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Lithium Ion Batteries in E-Mobility
Motivation
Design for Manufacturing
Trends
Klaus Grieshofer
04.03.2015
Outline
Introduction of Magna Steyr Battery Systems
Motivation for Electromobility
Development
Production
Future Trends
MAGNA STEYR BATTERY SYSTEMS
Battery systems for passenger
cars and commercial vehicles
based on state-of-the-art
lithium-ion technology
Li-Ion
battery systems Testing services
State-of-the-art test labs
in Europe and North
America ensure the
highest quality and safety
standards
Low-voltage
systems
B:LiON lightweight
battery systems for
automotive micro, mild
and hybrid applications,
as well as onboard power
supply
High-voltage
systems
B:LiON battery systems in
the high-voltage range as
an energy store for fully
electric or hybrid vehicle
applications
China Shanghai,
Changchun
Austria Graz, Zettling
North America Auburn Hills
Battery Systems
Top Quality Storage Systems for Electric and Hybrid Vehicles
13 March 2015 Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited
Battery Systems Locations Europe
• Austria (Europe)
Employees: 171 (Status Q3 / 2013)
Plant Size: 14,060 m²
• Functions
Battery Pack Engineering
Prototype Battery Builds
Battery Pack Assembling
Zettling (HQ)
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
• Michigan (USA)
Employees: 48 (Status Q3 / 2013)
Plant Size: 7,630 m²
• Functions
Battery Pack Engineering
Battery Testing
Material Testing
Battery Systems Locations North America and China
Auburn Hills
• China, Jilin Province
• Expansion of existing plant
Planned size: ~10.000 m²
Planned Production volume: ~35.000/(year)
• Functions
Battery Pack Assembly (SOP: Q2/2016)
Battery Pack Engineering
Changchun
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Battery Systems Portfolio Automotive Market
Energy Plug-In PHEV Hybrid (HEV) 48V 12V Truck PHEV
Energy
Content 16 - 36 kWh 6 - 18 kWh 0.2 - 3 kWh 0.25 - 1 kWh ~ 70 Wh 8 - 14 kWh
Power 50 - 120 kW 50 - 120 kW 10 - 50 kW 8 - 11 kW ~ 3 kW 100 - 170 kW
Voltage 400 V 400 V 120 / 400 V 48 V 12 V 400 / 700 V
Weight 180 - 400 kg 80 - 200 kg 10 - 40 kg ~ 15 kg ~ 5 kg 120 - 220 kg
Cooling liquid (optional) liquid air / liquid AC cooling /
liquid ---- liquid
Manuf.
Capacity 3,000 / year > 35,000 / year 50,000 / year 100,000 / year
< 100,000 /
year 3,000 / year
Serial Production Serial Production Serial Production Serial Production
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Matrix of Battery Pack Applications
TRUCK/BUS HEV*
HEAVY DUTY
POWER BATTERY PACKS
50
Tota
l E
nerg
y [k
Wh]
0
1
10
Power [kW]
1 10 100 1000
EV* Electric Vehicle
PHEV* Plug In Hybrid Vehicle
HEV* Hybrid Electric Vehicle
12 / 48V SYSTEMS
POWER BATTERY
PACKS
EV*
ENERGY
BATTERY PACKS
MILD HEV*
POWER
BATTERY PACKS
FULL HEV*
POWER BATTERY
PACKS
PHEV*
ENERGY BATTERY
PACKS
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
MSBS Track Record
2013
2010
BEV
Battery Pack
HEV Truck Gen II
HEV Truck Gen III
12V Light Weight Li-
Ion Battery
PHEV Battery Pack
Serial Projects with SOP Development
2009
2010 2011
2013
2014
2015 2016
High Power HEV Battery
12V Light Weight
Li-Ion Battery Gen II
HEV Truck Gen I
PHEV / HEV
Truck Gen IV
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Motivation for Electromobility
CO2 is a Global Reference Point for Hybridization
Legislative CO2 reduction requirements
EU: -27% (2012-2020)
NA: -33% (2012-2020)
TODAY
CO2 reduction requirements by OEM in EU
Source: IHS Automotive, Berlin March 2013
Legislative Convergence across TRIAD,
China, and SK
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Approach to reach the targets
Aero-
dynamics Propulsion-related CO2 measures achieve a good cost relation
Propulsion-related measures
Other measures
€/%
CO
2 R
ed
ucti
on
CO2 measures on NEDC vs. Costs
Propulsion
System
