from research .… to market

E-Mobility - Dusk or Dawn for

Remanufacturers? Starters, alternators, turbos, calipers, engines to

vanish - What will you remanufacture next?

Marcello Colledania,b

(a): Professor at the Department of Mechanical Engineering –

Politecnico di Milano – Italy.

(b): Research Associate at ITIA-CNR, Institute for Industrial

Technologies and Automation.

Electric Vehicles (EVs) market forecasts

EVs will outsell Internal Combustion Engine Vehicles (ICEVs) in about 20 Years.

The forecasts predict about 600 million

circulating electric vehicles worldwide by

2040, where the main markets include

Europe, United States and China.

Electric Vehicles (EVs): key figures

Cost structure of

conventional ICEVs and

EVs. Main differences:

• Battery Pack

• Drivetrain

Cost. The real take-off for EVs will

happen from the second half of the

2020s when electric cars become

cheaper to own than ICE models.

Manufacturing improvements, also for

battery energy density, are set to

cause a further fall of more than 70%

by 2030.

Electric Vehicles (EVs): context key figures

Total Cost of Ownership (TOC): by 2025

EVs competitive against ICEVs for a

annual range bigger than 35.500

Miles/Year. High utilization is needed.

Emissions: reduction during the use-phase,

increase during the production phase

(batteries). Long life-time.

Car Sharing: over USD 1.2 billion in 2015 with

34.8% CAGR estimation from 2016 to 2024. The

global fleet is forecast to grow at 18% CAGR,

and the number of members is projected to

exceed 30 million by 2024.

Charging infrastructure: clear

evolution in the number of charging

units.

Driving range: increasing with the

capacity of the battery packs.

Electric Vehicles (EVs): barriers

Circular Economy model for EVs

What is the opportunity for the

remanufacturing industry?

• The recycling of End-of-Life Vehicles is regulated by

the EC Directive [2005/53/EC], which fixes targets

for re-use and material recovery.

• The on-going transition to EVs poses serious

challenges on the achievement of these targets in

the future, due to the evolution in car design.

Li-Ion batteries CFRP lightweight

parts

Mechatronics and

engines

CFRP made Life

Module- BMW i3 &i8Li-Ion battery

system – Nissan

Leaf. VCU Vehicle Control System

Permanent

magnet e-

motor

Battery technology for vehicle applications

EUROBAT e-mobility Battery R&D Roadmap 2030

EV TYPES

1. Full electric vehicle (Tesla): chargewith

external energy source, without ICE

(internal combustion engine).

2. Hybrid electric vehicle HEV (Toyota):

ICE and electric battery are

complementary. Battery charges with

kinetic energy during driving.

3. Plug-in electric vehicle PHEV

(Chevrolet, Mitsubishi, Honda, BMW):

battery could be recharged both by an

external energy source and by energy

recovery during driving.

EV and batteries: the main component

BMW i8 BATTERY PACK ASSEMBLY VIDEO

Battery chemistry: past, present and future

US DOE (Department of

Energy) estimates, based

on GM and LG Chem, Tesla

and Panasonic

announcements, a costs

decrease due to higher

production volumes and

different battery design.

OECD/IEA, International Energy Agency

PAST PRESENT FUTURE

NiMH BATTERIES(Honda Insight, Prius)

Li-ion BATTERIES(Nowadays standard, usually NMC)

Li-air, Zn-Air, Na-air

Ni-NaCl, Ag-Zn

Just for HEV.

Heavy, bulky, less energy

density.

Easy to recycle and good

safety.

Good weight/power ratio, low memory

effect.

High production costs.

Li-ion polymer battery

Li-air: 5-15 times energy

density of LIB.

Limit: irreversible product

formation decreasing

durability.

Li-ion battery geometry and properties

• Steel case:

mechanical stability,

but high weight and

packing density.

• 18650 or 21700

type

• Safety vent

OEM CAR MODEL CELL GEOMETRY CELL MANUFACTURER

BMWEV: i3

PHEV: i3 REX, i8, 330e, X5, etc.Li-ion prismatic cell Samsung

CHEVROLETEV: Bolt

PHEV: VoltLi-ion prismatic cell LG Chem

FIAT EV: 500e Li-ion prismatic cell Samsung

MERCEDESEV: Classe B

PHEV: C350e, E350e, S500, GLC 350eLi-ion pouch cell SK Innovation

MITSUBISHIEV: iMiEV

PHEV: OulanderLi-ion prismatic cell GS Yuasa

NISSAN EV: Leaf, EVALIA Li-ion pouch cell AESC

RENAULT EV: Kangoo, ZOE, twizy Li-ion pouch cell LG Chem

TESLA EV: Model 3, Model S, Model X Li-ion cylindrical cell Panasonic

TOYOTA PHEV: Prius Li-ion prismatic cell Panasonic

VOLKSWAGENEV: e-golf, e-up

PHEV: golf GTE, passat GTELi-ion prismatic cell Panasonic

VOLVO PHEV: V60, XC90 T8 Li-ion pouch cell LG Chem

POUCH CELLPRISMATIC CELLCYLINDRICAL CELL

• Aluminum case:

protection with

lower weight.

