Post on 29-Jul-2018
Electromobility.
Battery Technology.Sustainable solutions fit for series production.
03
04 ElringKlinger worldwide
06 Focus on electromobility
08 Battery modules and energy storage units
10 System expertise with hofer powertrain
11 Battery components
11 Cell housings
12 Cell connectors
13 Cell contact systems
14 Module connectors
14 Plastic housings for energy storage units
15 Pressure equalizing elements
16 Development and testing
17 Electrical tests
17 Component validation
18 Prototyping and production
ADDITIONAL MATERIAL
Experience mobility – Drive the future.The ElringKlinger Group.
We are dedicated to developing cutting-edge solutions and new
technologies for current and future generations of vehicles. As
an expert development partner and approved OEM supplier, we
take an all-embracing approach and focus on the vehicle system
as a whole. Our particular strength is that we are one of the few
automotive suppliers capable of developing and manufacturing
technologically sophisticated components for all types of drive
system – based on either combustion engines or electric solutions.
Customized components from ElringKlinger for engine, transmis-
sion, exhaust gas system, underbody, chassis, and body are used
by virtually all vehicle and engine manufacturers and countless
automotive suppliers worldwide. Our product range includes gas-
kets, lightweight polymer components, shielding systems, battery
and fuel cell technology, transmission control plates, exhaust gas
purification systems, components made of high-performance
plastics, tooling technology, and development services. Building
on our innovative products, we set industry benchmarks and help
to achieve environmentally compatible mobility. We also supply
an extensive range of spare parts to the aftermarket sector in more
than 140 countries. In addition, ElringKlinger boasts a successful
track record in other branches of industry, e.g., with exhaust gas
purification systems, PTFE products, and fuel cells. These efforts
are supported by a dedicated workforce of more than 9,000 peo-
ple at 49 ElringKlinger Group locations around the globe.
CONTENTS
We have produced separate brochures with detailed information on our entire e-mobility range, our fuel cell solutions, and the products and services offered by our strategic partner hofer power train. Areas of application outside the automobile industry are described, for example, in our corporate brochure “The ElringKlinger Group” and in brochures published by our subsidiary new enerday GmbH.
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ElringKlinger worldwide.
Africa FRIK A
´
SOUTH AFRIC A
Johannesburg
North America
C ANADA
Leamington
USA
Plymouth
Southfi eld
Buford
Austin
Fremont
ME XICO
Toluca
South America
BR A ZIL
Piracicaba
Cylinder-head gaskets
Sealingsystems
Lightweight plastic components
Plastic modules
Thermal and acoustic shielding
systems
Exhaust after-treatment systems
Transmission control plates
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Asia
PR CHINA
Changchun
Suzhou
Qingdao
Chongqing
SOUTH KORE A
Gumi
Seoul
JAPAN
Tokyo
Saitama
Europe
GERMAN Y
Dettingen/Erms
Langenzenn
Runkel
Geretsried-Gelting
Thale
Lenningen
Bissingen/Teck
Bietigheim-Bissingen
Heidenheim
Mönchengladbach
Idstein
Rottenburg am Neckar
Magdeburg
Neubrandenburg
Nürtingen
SPAIN
Reus
ITALY
Settimo Torinese
Milan
HUNGARY
Kecskemét-Kádafalva
ROMANIA
Timisoara
TURKE Y
Bursa
GRE AT BRITAIN
Redcar
Gateshead
FR ANCE
Nantiat
Chamborêt
Poissy
SWIT ZERL AND
Sevelen
Elsau
NE THERL ANDS
Enschede
INDIA
Ranjangaon
INDONESIA
Karawang
THAIL AND
Bangkok
PTFE components
Engine development services
Tooling technology
PEM fuel cell stacks
Development services with hofer
powertrain
Battery technology
Electric Drive Unit
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0707
Electromobility. From future vision to reality.
The automotive industry is undergoing a period of transforma-
tion, the focus being on sustainable mobility and alternative
drive technologies. ElringKlinger has consistently been one
step ahead of these developments and so is actively helping to
shape the future of the automotive industry. Whether electric
motor, hybrid system, or combustion engine: we offer innova-
tive, tailor-made solutions for all types of drive technology.
Through our strategic partnership with hofer powertrain, an
engineering company in Nürtingen that specializes in electric
drive technology, we have significantly expanded our expertise
and range of products and services in the area of e-mobility.