Improved
efficiency
Rolling
resistance
Aero-
dynamiics
Leightweight
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
CO2 Reduction requires Diversification of Powertrains
Fuel cell vehicles
Range extended EV
Electric vehicles
High powertrain diversification expected over the years
For City emission free driving with PHEV and BEV
EU targets: 130 gCO2/km 95 gCO2/km tbc: 70 gCO2/km
rela
tive C
O2
em
issio
ns
up to -100%
up to -40%
up to -60%
Mild hybrids
Full hybrids
CNG/ LPG
Synthetic sun fuels
BiSG & CiSG, 12V/48V
Stop/start
ICE optimization
Light weight
Energy management
Aerodynamics &
Friction
PHEV
Cit
y
Lo
ng
Dis
tan
ce
-20 to -30%
Electric vehicles
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
A/B/C Segment Conventional
Vehicle
Electric
Vehicle
Co
mp
on
en
ts
Propulsion system Combustion engine
Gear box (6 gear)
Electric motor
Gear box (1 gear)
Converter
Inverter
Energy storage system Tank ~70l Battery pack ~ 350l
Onboard charger
Fu
nc
tio
ns
Range >1000 km Up to 500 km
Max. speed >180 >180 @ 1 shift
Refuel/charging 3 min Fast charge <20min
Energy recovery No 25-40%
CO2 emissions 140g/km 0g/km
Energy efficiency <30% ~70%
Comparison EV and conventional vehicle
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Germany
0
10
20
30
40
50
60
70
80
90
100
0
2
4
6
8
10
12
14
16
0 2,6 5,2 7,8 13 20,8 26 39 52 78 130 260 >260
Tage
sle
istu
ng
in %
, ku
mu
liert
Tage
sle
istu
ng
in %
PKW-Tagesfahrleistungen in kmSource: Bundesministerium für Verkehr,
Bau- und Wohnungswesen (BMVBW), 2002
At present average electrical
range of electric vehicles
120 150 km
• 90% of all trips are
shorter than 130km
• 70% of all Germans
drive less than
35km per day
• PHEV allows pure
electric drive up to
50km + full
conventional range Daily driving range [km]
Dail
y a
cti
vit
ies
[%
]
Da
ily a
cti
vit
ies
,
ac
cu
mu
late
d [
%]
Batterysolution
will increase
costs & weight
Daily Driving Range
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Development
MAGNA STEYR Battery Systems
Development Process
Electrical integration
Cell Selection
Software / Battery Management
Validation
Mechanical integration
• Customer tailored housing
• Modular concept
• Functional integrated
(Cooler + Housing)
• Low cost and high
integrated cell to cell
connection
• Battery disconnect
unit
• Interfaces
• Wiring of measure-
ment circuits
• Functional Safety Concept
• Balancing + Supervision of cells
• State Monitoring (State of Charge,
State of Power, State of Health)
• Communication/ CAN
• Usage Logging over life
• Tailored cell chemistry
• All cell housing types
and chemistries
feasible
Thermal concept
• Thermal simulation
• Cooling concept for cell
thermal management
• Liquid or air cooled
DESIGN
• Performance
• Transportation
• Mechanical
• Thermal and
Climatic
• Safety
• Life Cycle
• other
Costumized Pack
Mass Production
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Cell Selection - overview
• “Cell”? – (Galvanic) Cells are Accumulators (Secondary
Batteries or Rechargeable Cells) • the electrochemical process is reversible
– In an Energy Storage System (ESS), several cells are connected in series and parallel configuration
• Selection Topics: – Mechanical design
– Performance design
– Chemical components
– Safety features
Cylindric Cells Prismatic Cells Pouch Bag Cells
Battery weight distribution
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Cell Technology
10
10
100
1.000
100 1.000 10.000
Sp
ecific
Energ
y [
Wh/k
g]
Specific Power [W/kg]
1
10.000
NiMH Lithium-Ion
Super-Capacitors
Lithium-Ion-Capacitors
Lithium-Sulfur
Lithium-Air
Solid State R&D stage
serial after 2025 R&D stage
serial after 2020
R&D stage
serial after 2030
€/kWh 170
(2020)
300
(2013)
€/kWh 200
(2020)
220
(2013)
€/kWh ~8000
(2020)
>10.000
(2013)
R&D stage
serial after 2018
* Cost indication based on cell level
