ZEV mandate Limited range Long charge time Range anxiety Lead acid & NiMh 1990 Impact Electric vehicle concept car 1997 S10 Electric Li-ion batteries Longer life Reduced cost Shorter charge time No range issues
GM Electrically Driven Vehicles 1987 2012 from Lead acid to Lithium Ion batteries 1987 1990 1991-1993 1996-1999 2007 2010-2012 GM Sunraycer GM Impact Opel Astra Impuls GM EV1 Chevrolet S10 EV Opel HydroGen4 Chevrolet Equinox Fuel Cell Chevrolet Tahoe 2-Mode Hybrid Opel Ampera Chevrolet Volt Buick LaCrosse eassist AGgZn batteries Lead-Acid batteries NiCd, NaNiCI2 NiMH batteries PbPbO2 NiMH batteries Fuel Cell NiMH batteries Lithium-Ion batteries PM synchronous motor MosFET AC induction motor MosFET AC induction IGBT AC induction motor IGBT PM synchronous motor IGBT PM synchronous motor IGBT
MILD HYBRID TO PURE ELECTRIC TO DISPLACE PETROLEUM Petroleum and Biofuels (Conventional and Alternative Sources) Electricity (Zero Emissions Energy Sources) Light Electrification HEV PHEV Extended Range Electric Pure Electric Increasing Electrification CONSERVATION DISPLACEMENT 5
ELECTRIFICATION AT GENERAL MOTORS HEV PHEV EREV BEV Gen 1 Gen 2 Gen 2 Battery 6
2016 CHEVROLET MALIBU HYBRID -- HEV STYLE Mid-size 4-door Sedan Seats 5 RANGE & FUEL ECONOMY 47 MPG combined (GM est.epa) Estimated 5.0 L/100km in WLTP 540 Miles total range (GM est) Estimated total range 870 km PERFORMANCE 0-60 mph in 7.8s 0-30 mph in 2.9s
2016 CHEVROLET VOLT EREV STYLE Small 5-door hatchback Seats 4+1 RANGE & FUEL ECONOMY 53 miles EV (EPA City &HWY mix) 85 km (WLTP estimated) 420 miles total range 676 km 42 MPG combined 5.6 l/100km PERFORMANCE 0-60 mph in 8.4s 0-30 mph in 2.6s
2017 CHEVROLET BOLT EV BEV 2017 OPEL AMPERA-E BEV STYLE Small 5-door CUV Seats 5 RANGE & FUEL ECONOMY 238 miles EV total range (EPA) > 500 km (NEDC) PERFORMANCE 0-60 mph in < 7s
KEY METRICS FOR BATTERIES: HEV EREV(PHEV) - BEV HEV EREV (PHEV) BEV Energy 1.5 kwh 18.4 kwh 60 kwh Discharge Power 52 kw 120 kw 160 kw Mass 43 kg 183 kg 429 kg Power to Energy Ratio kw per kwh 35 6.5 2.7 * * * *) ilustration, not to scale 10
MODULARITY ENABLES EREV AND PHEV BATTERY Pouch cells integrated in modules. Design enables parallel connections. Common Modules used in different arrangement.