Drawing on this know-how, we can therefore support our cus-
tomers at an even earlier stage and even more comprehensively
in the realization of future-oriented drive concepts.
BAT TERY AND FUEL CELL :
ELEC TRIF YING SOLUTIONS
An efficient energy storage unit is regarded as key technology
for future-proof electric vehicles. ElringKlinger already manu-
factures various components for lithium-ion batteries in highly
economical series production, e.g., cell contact systems and mod-
ule connectors. In addition, we also develop and manufacture
entire battery modules, battery systems, and integrated energy
storage units.
One of the key benefits of buses and passenger cars equipped
with fuel cell propulsion systems is their long range. Fuel cells
can also be used as range extenders for battery-operated vehi-
cles. Depending on system design, the electric drive can thus be
supplied with energy directly or the battery can be recharged.
In the field of fuel cell technology, the advantages offered by
ElringKlinger are its proprietary stacks, patented designs for
metal bipolar plates, and plastic media modules that allow
substantial simplification of the fuel cell system (see also our
specialized brochure “PEM fuel cells”).
As regards the automotive future, both concepts, the battery
and the fuel cell, are viable options on account of their specific
characteristics and benefits. In addition, they can display their
strengths in combination. Our mission is to drive innovations
forward, set standards, and play an active role in technological
change with highly competitive, top-quality product solutions.
For sustainable mobility – worldwide.
Battery modules and energy storage units. Pioneering, fl exible, reliable.
In the case of battery modules, the core competence of
ElringKlinger, i.e., bringing together a large number of differ-
ent components to make an assembly in a reliable process, is
proving to be a valuable asset. Voltage and temperature moni-
toring is already integrated in our cell contact system. Through
specifi c cell balancing the battery modules of ElringKlinger
achieve a long service life whereby our systems make a contri-
bution to the conservation of resources.
Our battery modules are structured in such a way that we can
provide a fl exible response to customers‘ needs. The basis is a
48 V module, which on account of its technical design can be
used for integrated systems up to 800 V. A modular approach
allows cost-effective series production. Furthermore, our bat-
tery systems can be used in fi elds of application beyond the
automotive industry. Via an interface, customer-specifi c bat-
tery management systems can be integrated. Alternatively, a
solution designed by ElringKlinger can be used.
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Performance of ElringKlinger battery modules
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1
2
36 48 60
EN
ER
GY
(kW
h)
7 98 10 11 12 13 14 15 16
MODULE LENGTH (mm)
VOLTAGE (V)
300 400 500
12s1p MODULE
7s1p MODULEMODULELENGTH
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1 Customer-specific modules with different capacities and voltages are available on request (max. 32 cells).2 Conditionally and in dependence of future cell development3 Depending on cell capacity
TECHNIC AL DATA 4 8 V MODULE
MODULE CONFIGURATION 1 12s1p
CELL TECHNOLOGY Lithium ion (NMC)
CELL TYPE Prismatic (PHEV2)
NOMINAL VOLTAGE (V) 43.8
NOMINAL CAPACITY (Ah) 2 ≥ 37
SPECIFIC ENERGY (kWh) 2 ≥ 1.6
MAX. CONTINUOUS CHARGE CURRENT (A) 3 148 / 4 C
MAX. CONTINUOUS DISCHARGE CURRENT (A) 3 259 / 8 C
MAX. PULSE DISCHARGE CURRENT (10 s) (A) 3 370 / 10 C
DIMENSIONS (mm) 370 x 157 x 125
WEIGHT (kg) 9.8
SAFETY FEATURES Integrated cell balancing; interface for optional BMS
LIFE TIME (UNTIL 80 % CAPACITY) 2,000-6,000 cycles (depending on application)
THERMAL MANAGEMENT Solutions for liquid and air cooling available on customer request
ENVIRONMENTAL TEMPERATURE (°C) Charge: 0-45 Discharge: -20-60Storage, transport: -40-45
MAX. SYSTEM VOLTAGE (V) 800
CONFORMITY UN 38.3, CE and on customer request
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Thanks to a strategic partnership with hofer powertrain, the
ElringKlinger Group has signifi cantly expanded its expertise
and range of products and services in the fi eld of electromobil-
ity. The engineering company hofer powertrain is regarded as
a specialist in electric drive technology; it has already amassed
ten years of series production experience in this fi eld. What is
crucial is the overall know-how: system integration, electric
machines, power electronics, automatic control software, trans-
missions, thermal management/cooling, and safety concepts
are an integral part of the portfolio.