** Source: Magna-internal information based on 10 market studies as well as cost indications from serial production requests
*** Specification based on reachable energies
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
PHEV HEV 48V 12V
Cell capacity 22 - 40 Ah 6 – 10 Ah 6 – 10 Ah 10 - 20 Ah
Peak Power / Cell 1000 W 700 W 800 W 1200 W (crank)
Grav. Energy > 170 Wh/kg > 80 Wh/kg > 80 Wh/kg >100 Wh/kg
Thermal Active cooling Active cooling Reduced thermal
control passive cooling
Life 10 years of service life
Tailored cell technologies to specific applications
Anode material
Cathode material
Electrolyte
Separator
Mechanical design
NMC, NCA, LMO, LFP NMC,LFP
Graphite Graphite, HC SC, HC, LTO
Reduced particle size, thinner electrodes, high surface area
Reduced particle size, thinner electrodes, high surface area, coatings
voltage stability thermal stability, low T performance
Solvent mix, functional additives, salt concentration
+ thermal stability, no shrinkage ceramic modified PE/PP
Low transport resistance tailored to mod. electrolyte
Metal can pouch type cells
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Thermal integration concepts - overview
21
Energy Plug-In Hybrid 48V 12V
Energy Content 16-36 kWh 6-18 kWh 0,2-3 kWh 0,6 -1 kWh 0,25 -1 kWh
Power 50-120 kW 50-120 kW 10-50 kW 10-2 kW 3 kW
Heat generated 200-300 W 200-300 W 200-300 W < 60 W < 15W
Passive cooling
Air Cooling
Liquid cooling
Refrigerant
Cooling
passive cooling should be sufficient for
limited performance.
Cost efficient air cooling option
For EV and PHEV applications best compromise in matter of packaging,
cooling and heating performance, safety and comfort
For HEV refrigerant cooling is an
option to avoid a own liquid cooling
circuit for the battery pack.
passive cooling should
be sufficient for low
C-rates applications.
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Trends in liquid cooling design
• Bottom cooling via cooling tubes • Bottom cooling via double-wall housing
Housing-integrated cooling:
Cooling plate designs:
• Thin sheet cooling plates
• Cooling plates with structural function
• Impact on:
Performance, Life, Safety
• Design criteria
• Cell operation T of ~ 35°C
• Homogeneous
temperature distribution on
cell and module level
• Methods:
• Simulation (0d, 1d, 3d)
• Functional integration
• Verification
Thermal management
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Thermal cooling design
3D Computational Fluid Dynamics (CFD)
3D – Temperature distribution
Temperatures
Velocities
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Mechanical integration - Overview
Serial Production Program, fully qualified battery pack
Prototype build-up, concept validated
Feasibility study, concept simulated and analyzed
EV PHEV / REX Hybrid (HEV) 12V / 48V Bus / Truck
Steel deep drawn Concept Serial Concept PT Concept
Steel welded Serial PT PT - Serial
AL-deep drawn - Serial (cover) Concept (cover) Concept PT (Cover)
Al Casting - Serial PT Concept PT
Al extrusion profile - Concept - Concept -
Polymer Serial (Cover) Concept (Cover) - Serial -
Serial Production Serial Production Serial Production Serial Production
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Trends in PHEV housing design
• Package arrangement
• Integration of Cooling
• Crash performance
• Mechanical endurance (life
time)
• Vibration and shock durability
• Temperature / humidity
durability
• Design for manufactoring
Mechanical design PHEV die-cast housing
Material: Aluminum crash alloy
+) Complex geometry possibilities
+) Low cost at high volume
+) crash & shock requirements
- ) Limitation in size
Material: Extruded aluminum profiles
+) High mechanical strength
+) crash
+) For low and high volume, all sizes
- ) Not suitable for complex installation space shapes
Al-Extrusion housing
