Workshop “Solutions to electromobility challenges” · 2019. 11. 15. · Workshop “Solutions...

GV-06-2017

iModBatt and GHOST projects have received

funding from the European Union’s Horizon2020

Programme for research and innovation under

Grant Agreements No. 770054 & 770019

Hotel ARIMA, Paseo de Miramón, 162, 20014

San Sebastián, Spain, 18th October 2019

Workshop “Solutions to electromobility challenges”Hosted by CIDETEC Energy Storage with the support of CRF

The GHOST Project:

InteGrated and PHysically

Optimised Battery System

for Plug-in Vehicles

Technologies

Workshop “Solutions to electromobility challenges”, 18th October 2019, San Sebastian (Spain)

Project overview

Project typology: Innovation Action Call: H2020-GV06-2017

Acronym: GHOST

Title: InteGrated and PHysically Optimised Battery System for Plug-in Vehicles

Technologies

Coordinator: CRF

Partners (from 6 EU countries): IVECO, Toyota Motor Europe, Infineon, Valeo, EVE

System, UMICORE, AVL (AT & DE), Fraunhofer (IIBS & LBF), Laborelec, Ikerlan,

VUB (co-coordinator)

Start: October 2017 Overall Budget: 8.87 M€

Duration: 42 months EU funding: 7.15 M€


Consortium partners

• OEMs: CRF, IVECO, Toyota Motor Europe

• Automotive Suppliers: Infineon, EVE Systems, VALEO

(NB. Johnson Matthey Battery Systems withdrew from the consortium early 2018

following take-off by Cummins)

• Application Oriented Research Organisations: Fraunhofer Institute (IISB & LBF),

Ikerlan, ENGIE Laborelec

• Engineering Company: AVL (AT & DE)

• Large Enterprise in Recycling Business: UMICORE

• University: VUB (Brussels)


BS: from Cell to System

Single

CELL

Chemistry

+

CAPACITY (Ah)

=

“FIXED” amount

of energy (Wh)

in one CELL

Cells (series and/or parallel

connected)

+ signal and HV connections

+ monitoring electronics

+ mechanical and cooling

=

one MODULE

MODULE

MODULES

+ signal and HV connections

+ management electronics

+ HV distribution and fuses

+ cooling/heating

+ housing and ext. interfaces

=

BATTERY SYSTEM

BATTERY SYSTEM


Expected impacts (according to the Call)

1. Energy density improvement of Battery Systems:

increased by 15-20%

2. Battery integration costs (excluding cell cost):

reduced by 20 to 30%

3. Strengthening the complete chain:

from design and manufacturing to dismantling and recycling


BS weight breakdown (Fiat 500e)

BBS (Bosch Battery System ) BS (97S1P - 66 Ah)

Total installed energy 24 kWh

BS total weight 272 kg

- Cells 182 kg (67% of BS)

- BS w/o cells 90 kg (33% of BS)

BS potential weight saving [%]* 16

specific energy increase [%]* 20

Liquid cooled*Fraunhofer LBF Evaluation


BS enhanced thermal management

Enhanced cell thermal management to:

• improve heat transfer

• increase module and BS temperature

uniformity

• smooth thermal transients

• protect against cell to cell thermal

runaway

Effects:

• higher discharge/charge rate (ultrafast partial charging)

• cells life increase

Example of Module with PCM + Al foam


BS recycling and second life

An effective process for the BS (and its modules)

assembly-disassembly is the most relevant action

to reduce time and costs of the recycling process

and an enabler for second life applications

“Press fit” module connection

For second life, it is also important identifying the

first life data to be stored in the BMS to reduce the

module electric tests to prepare the second life BS


Expected results

Ambition:

Develop Battery Systems for multiple applications at TRL (Technology Readiness Level) 7:

• Passenger cars and buses

• P-HEV (less than 10 kWh) and BEV (tens of kWh)

• Standard AC charging (6,6 kW) and fast DC charging (at least 150 kW)

• 400 and 800 V

• Liquid or direct refrigerant fluid based cooling

based on an integrated common standardised Li-ion module able to manage different

energy-power requirements through appropriate series-parallel connection and

dedicated integrated thermal management solutions


Vehicle validation

• Passenger Car: P-HEV 500X

One 400V basic unit without fast charging

• BEV bus: GX 337 E

Six units (2S3P) with superfast charge

capability (opportunity charging)

Demonstration of GHOST BS solutions in two vehicle validators:


Vehicle validation

Demonstration under real life conditions: 400V P-HEV application

Example of BS cooling circuit coupled through the

chiller to the air conditioning one

Fiat 500X eAWD P-HEV (CRF)

BS


Demonstration under real life conditions: 800V EV application

Example of direct BS cooling through refrigerant fluid

(for ultra fast partial charging)

Vehicle validation

BS

IVECO BEV Bus


Project structure with main interactions


• Electrical design activity to support the modular nature of theBS concept while providing flexibility for multiple configurationsand scales with respect to the two different applications ofinterest:

Progress to Date: WP3

WP3 “Modular Battery Architecture, Design, Prototyping & Manufacturing”:

Fiat 500X P-HEV

- 400 V- 1 Basic Unit

IVECO BEV Bus

- 800 V- 6 Basic Units

(3 in parallel x 2 in series)


• Development of novel compound sandwich material for the housing and structure

to reduce weight and volume of the mechanical ‘overhead’, and improve thermal

insulation




• Integration of reversible cell-to-cell connections with voltage, temperature &

current measurement into the novel Power PCBs, monitored by the BMS:




• Investigation into a new cell temperature monitoring system based on

electrochemical impedance spectroscopy (EIS) measurements with

feasibility studies on EIS hardware and the preparation of an PCB

demonstrator board with the development of algorithms in the

microcontroller firmware



Cell Temperature Estimation Accuracy


• Innovative direct refrigerant coolingsolution to achieve the performance,

weight/volume and cost targets:

� optimised for refrigerant operation tosatisfy the challenging fast chargingrequirements (up to 350 kW for the800 V system) at minimised tempera-ture gradients

� can be operated in moderate applica-tions with conventional liquid coolantfor greater flexibility (e.g. second use)





WP9 “Dissemination & Exploitation”:


General Conclusions

Thanks to the excellent collaboration between the partners in the consortium, the GHOST

Project is on track to ultimately deliver:

• new architecture and design solutions (supported by new models and tools) to enable

the development of a Battery System with higher energy density, lower cost (recycling

process included) and effective applicability for second life

• effective integration of the battery cells in the BS and of the BS in the vehicle - key

elements for wider marketability of the plug-in electric vehicles (BEVs and P-HEVs)

• assessment of new materials and smart integration approaches to address the new

challenges coming from ultra fast (opportunity) charging

• modularity and standardisation at BS module level to address different application

requirements and current (Li-ion) / future (post Li-ion) cell chemistries

Thanks for your

attention!

GV-06-2017

iModBatt and GHOST projects have received

funding from the European Union’s Horizon2020

Programme for research and innovation under

Grant Agreements No. 770054 & 770019

Workshop “Solutions to electromobility challenges” · 2019. 11. 15. · Workshop “Solutions...

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