The benefi t for ElringKlinger: working in close collaboration
with our customers, we can offer the very best in integrated
solutions tailored to their requirements. Our demonstrable
know-how in battery technology, processes, and production
methods in conjunction with pooled engineering expertise from
hofer powertrain provides the basis for achieving specifi ed
goals quickly and effi ciently. Building on our holistic view of
the entire chain of energy conversion in the vehicle, we are able
to leverage the full range of opportunities with regard to cost,
quality, and system performance.
System expertise with hofer powertrain.Implementing integrated solutions. Without fail.
know-how in battery technology, processes, and production
methods in conjunction with pooled engineering expertise from
hofer powertrain provides the basis for achieving specifi ed
goals quickly and effi ciently. Building on our holistic view of
the entire chain of energy conversion in the vehicle, we are able
to leverage the full range of opportunities with regard to cost,
EDU (Electric Drive Unit), consisting of a machine, an inverter, and a transmission based on the hofer powertrain platform.
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When it comes to the development and production of cell hous-
ings, we also benefi t from our expertise as a development partner
and series-production supplier to the international automotive
industry. In this sector ElringKlinger concentrates on the manu-
facture of prismatic hard-case housings. The outstanding relia-
bility of our products, despite the substantial volumes involved,
is based on our experience with regard to large production series
and our expert knowledge in the fi eld of sealing and forming
technology. High-current-capable joining processes and opti-
mized sealing concepts ensure that the cell has a long service
life. Highly effi cient safety systems for excess pressure, excess
current, or elevated temperatures enable a high degree of safety
even at cell level.
All components of the cell housing are from a single source and
are perfectly matched to each other – ensuring top quality and
functional reliability.
Battery components.Powerful, reliable, customized.
Cell housings.
Apart from lithium-ion battery modules for installation in inte-
grated storage systems, ElringKlinger, with its wide range of
battery components, is also ideally lined up for alternative drive
technologies. Our portfolio covers not only cell housings, cell
connectors, and cell contact systems but also module connec-
tors, plastic energy storage unit housings, and pressure equal-
izing elements.
On account of many years of experience in the fi elds of metal
forming, plastic injection-molding, joining and coating technol-
ogies, automated assembly processes, and an in-house tool-
making and mold-making facility, we can deliver customized,
mass-production-ready products for present and future electro-
mobility.
functional reliability.
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Cell connectors.
The conduction of current between the individual cells of a
module is handled by cell connectors. The latter have to be
as fl exible and thin as possible, on the one hand, in order to
compensate for tolerances between the cells; on the other hand,
they have to transmit very high currents, for which purpose a
large cross section is required. The specifi c, weight-optimized
connection solutions developed by ElringKlinger offer not only
the necessary fl exibility but also the matching cross sections for
the best current-carrying capacity possible. Due to extremely
high thermal and physical strength, temperature fl uctuations
between the cells are optimally compensated for at all times.
Compensation for forces results in a longer service life for
the cells.
Another benefi t: the surface of our cell connectors meets the
highest standards in terms of cleanliness, surface tension, rough-
ness, degree of refl ection, and fl atness, so it can be subjected
to automated laser welding. ElringKlinger offers solutions for
all types of cells, while various material combinations can be
adapted accordingly, including material transitions within the
cell connector – even in cost-effective series production.
In the case of ElringKlinger cell connectors, thermal expansion is optimally compensated for at all times, i.e., forces are restricted to the cell terminals.
DYNAMIC EXPANSION COMPENSATION ASSEMBLY TOLERANCE COMPENSATION
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Cell contact systems.
ElringKlinger cell contact systems for lithium-ion batteries in
various confi gurations are precisely matched to the customer‘s
particular specifi cations; they can be directly mounted on the
cell combination and welded together accordingly. The systems
are comprised of a plastic carrier frame that accommodates
the cell connectors and ensures installability in all tolerance
positions.