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Electrical design - examples
• HV-Path
• LV-wiring
• Interconnections
• Insulation / HV Protection
• Battery Disconnect Units
• EMC Filters
Electrical design
Compact EMC Filter:
• Compact design
• Easy assembly
• Highly effective
• Automated HV connection
• Automated wiring to PCB
• Integrated temperature sensor
Compact high-voltage connection board:
• Designed for automated
assembly
Integrated cell connection unit for battery module
sen
so
r
fuse
2 relais
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Implemented Functionality
Battery Management System Overview
BMU/ CSC functions
Cell measurement
-Cell voltage
-cell temperature
Pack measurement
-pack voltage
-pack temperature
System measurement
-Cooling media inlet and
outlet temperature
SOC Estimation
SOH Estimation
Power limit calculation
Cooling control
Wake up/ Stop control
Cell balacing control
HV Isolation Monitoring
Diagnostics
CAN Communication
SOC („Range“)
Available power
State of health
Warning
messages
Diagnostics
Wake up / Stop
CAN
Communication Vehicle
Cell
balancing Cooling
HV
contactors
HV
Interlock
Wake up
Crash Signal
Battery
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Electronics / Battery Management
• Main components: – Battery Management Controller (also unit)
• Data treatment/analysis
• Functional/safety algorithms
• Vehicle communication
– Cell Voltage Monitoring • LV measurement of cells
• Temperature measurement
• Balancing components
– HV components: • Relais
• Fuse
Cell voltage monitoring
Battery management controller
CSCCSC
Lion
Cell
Ve
hic
le H
V
Su
pp
ly+
-
+
-
Service Lid
Co
oli
ng HV Fuse
Relay V-
Relay V+
BMU
Current Sensor
(redundant)
Lion
Cell
Lion
Cell
KL
30
KL
30
c
HV
IL
CA
N
CSC CSC
Pre-Charge Relay
Hardware architecture
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Software / Battery Management Cell model
Deta
iled D
esig
n S
W SW
Module
test
SW Implementation
Design
SW
Design
HW
System Integration Test
(System Testbench)
SW Integration
Test
(HiL)
Requirements Development
System Design
Acceptance Tests
SW HW
Component Production
(Electrics & Mechanics)
Com
ponent te
st
Ele
ctr
ics &
Mechanic
s
SYSTEM LEVEL
SUBSYSTEM LEVEL
COMPONENT LEVELT
oolin
g c
onstru
ctio
n
Cre
ate
pro
ductio
n d
ata
Electronics Production
Set in
to o
pera
tion, H
W
Module
test
Deta
iled D
esig
n
Software
Implementation
Module
Test S
W
Subsystem Integration Test
(System Testbench)
SW Test
(HiL)
Desig
n V
erification (
DV
)
Ele
ctr
onic
s, M
echanic
s &
E
lectr
ics
Desig
n E
lectric
s &
Mechanic
s
Design
System Functions
Onboard Diagnostic OBD-2target: monitor emission relevant faults
detection: defective sub-component
monitoring of cellvoltage
monitoring of systemcurrent
monitoring of celltemperature
monitoring of celltemperature
monitoring of cellvoltage
monitoring of systemcurrent
monitoring of systemvoltage
monitoring of coolanttemperature
insulation monitor
monitoring of high voltage plugs and
service lid
monitoring of high voltage fuses
monitoring of high voltage relay
cell voltage balancing
battery management functionality
Safety Systemtarget: monitor safety relevant faults
detection: hazard / non-hazard
advanced diagnostics
Basic Software
ApplicationSoftware
Cell Modeling
• Cell characterization
• Battery algorithm
• System functions
• Application software
• AUTOSAR configuration
•Driver development
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Safe Operation of Li-Ion Batteries
4 Level Concept
Cells Pack Design Pack Functions Application
• Qualified to Hazard
Level <= 3
• coated separator
• Pure and safe cathode
and anode material
• integrated safety
devices
• Robust and qualified
mechanic and electric
design
• Usage of self-
extinguishing materials
• Safe gas release to
ambient
• Safe Battery Mgmt.