• Higher production

costs

• Swelling

• Multi-material

case: the lightest

• No design

standards

• Swelling

Remanufacturing opportunities for second-life modules

Second-life stationary

systems (renewable

energy, home, office)

E-mobility

Thermally controlled box

for IES.(Electrochemical

Impedance Spectroscopy )

• Average life-time 8 years.

• Current cost 150 Euro kWh.

• Residual capacity 50%.

• Warranty for manufacturers usually for 5

years (e.g. Tesla, Nissan).

Battery collection challenge: thermal runaway

FIRE CAUSES

• Mechanical damages.

• Electric issues (overcharge, poor

materials, etc.).

• Thermal issues (high Temperature).

SOLUTIONS

• Metallic shield under battery pack to avoid

shocks (since 2013 Tesla Model S has

Titanium shield and Aluminum deflectors).

• BMS control.

• Cooling/venting system. Tesla Model S in a charge station in Norway, 2016

SOME REAL CASES

1. After Sandy hurricane (2012) some Prius and 16 Fisker Karma burned: cars, submerged

in salty water for many hours, had a short circuit.

2. Tesla Model S in 2013 impact with a metal piece on the street: car warned the driver to

abandon the vehicle.

3. A woman crashes into the guardrail in Austria: firemen extinguished the fire following

Tesla instructions.

Cobalt value trend

Trend of Cobalt price. Source: Attualitix. World Atlas.

44,86 €/kg

17,82 €/kg

$/t

on

€-

€100,00

€200,00

€300,00

€400,00

€500,00

€600,00

2010 2015 2020 2025 2030 2035 2040 2045

Battery price trend

Euro/kWh

Trend of BOL battery price. Source: Bloomberg New Energy Finance.

150 €/kWh

in 2017€ /kW

h

Remanufacturing, direct module reuse and recycling

Base scenario:• Willingness to pay= 70%

• Cobalt value = 44,86€/kg

• Decreasing trend of BOL battery

price.

• Collection rate: 80%.€-

€1

€1

€2

€2

€3

€3

€4

2010 2015 2020 2025 2030 2035 2040 2045

Bill

ion €

Year

Profits in the base scenario

Recycling Direct use Remanufacturing

Scenario 3:• Willingness to pay= 70%

• Cobalt value = 44,86€/kg

• Constant trend of BOL battery price

(equal to 150 €/kWh)

€-

€1

€2

€3

€4

€5

€6

€7

€8

€9

€10

2010 2015 2020 2025 2030 2035 2040 2045

Bill

ion €

Year

Profit of scenario 3

Recycling Direct reuse Remanufacturing

Lightweight materials for EVs

• New lightweight materials

compensate for battery and e-motor

weight in EVs:

− Aluminum alloys.

− Use of composite materials

(CFRP- Carbon Fiber

Reinforced Plastics).

− Use of hybrid materials

(composite/aluminum alloys).

Magna lightweight door:

aluminum alloys resulting in a

42,5% weight reduction.

CFRP control arm with piezo

ceramics: weight reduction of 45%.

Other CFRP made

parts

• Using lightweight materials a mass

reduction up to 75% can be achieved:

− Longer driving range and

batteries life of HEVs and EVs.

− Possibilities of integrate more

sensors and safety systems

maintaining the same weight.

Lucintel

• The industrial sector with the highest growth in

demand for carbon composites is the automotive

industry, which will become the most important

sector for CRP manufacturing in 2020.

• The global automotive composites market is

projected to reach a value of 6.5 B€/year in 2018.

Lightweight materials for EVs

Today, composites are

mainly disposed in

landfills. Can

remanufacturing be a

solution?

• Lamborghini collaborated with Boeing to develop

a strategy for assessing the level of damage

sustained by CFRP elements, providing direct

customer support in case of repair with high

specialized technicians.

• In case of a high impact carbon fibers of BMW i3

will possibly be damaged but due to CF

properties, the damage is localized to a specific

area which could be easily removed (through

specific designed cut away sections), replaced

and repaired resulting in low repair time and low

costs (equivalent to conventional cars).