The required voltage and temperature sensors are already inte-
grated, while the electronic cell supervision circuit (CSC) can be
integrated by customers themselves. At the interfaces, approved
or even newly developed automotive connector systems are
used (Plug and Play). The cell connectors have a compensation
element to reduce forces acting on the cell terminals. Voltage
taps are used to monitor the cells and enable active/passive cell
balancing. For thermal monitoring of cells there are many differ-
ent types of temperature sensors in use – with an optimal heat
link to the cell connector.
Our cell contact systems are manufactured in fully automated
inline production; they undergo a 100% end-of-line inspection.
Development, validation, and release of the assemblies take
place according to the customer‘s requirements and in com-
pliance with automotive standards such as LV 124 or DIN EN
60068. ElringKlinger cell contact systems are ideal for use not
only in hybrid vehicles but also in full-electric vehicles.
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Module connectors.Plastic housings for energy storage units.
In order to create an energy storage unit, module connectors are
required as interfaces between the individual modules and the
cell contact systems. The modules are connected not only with
each other but also with the power electronics of the vehicle.
ElringKlinger module connectors can also be directly integrated
into the cell contact system as an optional feature. This means it
is possible to create extended, bolted solutions as well as combi-
nations of them. All approved contact systems can be used; alter-
natively, newly developed, requirement-compliant systems can
be implemented together with engineering partners if needed.
Flexible wiring with specifi c contact systems ensures optimal
adaptation of our module connectors to customer specifi cations.
At ElringKlinger, it can be taken for granted that development,
confi guration, and approval conform to the automotive stand-
ard LV 214.
The housing of a battery storage unit must meet numerous
requirements. For example, the installation footprint in the vehi-
cle has to be taken into account in the best possible way in
housing design. In addition, it must be possible to fi t additional
components, such as seals and electric terminals, at low cost.
When in operation, the housing is exposed to many mechanical
and thermal stresses.
ElringKlinger‘s solution: energy storage unit housings made
of plastic that are optimized for weight, are robust, and allow
the integration of additional functions; their design can be opti-
mally adapted to existing installation spaces. For this purpose,
we draw on our extensive knowledge in the fi eld of plastics pro-
cessing of large-format components and in sealing technology
and implement innovative solutions with injection-molding pro-
cesses, plus hybrid design. If necessary, areas can be strength-
ened via sandwich structures and an EMV shielding can be
implemented by using metallic foils.
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Pressure equalizing elements.
The energy storage unit housing must be able to compensate
for different pressures between the interior of the storage unit
and its environment. Such pressure differences arise, for exam-
ple, when driving uphill or downhill, if there are temperature
differences, or when transporting battery modules or electric
vehicles by air in freight chambers not equipped with pres-
sure equalization systems. ElringKlinger pressure equalizing
elements with an integrated safety function compensate for
such differences in pressure. On account of permeability to water
vapor, condensation in the energy storage unit is also reduced.
An emergency degassing function that is also integrated into
the pressure equalizing element opens up a port with a large
cross section in the event of gas emission from a battery cell;
this brings about controlled pressure equalization in the stor-
age unit housing as quickly as possible. Due to the use of a
porous PTFE membrane, we are also able to adapt air fl ows
to requirements in the best possible manner. In this context,
we benefi t from the PTFE material expertise of our subsidiary
ElringKlinger Kunststofftechnik GmbH. Depending on the cus-
tomer‘s request, compliance with all IP protection classes
specifi ed by DIN EN 60529 is possible (water column, splash-
ing water, pressure washer, etc.).
TECHNIC AL DATA PRESSURE EQUALIZING ELEMENT
HEIGHT 24.5 mm
MAX. WIDTH 91.2 mm
AIR EQUALIZATION CAPACITY [AT A DIFFERENTIAL PRESSURE OF 0.1 BAR] 25 l / min
DEGASSING CROSS SECTION 590 mm²
PRESSURE THRESHOLD FOR EMERGENCY DEGASSING 0.35 bar
IP PROTECTION CLASSES
(ON REQUEST) IP66, IP67, IPXXC (IP6K, IP9K)
FIRE RATING V0
OPERATING TEMPERATURE -25 to 80°C
INSTALLATION With a bolt fl ange; introduction of threads in the storage unit wallwith threaded holes or, for example, with inserts
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Development and testing.Electrifying solutions.
