Dr. Wenzel Prochazka

AVL List GmbH (Headquarters)

Public

BEYOND TEARDOWN -

AVL SERIES BATTERY BENCHMARKING

Getting from low level parameter to target orientation

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CONTENTS OVERVIEW

1. AVL Introduction – Focus Series Battery Benchmarking

2. Analyzing & rating of the system –Benchmarking process & metrics

3. Battery benchmark examples

4. Summary

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AVL AT A GLANCE

5 powertrain elements

EXPERIENCE

65 years !

GLOBAL FOOTPRINT

30 engineering locations >220 test beds Global customer support

network

ONEPARTNER

INNOVATION 1500granted patents

RESEARCH 10% of turnover in-house R&D

STAFF

8.050 employees

65% engineers & scientists

GROWTH

SALES 1995:

0.15 billion €

2015:1.27 billion €

20161.41 billion €

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Mio. €

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OVERVIEW OF AVL´S BATTERY ACTIVITIES:FROM CONCEPT TO START OF PRODUCTION

BMS & MCU development (SW & HW)

Systems Engineering Electrical & Mechanical

Design Engineering Design for Production

Prototype build Generation 1&2

build-up

Validation target:

300.000 km cycle life

12 years calendar life

EMC targets fulfilled

System interaction ok

Test equipment for pack testing

turnkey solutions for battery labs

+

Module integration Thermal Simulation Mechanical Simulation Cell Modeling

Testing & Benchmarking

System validation Planning,

optimization & monitoring

5Public Public8 key attributes analyzed during AVL Series Battery Benchmarking

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AVL benchmarking program:

approx. 4-5 vehicles (PHEV or EV) per year

10 work packages with ~240 benchmarking criteria, derived >80 objectives, evaluated in 8 attributes

Attributes, targets and criteria System Design Values, Requirements, Specification

Standardized reports and documentation

BENCHMARKING OF BATTERIES

Vehicle

Level

Assessment

Battery

Assessment

Tear

Down

Design

Concept

Identification

Production

Concept

Identification

Cost

study

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Currently in Benchmark:

Mitsubishi Outlander PHEV Model 2015 (with OBD) - finishing Q1 2017

Tesla Model X P90DL (upgrade to P100DL in March 2017)vehicle arrived – pretests started 12/2016

Chevrolet Bolt EV – started 28.12.2016

Vehicles in Planning for 2017:

BYD Tang 03 2017 – 2nd half 2017

BMW i3 2017 – 2nd half 2017?

Audi Q7 PHEV – 2nd half 2017?

Current proposals for next vehicles:

Volvo XC90

Volkswagen eGolf

Nissan Leaf 2017

VEHICLES IN THE BENCHMARKING PROGRAM

Images: Wikipedia.com & OEM Websites

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CONTENTS OVERVIEW

1. AVL Introduction – Focus Series Battery Benchmarking

2. Analyzing & rating of the system –Benchmarking process & metrics

3. Battery benchmark examples

4. Summary

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AVL BENCHMARKING - REVERSING THE V-PROCESS

AVL’S BENCHMARK AIMS TO ASSESS HOW WELL THE BATTERY SYSTEM FULFILLS REQUIREMENTS THAT ARE CONNECTED TO 8 MAIN ATTRIBUTES

Level 0Vehicle

Level 1Vehicle Systems

(i.e. Powertrain)

Level 3Elements Sub-Systems

(i.e. Module, Cooling System)

Level 4HW Parts / SW Systems /

Electronic Hardware

Global Vehicle Benchmark

System & Component Benchmarking

Battery Benchmark Attributes

Performance DriverExperience

Efficiency Safety

EngineeringRequirements

ProductionCapability

Serviceability Cost

BEN

CH

MARK C

RIT

ERIA

& P

ARAM

ETERS

BEN

CH

MARK D

ATA G

EN

ERATIO

N

Level 2Elements

(i.e. Battery)

Component Testing

Subsystems Teardown & Testing

Single parts assessment

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BATTERY ATTRIBUTES

EACH BATTERY ATTRIBUTE IS EVALUATED VIA AVL METRIC THAT USES DIRECT MAPPING OF EVALUATED PARAMETERS

Number of Parameters

PerformanceDriverExperience

Efficiency SafetyEngineering Requirements

Production Capability

Serviceability Cost General Data

Power: 4Thermal: 6Specific:24Energy: 15Sum: 49

Availability ext. Temp.: 6SOX: 5Power Pulse rep.:2Sum: 13

Gravimetric:8Volumetric:9Electric:2Thermal:11Sum: 30

Electrical:12Thermal:7Mechanical:18Functional:10Homologation:1Sum:48

Mechanical:8Electrical:12Thermal:2Sum:22

Assembly:5Modularity:5Sum: 10

ComponentChange: 8Battery (dis)-mounting: 6Non-exchangeable: 8Diagnostics: 6Sum: 28

Warranty:4Service:4Production:2Further Use:2Sum:12

Power to EnergyP/E: 2Driversupport: 10Sum:12

TOTAL 224 assigned criteria

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SCATTERBAND - EXPLANATION

THE PARAMETERS ARE TRANSLATED TO RATED CRITERIA. THESE CRITERIA ARE RATED SUB-DIVISIONS OF ONE ATTRIBUTE – WEIGHTING AND RATING DIFFER FOR SPECIFIC SEGMENTS

0,45 Gravimetric energy density battery (Wh/kg)

130

0,15 Gravimetric energy density module (Wh/kg)

170

0,05 Gravimetric energy density cell (Wh/kg)

250

0,20 Volumetric energy density battery (Wh/l)

