Steve Lehnert, AUDI AG
2 Contents Overview of the battery system Mechanical Overview Advantages/disadvantages of common battery package Architecture Modular set part concept Advantages of set part concept Cooling system
3 Audi A6 PHEV 2,0l TFSI Drive Train Engine 2,0l TFSI Power Electronics HV Battery System Electric Machine Charging Point HV wiring harness Performance Data System power: 180 kw System torque: 500 Nm Electrical speed: 135 km/h Electrical range: 50 km Onboard Charger
4 Audi A6 PHEV 2,0l TFSI Location of the Lithium-Ion Battery Cell box inside luggage compartment Reduced environmental influences Fits under the rear luggage cover Crash protected Inside Interfaces in the outside No HV-connections and no coolant tubes inside luggage compartment Challenge to match inside/outside requirements HV Battery system Outside
5 Structure Cover Low-Voltage Harness High-Voltage Connection Cell Module Battery Management Controller Cooling Plate Battery Housing Coolant Distributor Battery Junction Box
6 Mechanical Structure Aluminum 2-Layer Cover Low weight High stiffness, supporting stiffness of the car body Good crash performance Challenge of tight welding seams Aluminum extruded profiles
7 Common battery package A6 Battery Common Cellbox Adaption for new vehicle Advantages / Disadvantages Reuse of whole cell box Adaption of fixation to car body Limited flexibility regarding project specific requirements
8 Technical Data Battery system Battery system Cell Cell Module Topology Energy Peak Power Voltage 37 Ah (Pouch) 8x 13 cells (13s1p) 104s1p 14,1 kwh (BOL) 110 kw (25 C, 18 s, BOL, 50% SOC) 382 V (nom.) Peak Current -335 A (18 s) Operating Temperature Cooling Protection Class Weight -28 C 60 C Fluid cooling IP6K4K (Inside) IP6K6K, IPx7, IPx9K (Outside) 140 kg
Peak Power Peak Power 9 Technical Data Battery system Discharge Power Charge Power 140000W 140000W 120000W 120000W 100000W 100000W 80000W 60000W 40000W 20000W 0W 95% 80% SOC 65% 50% 35% 15% 5% -10 C -25 C 60 C 40 C 25 C 10 C 0 C Temperature Wide temperature- & SOC-range with high Discharge Power 80000W 60000W 40000W 20000W 0W 5% 15% 35% SOC 50% 65% 80% 95% -10 C -25 C 0 C 60 C 40 C 25 C 10 C Temperature Colt cranking capability until -28 C Wide range for onboard charging up to 7,2 kw
10 Technical Data: set parts Battery Junction Box Battery Junction Box HV-sensor system & safety box Separate housing HV-interface to the vehicle Direct contacting system between Battery Junction Box and Battery Housing Service friendly Challenge outside requirements Battery Management Controller Battery Management Controller Battery intelligence Separate housing inside luggage compartment LV-interface to the vehicle Service friendly Only 12V
11 Technical Data: set parts Cell Module Cell Module Topology Cell Module Controller Dimensions Weight Cooling 13s1p Integrated 387 x 151 x 108,5 mm 12,3 kg Indirect Cell Module Controller Cell Single cell Cell Technology Li-Ion Pouch Capacity 37 Ah Chemistry Li NMC / Graphite Dimensions 327,5 x 102,2 x 10,6 mm Weight 0,70 kg Energy density 386 Wh/l 195 Wh/kg
12 Set part concept Cell Module Battery Management Controller Battery Junction Box Modular concept Service friendly Reuse of components in different projects
13 Cooling system Cell Module Thermal Pad Cooling Plate Coolant Connector Coolant Distributor Coolant Inlet / Outlet
14 Conclusio Perfect integrated without loss in luggage space Robust mechanical Design High Power Common Cellbox Design Efficient set part concept
15 Prospect Increase of Energy density (electrical range > 50 km) Decrease of cost 600 500 400 300 37 Ah 200 100 25 Ah 28 Ah 2013 2014 2015 2016 2017 2018