Short development cycles, complex interaction between the
individual components, and high demands with regard to cost
efficiency and sustainability can only be implemented by means
of an all-embracing approach. This is essential when it comes to
achieving smart solutions at the highest technological level pos-
sible. At our purpose-built E-Mobility Development Center all the
necessary test and validation facilities are brought together under
one roof. Be it a cell test, a module inspection, or a component
validation test – we handle all the various procedures. In taking
this approach, we can offer our customers the very best condi-
tions when it comes to pursuing new routes and achieving goals
sooner; this also applies to small batches and prototypes. Other
automotive suppliers also take advantage of our expertise and
have tests performed by us. Reliable, economical, comprehensive.
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Development and testing.Electrifying solutions.
When it comes to electrical and mechanical module design, it is
absolutely essential to have a thorough understanding of cell
behavior under various extraneous boundary conditions. For
example, the service life of battery cells is directly dependent
on temperature, the rate of charging and discharging, and the
mechanical environment. When cells are interconnected to cre-
ate a module there are also other effects that have to be taken
into account, such as mutual cell infl uence and an altered cool-
ing characteristic, which also depends on the location of the cell
in the module and hence a change in cell temperature. Further-
more, while cells are not identical, they are all exposed to the
same level of current in the module.
Using electrical cell and module test benches, we investigate
these and other effects in order to achieve the best possible con-
fi gurations for our modules. At these test stations it is possible
to rigorously check multiple cells and modules under various
climatic conditions in a single procedure. The various test spec-
imens can all run through one and the same electrical stress
profi le or be exposed to loads that are different from each other.
Simple charge/discharge cycles are possible, but also driving
profi les such as the Artemis cycle or the American FTP-75.
The components of an energy storage unit must – like all compo-
nents in the automotive sector – meet demanding requirements
in terms of ruggedness and durability. The focus of testing is
on the various connections between the components, which
have to be validated in specially adapted tests with regard to
their durability over the entire life of the vehicle. Here, too, we
can take advantage of the experience we have acquired over
decades.
Typical examples are mechanical tests such as peel tests, shear
tests, tensile tests, vibration tests, vibration resistance tests,
shock tests, electrical tests such as dielectric strength tests,
maximum continuous current tests, and short-circuit tests at
several thousand amps.
In addition, we conduct all standard environmental simulation
tests and battery-specifi c tests for chemical infl uences. Exam-
ples include climatic tests, thermal cycling tests, media resist-
ance tests such as salt spray tests, or the testing of various
materials for resistance to electrolytes.
Electrical tests on battery cells and modules.
Componentvalidation.
Cell and module test benches Testing of battery components
1818
Prototyping and production. Series-produced quality. Worldwide.
New types of products call for new, innovative manufacturing
concepts. ElringKlinger attaches great importance to its own
process development and the associated expansion of expertise
to meet the full range of quality requirements. All processes and
procedures necessary for the products are validated and con-
stantly refi ned. Thanks to the close interaction between develop-
ment, prototype construction, and product commercialization,
an optimum quality standard can be achieved from the very start
of production.
Within a short space of time and to a very high standard,
ElringKlinger produces samples and small batches at its in-house
prototyping facility, the equipment of which is very close to that
of full-scale production. We have resources available for all the
manufacturing processes that are also used in series production,
e.g., ultrasonic welding and laser welding systems. In this way,
we achieve continuity in all processes from prototyping to series
production – only the degree of automation has to be adjusted.
At an early stage, during prototype construction, it is possible
to ensure seamless 100% traceability, as in subsequent series
production.
ElringKlinger also operates high-performance production lines
for manufacturing the various components in series. Adapted to
specifi c customer requests and product requirements, we imple-
ment highly fl exible, scalable or fully automated production solu-
tions – integrated in a continuous quality concept. Our mission
is to achieve competitive series production geared to specifi c
product requirements. Effi ciently, safely, and reliably. Worldwide.
W W W.ELRINGKLINGER .COM
ElringKlinger AG
Max-Eyth-Straße 2
72581 Dettingen/Erms
Germany
Phone +49 7123 724-0
Fax +49 7123 724-9006
E-mail info@elringklinger.com
www.elringklinger.com 08/1
7
The information provided in this brochure is the result of technological analyses and may be subject to changes depending on the design of the system. We reserve the right to make technical changes and
improvements. The information is not binding and does not represent warranted characteristics. We do not recognize any claims for compensation based on this information. We accept no liability for printing errors.