Drivetrain: Mechatronics and power electronics

Main evolution in power

electronics:

• Improved cooling

• Higher power density

• Mechatronics

improvement

A power inverter of a Tesla

Roadster

VCU vehicle control

system

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Mass (tot = 54kg) - Value (tot c.ca 350€)

Composition of the 80 kWNissan Leaf Motor

Aluminum

Nd(Dy)FeB

Copper

Electrical steel

Coating and insulationLow-alloy medium carbon steel

Average life-time 400.000 Miles [Tesla].

Permanent magnets synchronous motors

Nissan Leaf, Toyota Prius, Mitsubishi i-MiEV, Citroën C-Zero, Ford Fusion Hybrid,

Chevy Volt, Volvo C 30 E, BMW i3, Fiat 500e, Peugeot iOn, Ford Escape

Permanent magnets synchronous motor

Representative

disassembly

sequence of PM

motors. [Vanguard De-and

Remanufacturing Pilot

Network]

Examples of e-motors in EVs

and HEVs [Vanguard De-and

Remanufacturing Pilot Network]

Possible Scenarios and guidelines

EVs and car-sharing

(non-ownership

business model)

Better control of post-

use cars and

components

High Collection rates

(e.g. for batteries)

Recommendations:

• At association level, create synergies with other initiatives. For example, battery

collection consortia (e.g. EUCOBAT) and car-makers (e.g. EBA).

• At company level, create partnerships. Information sharing, from the car/component

design, dismantling to the remanufacturing is of strategic importance in EVs.

• Innovate. In order to deal with the variety of components in EVs and safety requirements, a

new generation of smart de-and remanufacturing systems should be adopted.

• In Europe, battery collection is regulated by Directive 2006/66/EC which is implemented by

specific consortia, currently cooperating with recyclers. Can they cooperate with

remanufacturers in the future?

• For lightweight structures, new disassembly guidelines shall be given to car dismantlers.

• For mechatronics, the collection scenario may not drastically change (but engines life-time

doubles with respect to ICEVs).

European Battery Alliance (EBA)

The OBJECTIVE is to “create a competitive and

sustainable, battery cell manufacturing in Europe

supported by a full EU-based value chain.”(speech of Vice-President for Energy Union Maroš Šefčovič)

➢ In 2025, EU battery market will reach 250 billions

euros/year (equal to the whole Denmark economy)

➢ 20 Giga Factory construction in Eu for a 20 billion

investment

➢ Must be driven by industry with EU as system integrator

EU strength:

• a growing battery market

• a strong R&I system

• leading companies on batteries

• strong recycling competences

• a strong automotive industry

• and a highly-skilled workforce.

BUT

Nowadays battery market is

dominated by Japan (Panasonic and

NEC), Korea (LG and Samsung),

China (BYD and CATL), US (Tesla).

FiberEUse Project

Duration: 48 months, starting on June 2017.Consortium: 21 partners, from 7 EU countries.Coordinator partner: Politecnico di MilanoEC Funding: ca. 10 mln €.

Large scale demonstration of new circular economy value-chains based on the reuse ofend-of-life fiber reinforced composites.

Topic: Systemic, eco-innovative approaches for the circular economy: large-scale demonstrationprojects (CIRC-1-2016)

The FiberEUse project aims at integrating in a holistic approach different innovation actions aimedat enhancing the profitability of composite recycling and remanufacturing in value-added products.

21

CarE-Service consortium

Title: Circular Economy oriented services for re-use and remanufacturing of

hybrid and electric vehicles components through smart and movable modules

Acronym: CarE-Service

Topic: Systemic, eco-innovative approaches for the circular economy: large-

scale demonstration projects (CIRC-1-2017)

Type of Action: Innovation Action

Date of Submission: 05/09/2017

Funding: 6.229.505€

22

Enablers developed in the project

Smart Movable Modules (SMMs) for on-site disassembly and

testing/certification of E&HEVs parts

23

Enablers developed in the project

CarE-Service ICT Platform

24© ITIA-CNR

De-and remanufacturing Plant: Research/ Teaching Factory

An integrated Pilot Plant for the remanufacturing and recycling of mechatronic

components (automotive, large machinery, electronics, white goods), is being

designed and installed at ITIA-CNR (January 2013). The pilot project was funded

by Regione Lombardia with a grant of 1.5 Million Euro.

Cell 1: Disassembly

Cell 2: ReworkingCell 3: Recycling

from research .… to market

E-Mobility - Dusk or Dawn for

Remanufacturers? Starters, alternators, turbos, calipers, engines to

vanish - What will you remanufacture next?

Marcello Colledania,b

(a): Professor at the Department of Mechanical Engineering –

Politecnico di Milano – Italy.

(b): Research Associate at ITIA-CNR, Institute for Industrial

Technologies and Automation.