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AVL SERIES BATTERY BENCHMARKING

Getting from low level parameter to target orientation

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CONTENTS OVERVIEW

1. AVL Introduction

2. Focus Series Battery Benchmarking

3. Benchmarking process

4. Target comparability - Analyzing & rating of the system

5. Battery benchmark example

6. Summary

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ENTERPRISE DEVELOPMENT AUTOMOTIVE

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

GROWTH

SALES 1995:

0.15 billion €

2015:1.25 billion €

prev. 20161.41 billion €

STAFF

8.050 employees

65% engineers &

scientists

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100

200

300

400

500

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700

800

900

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1.500

Mio. €

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• AVL high accuracy battery state calculation algorithms: SOx and battery cell wear detection -enable increased driving range, reduced charging time and extended operability

• AVL algorithms developed together with AVL battery chemistry team - strategic development partner for cell manufacturers

• AVL control solutions for battery system from 12V to 1000V – scalable for platform usage• 3rd generation integrated battery module controller and ASIC’s – Reduction: electronic

component number, costs, size and weight• Complete AVL battery control logic proven in production for several applications• AVL Semiconductor based main switches R&D Project to reduced the cost, increase robustness

and extend the modularity• AVL HV battery EMC simulation service of full parametrized battery model for several OEMs

with analog 3D model description, cell packages, SOC, aging, coupling effects of various geometrical aspects of enclosure, bus bars and battery modules

• AVL HV battery EMC simulation competence of H-field distribution of new batteries regarding ICNRIP requirements and exposure to human beings at various positions of the body

• HV battery EMC development assistance in terms of shielding, EE-box arrangement, wire routing LV, HV/LV attenuation and bus bar routing

• HV battery EMC full 3D and analog simulation of filters integrated within HV battery

HV-BATTERY

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OVERVIEW OF AVL´S BATTERY ACTIVITIES

BMS & MCU development (SW & HW)

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

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CONTENTS OVERVIEW

1. AVL Introduction

2. Focus Series Battery Benchmarking

3. Benchmarking process

4. Target comparability - Analyzing & rating of the system

5. Battery benchmark example

6. Summary

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AVL runs a benchmarking program for xEV batteries:

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

10 work packages with benchmarking of ~240 single criteria

Derivation of >80 objectives for better comparability

Management view available through final evaluation in 8 attributes

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

Standardized reports and documentation available

BENCHMARKING OF BATTERIES

Vehicle

Level

Assessment

Battery

Assessment

Tear

Down

Design

Concept

Identification

Production

Concept

Identification

Cost

study

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AVL SERIES BATTERY BENCHMARKING -PROGRAM KICKED OFF JULY 2016

Vehicles in Planning for 2016/2017:

Mitsubishi Outlander PHEV Model 2015 (with OBD) – started – finishing Q1/17

Tesla Model X P90DL (X P100DL) - vehicle arrived – start within 10/2016

Chevrolet Bolt – start Q1 2017

BYD Tang – start Q1 2017

Audi Q7 PHEV – start Q2 2017

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CONTENTS OVERVIEW

1. AVL Introduction

2. Focus Series Battery Benchmarking

3. Benchmarking process

4. Target comparability - Analyzing & rating of the system

5. Battery benchmark example

6. Summary

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10 Work Packages (sequential):

Vehicle

Powertrain Tests

Vehicle Integration

Battery Data

Battery Testing

Tear Down

Module Tests

Cell Tests

Cost Analysis

Abuse Testing

Number of Criteria: ~240

CONNECTING WORKING PACKAGES TO BENCHMARK ATTRIBUTES

8 Attributes to be assessed:

AV

L o

bje

ctive

ra

tin

g

Connection:

How to?

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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 C

RIT

ERIA

& P

ARAM

ETERS

Level 2Elements

(i.e. Battery)

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CONTENTS OVERVIEW

1. AVL Introduction

2. Focus Series Battery Benchmarking

3. Benchmarking process

4. Target comparability - Analyzing & rating of the system

5. Battery benchmark example

6. Summary

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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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BATTERY ATTRIBUTES DETAIL VIEW

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

Parameters Weighting

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

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

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

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

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

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

Sum 1

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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

CRITERIASUB-ATTRIBUTE PARAMETERALGORITHM

𝑓 𝑥

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CONTENTS OVERVIEW

1. AVL Introduction

2. Focus Series Battery Benchmarking

3. Benchmarking process

4. Target comparability - Analyzing & rating of the system

5. Battery benchmark example

6. Summary

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RENAULT ZOE BATTERY BENCHMARK VEHICLE

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

Driving

Battery cooling only active during charging

Increasing temperature difference between modules

Test Conditions:

Driving in 3 segments

After each segment charging

Results interpretation:

Air cooling is needed only during charging in 20°C ambient conditions

Temperatures are not equalized during driving

Temperature spread between modules is rising due to a metal crash protection profile halfway through pack

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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 ductDetail: structural aluminum profile in side view

Cooling air

distribution is

disturbed by

structural profile

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TESLA MODEL S BATTERY BENCHMARK VEHICLE

Official Battery Data

Energy: 85kWh

Voltage Nominal: 355V

Voltage Max: 400V

Cell number: 7104

Configuration: 96s74p

Cooling: Liquid

Weight: 618 kg

Official Vehicle Data

Power: 270 kW

Torque: 440 Nm

Speed: 201 kph

Acceleration: 0-100 kph 5,6 sec

Range: 482 km (NEDC)

Weight: 2108 kg

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Source: Official product and website information, Tesla

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PACK TESTING COOLING SYSTEM EVALUATION

Test conditions:

Start temperature +20°C

Symmetric rectangular current profilee.g. ±100/200/250A, 0.05Hz

Coolant flow ratee.g. 3/4/5Lt/min (+20°C)

Result interpretation:

Pack temperature spread up to 9.8K

module temperature spread up to 8.0K

T1 [°C]

T2 [°C]

legend

module

number

Temperature data just after end of test

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CONTENTS OVERVIEW

1. AVL Introduction

2. Focus Series Battery Benchmarking

3. Benchmarking process

4. Target comparability - Analyzing & rating of the system

5. Battery benchmark example

6. Summary

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Vehicle to screw analysis Functions and performance on vehicle level is brought into context of design and parts

Building functional understanding AVL developed test program clearly shows function principles and their limits

Orientation in the target system Comparable evaluation via AVLs rating system transparently shows strengths and

weaknesses

Comparable evaluation supports positioning your future products in the market

AVL BENCHMARK ADDS VALUE TO YOUR BENCHMARKING AND DEVELOPMENT ACTIVITIES:

SUMMARY

www.avl.com

THANK YOU