EXTENDED RANGE ELECTRIC VEHICLES Gen 1: Opel Ampera MY 2012 Chevy Volt (not shown) Gen 2: Chevy Volt MY 2016Gen 12
EREV Battery System Gen 1 Opel Ampera MY 2012 GEN 1 BATTERY SYSTEM EREV No. of cells: 288 Liquid thermal system (Cooling & Heating) Energy content: 16 kwh (> 10 kwh useable) Power discharge: > 115 kw Nominal voltage: 360 V Charging time: 4 h @ 230 V & 16 A Warranty: 8 years / 160,000 km System weight: 193 kg
GEN 2 BATTERY SYSTEM EREV) OPTIMIZED CHEMISTRY AND NEW CELL DESIGN Energy density increased by 20 percent (pack Wh/l) Total capacity increased: Fewer 192 cells /larger cells (~50% thicker) Simplified controls architecture Total mass reduced by 10 kg Active thermal system (Cooling, heating) -> More energy at reduced cost BATTERY DETAILS Gen 1 (2010) Gen 2 (2016) Difference Mass 193 kg. 183 kg - 10 kg Energy 16 kwh 18.4 kwh +15 % Cells 288 192-96 cells
EREV GEN 2 CELL CAPACITY Ratio of NMC-LMO optimized for desired power to energy ratio Single layer G4 separator for 9% increase in power 6% increase in active material area Cell height increased by increasing available module height Cell width increased by wing folding of the pouch Results (Comparing the latest Gen 1 cell to the Gen 2 cell) 12.3% improvement in energy density (Wh/l) 10% improvement in specific energy (Wh/kg) Cells by
BATTERY ELECTRIC VEHICLES (BEV) Gen 1: Gen 2: Chevy Spark Opel Ampera-e Chevy Bolt
BEV BATTERY SYSTEMS GEN 1 & 2 Vehicle Name Gen 1 Gen 2 Range (EPA) 82 Miles 238 Miles (EPA) Battery Chemistry Lithium Ion Lithium Ion (Nickel rich) Battery Nominal Energy 18.4 kwh 60 kwh Battery Mass 215 kg 430 kg Max Battery Power 120 kw 160 kw Battery Nominal Voltage 360V 350V Gen 1 Battery Position Underfloor Underfloor Battery Thermal System Liquid active thermal control Liquid active thermal control Energy Density Pack 86 Wh/kg 140 Wh/kg Gen 2 17
PROGRESS OF BEV BATTERY GEN 1 TO GEN 2 Triple the energy to 60 kwh +50% energy density in Wh/kg Power increase by 33% to 160 kw Effective vehicle integration ease of passenger egress/ingress High volumetric density -> +150 % volumetric energy density Wh/l More than double the cell capacity in Ah Large format pouch cells, footprint to enable flat pack lower P/E ratio, while meeting power requirements Designed for long-life with advanced thermal system and controls BEV Gen 2 cell 18
GEN 2 BEV BATTERY Technology Enablers for 60 kwh Improved integration into vehicle structure Cell sizing to module format optimization Cell and bi-cell optimization for power and energy Advanced cell chemistry Nickel-rich NMC Active cooling / heating packaging optimization Topology optimization to meet all internal and external safety and crashworthiness requirements 19
Energy [kwh], Power [kw], Troughput [kwh], Temperature [ C] Cost [$], Mass [kg], Size [dm³] TARGETS FOR BATTERY DEVELOPMENT Reduce: Cost [$] Weight [kg] Volume [dm³] Increase: Energy [kwh] Power [kw] Energy throughput or cycle life [kwh] Range of temperature [ C] Introduction [calendar years] Introduction [calendar years] Progress of batterie packs is evolution and optimzation 20
BATTERY TECHNOLOGY ROAD MAP REALITY Graphite/Layered, Spinel, or Olivine Cathode Silicon or Metal Alloy High-V Cathode Challenges Cell Expansion Cycle Life Electrolyte Stability Manufacturing Cost Li-Sulfur or Li-Air or beyond lithium... Today 2020 202x 21
GM BROWNSTOWN BATTERY ASSEMBLY PLANT Brownstown Battery Assembly Plant opened in summer 2009 Assembles lithium-ion batteries for: Chevrolet Volt Chevrolet Malibu Hybrid Chevrolet Silverado eassist GMC Sierra eassist Buick LaCrosse Hybrid Cadillac CT6 Plug-In Hybrid 22
CONCLUSION EREV batteries improved significantly Increased energy Reduced Cost GEN 2 BEV battery system delivers energy of 60 kwh and power of 160 kw Energy density (mass) Wh/kg plus 50% (system level) Energy density (volume) Wh/L plus 150% Reduction of specific ($/kwh) system cost Progress in the future will require Lithium Ion cell material innovation, Lithium Ion cells and further improved battery pack design. Executing the battery roadmap requires resources in research and engineering 23
Thanks to all involved engineers at General Motors and our suppliers! Thank you for your attention!