360

0,10 Volumetric energy density module (Wh/l)

410

0,05 Volumetric energy density cell(Wh/l)

480

SUB-

PARAMETER

Weight, Energy, volume, …

4.3 Rating

4.2 Weighting

0,45 Specific Power 5.2

0,55 Specific Energy 6.3

0,32 Power 7.6

0,15 Thermal 5.2

0,26 Specific 5.8

0,27 Energy 6.46.4

CRITERIA

EVALUIATION

SUB-ATTRIBUTE PARAMETERALGORITHM

𝑓 𝑥

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CONTENTS OVERVIEW

1. AVL Introduction – Focus Series Battery Benchmarking

2. Analyzing & rating of the system –Benchmarking process & metrics

3. Battery benchmark examples

4. Summary

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Renault Zoe 2015

Denza

VEHICLES CURRENTLY ON THE MARKET

Tesla Model S

Renault Kangoo ZE

Renault Zoe 2017

VW eUp

Nissan Leaf

Nissan NV200

BYD e6

Yutong Electric City Bus

Smart EV

BMW i3BMW i8

Mitsubishi Outlander PHEV

Already benchmarked

vehicles

Vehicles in work /

planned for 2017

Tesla Model X

Volvo XC90

Audi Q7 PHEV

BYD Tang

Chevrolet Bolt

Current proposals for

next vehicles

VW Passat GTE

Tesla Model 3

(2018)

VW eGolfImages: Wikipedia.com & OEM Websites

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BATTERY BENCHMARK VEHICLE RENAULT ZOE

Official Battery DataEnergy total: 25,9 kWh (battery label)Voltage Nominal: 360VCell number: 192Configuration: 96s2pCooling: closed air coolingWeight: 279 kg (incl. side profiles)

Official Vehicle DataPower peak: 65 kWPower continuous: 43 kWTorque: 220 NmSpeed: 135 kphAcceleration: 0-100 kph 13,5 secRange: 210 km (NEDC)Weight: 1468 kg

Source: Official product and website information, Renault, own picture

Best sold BEV in Europe 2015

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CLOSED AIR COOLING - ASSESSMENTON ROAD MEASUREMENT

Module temperatures during demanding driving and charging

Continuous operation leads to ΔT > 10°C

Driving

Battery cooling only active during charging

Increasing temperature difference between modules

Charging Driving Charging Driving Charging

*

* Outside air temperature

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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

Central air

distribution duct Detail: structural aluminum profile in side view

Cooling air distribution

is disturbed by structural

profile used for crush

safety!

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PACK WEIGHT AND VOLUME EFFICIENCYBROUGHT INTO CONTEXT

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40 45 50 55 60 65 70 75 80

Pack V

olu

me E

ffic

iency (

%) –

Cell/

Pack

Pack Weight Efficiency (%) – Cell/Pack

refrigerant cooling

water/glycol cooling

air cooling

Renault Zoe

Renault Zoe – cooling system volume included

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BATTERY BENCHMARK VEHICLETESLA MODEL S

Official Battery DataEnergy: 85kWhVoltage Nominal: 355VVoltage Max: 400VCell number: 7104Configuration: 96s74pCooling: LiquidWeight: 618 kg

Official Vehicle DataPower: 270 kWTorque: 440 NmSpeed: 201 kphAcceleration: 0-100 kph 5,6 secRange: 482 km (NEDC)Weight: 2108 kg

Source: Official product and website information, Tesla

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BATTERY CRASH PROTECTIONTESLA MODEL S

Battery housing mainly Aluminum parts (rectangular profiles, casted parts and sheets), rather massively constructed

In case of side crash, protection only in combination with the special vehicle side structure

“Shield” is added to the front underfloor for impact protection

battery housing side structureExplicit view of Mountingprofile side in detail in mm

Mounting profile front small (including

outer profile) in detail in mm

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BATTERY BENCHMARK VEHICLE MITSUBISHI OUTLANDER PHEV MODEL 2015

Official Battery DataEnergy total: 12 kWh (battery label)Voltage Nominal: 300VCell number: 80Configuration: 80s1pCooling: closed air coolingWeight: 183 kg (incl. mounting)

Official Vehicle DataPower peak (electric): 76 kWPower cont. (electric): 50 kWTorque (electric - front): 137 NmTorque (electric - rear): 195 NmSpeed: 170 kphAcceleration: 0-100 kph 10,3 secRange: 52 km (NEDC)Weight: 1969 kg

Best sold SUV-PHEV worldwide in 2015Source: Official product and website information, Mitsubishi, Own picture

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Driving experienceTechnologyEconomy

AVL scatter band

GLOBAL VEHICLE BENCHMARKINGEXAMPLE GIVEN - PREMIUM PHEV SUV

Vehicle Attributes

BMW X5 xDrive40eGasoline, AWD, 1997 ccm

Volvo XC90 T8Gasoline, AWD, 1969 ccm

Mitsubishi Outlander (III) Plug-In HybridGasoline, AWD, 1998 ccm

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CONTENTS OVERVIEW

1. AVL Introduction – Focus Series Battery Benchmarking

2. Analyzing & rating of the system –Benchmarking process & metrics

3. Battery benchmark examples

4. Summary

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Vehicle benchmark knowledge extended to sub-system and component level

Advanced component testing and analysis (e.g.: abuse testing)

Assessment of overall component interaction to fulfill vehicle targets

Evaluation of requirements and achievement from system to component level

Methodical approach to objectively compare battery system metrics

AVL BENCHMARK ADDED VALUE

SUMMARY

www.avl.com

THANK YOU