Post on 25-Jun-2018
Steve Lehnert, AUDI AG
Lithium-Ion Battery for Audi A6 PHEV
2
› 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
Contents
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
3
Audi A6 PHEV 2,0l TFSI
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Drive Train
Performance Data
System power: 180 kW
System torque: 500 Nm
Electrical speed: 135 km/h
Electrical range: 50 km
HV Battery System
Onboard Charger
Charging Point
HV wiring harness
Power Electronics
Engine 2,0l TFSI
Electric Machine
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Audi A6 PHEV 2,0l TFSI
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Location of the Lithium-Ion Battery
Cell box inside luggage compartment
Reduced environmental influences
Fits under the rear luggage cover
Crash protected
Interfaces in the outside
No HV-connections and no coolant tubes inside
luggage compartment Challenge to match inside/outside requirements
Inside
Outside
HV Battery system
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Structure
Battery Junction Box
Cover
Coolant Distributor
Battery Housing
Cell Module
Cooling Plate
High-Voltage Connection
Low-Voltage Harness
Battery
Management Controller
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Mechanical Structure
Low weight
High stiffness, supporting stiffness of the car body
Good crash performance Challenge of tight welding seams
Aluminum 2-Layer Cover
Aluminum extruded profiles
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Common battery package
Advantages / Disadvantages
Reuse of whole cell box
Adaption of fixation to car body
Limited flexibility regarding project
specific requirements
A6 Battery Common Cellbox
Adaption for new vehicle
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Technical Data Battery system
Battery system
Cell 37 Ah (Pouch)
Cell Module 8x 13 cells (13s1p)
Topology 104s1p
Energy 14,1 kWh (BOL)
Peak Power 110 kW (25 °C, 18 s, BOL, 50% SOC)
Voltage 382 V (nom.)
Peak Current -335 A (18 s)
Operating Temperature
-28 °C – 60 °C
Cooling Fluid cooling
Protection Class IP6K4K (Inside)
IP6K6K, IPx7, IPx9K (Outside)
Weight 140 kg
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Technical Data Battery system
-25°C
-10°C
0°C 10°C
25°C 40°C
60°C 0W
20000W
40000W
60000W
80000W
100000W
120000W
140000W
95% 80%
65% 50%
35%
15%
5%
SOC Temperature
Pe
ak
Po
we
r
-25°C
-10°C
0°C 10°C
25°C 40°C
60°C 0W
20000W
40000W
60000W
80000W
100000W
120000W
140000W
5% 15%
35% 50%
65% 80%
95%
Temperature SOC
Pe
ak
Po
we
r
Discharge Power Charge Power
Wide temperature- & SOC-range with high Discharge Power
Colt cranking capability until -28 °C
Wide range for onboard charging up to 7,2 kW
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Technical Data: set parts 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
Battery Management Controller
› Battery intelligence
› Separate housing inside luggage compartment
› LV-interface to the vehicle
Service friendly
Challenge outside requirements
Service friendly
Only 12V
Battery Management Controller
Battery Junction Box
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Technical Data: set parts Cell Module
Topology 13s1p
Cell Module Controller Integrated
Dimensions 387 x 151 x 108,5 mm
Weight 12,3 kg
Cooling Indirect
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
Cell
Single cell Cell Module
Controller
Cell Module
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Set part concept
Cell Module
Battery Management Controller
Modular concept
Service friendly
Reuse of components in different projects
Battery Junction Box
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Cooling system
Coolant Distributor
Cell Module
Cooling Plate
Coolant Connector
Coolant Inlet / Outlet
Thermal Pad
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Conclusio
Perfect integrated without loss in luggage space
Robust mechanical Design
High Power
Common Cellbox Design
Efficient set part concept
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Lithium-Ion Battery for Audi A6 PHEV
AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017
› Prospect
Increase of Energy density (electrical range > 50 km)
Decrease of cost
2013 2014 2015 2016 2017 2018
100
200
300
400
500
600
25 Ah 28 Ah
37 Ah