Electronics and SW
• Monitoring of all safety
relevant operation
parameters
• Safe shutdown
• Thermal management
• Integration area
• Vent gas management
• Crash reaction
Level 1 Level 2 Level 3 Level 4
• Cell Design Qualified to Hazard Level <= 3
• Robust and qualified mechanic and electric pack design
• Safe Battery Management Electronics and SW
• Integration into vehicle safety concept
• Extensive Validation
Safety Risk minimization by a 4 Level Safety Concept
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Production
Serial Production of Lithium Ion Batteries
PHEV serial production line
Module
1. Check / Preparation
2. Glueing
3. Welding
Pack
4. Assembly/Wiring
5. EOL Testing
1
2 3
4
5
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Process: Check / Preparation / Glueing
• Plasma cleaning of the cooling plates
• Adhesive application on the cooling plates
• Adhesive needs to be thermally conductive, electrically
insulating, providing highest strength, process friendly
• Laser cleaning of the cells electrically isolated stacked
together
• Glueing of cell stack to cooler
Plasma Cleaning of Cooler
Laser Cleaning of Cell stack
Glue application to cooler
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Process: Welding
• Connector board for cell connection is pre
assembled
• Aluminium busbars are cliped into a
polymer carrier
• Welding of busbars to the cell measuring
system
• Connector board is attached on top of the
cell stack which is glued on the cooling plate
• Aluminium busbars are laser welded onto
the cell terminals.
• All weld beads are controlled optically by
a surface scanner
Assembled modules
Module Connector board
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Process: Assembly / Wiring / EOL Test
• Assembly and screwing of the cell
modules in pack housing.
• Wiring of module electronics to battery
management unit
• Wiring of modules and conectors
• Mounting the cover and end of line test.
• High Voltage End of Line Test performing
Safety, Capacity
Tests and Charging Operation
• Battery complies with an absolute contact
protection
3/13/2015
Assembly of 3 modules in bottom housing
Wiring of modules
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited
Future Trends
Pouch housing
0
20
40
60
80
100
120
140
160
Ford MC346
GM Volt Mitsubishii-MiEV
Magna E-Car
serialprogram
2010
Magna E-Car
concept2010
Magna E-Car
concept2011
MagnaSteyr
concept2013
MagnaSteyr
concept2014
~79 ~88 ~80 65,5 78,7 88,7 95 110
Gra
vim
etr
ic E
nerg
y /
Wh
/kg
Mechanical Design & Integration
Self supporting module structure
Cell is used as mechanical structural part
Reduced weight of cooling air cooled system
Weight: 110 kg (10,5 kg/ kWh)
Dimensions: 1000 x 250 x 600mm (b x h x t) mm
Wh/kg on cell level
liq
uid
liq
uid
air
air
Pouch housing Steel metal can housing Al can housing li
qu
id
liq
uid
air
Package based on Standard Modules
Functionally combined Housing and cooling
Crash resistent Al housing 20
11
20
15
liq
uid
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Battery price* development / kWh – estimation**
€ 315
€ 250
€ 200 € 180
€ 450
2009 optimization ofproductions (mass
production, cell power)
new materials cell standard material pricestandardization
2018
-30%
-15%
-10%
-5%
-60%
100%
80%
60%
40%
pri
ce
in
%
* supplier to OEM
** source: Continental AG Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Standardization on sub module/component level is a feasible approach to fulfill OEM
requests and shows quality & economy of scale effects on component level.
Cost target Standardization is the Enabler
Sta
nd
ard
izatio
n p
ote
ntia
l
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015
Current Products
Innovation Fields
New Products
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2020
From 12V systems up to high energy BEV applications Product diversification driven by matching market needs
BEV
Battery Pack
Battery Systems Product Roadmap
HEV Truck
Gen I
12V Light Weight
Li-Ion Battery
PHEV
Battery Pack HEV Truck
Gen III
PHEV / HEV
Truck Gen IV
48 V System
Gen I
High Power
HEV Battery
12V Light
Weight Li-Ion
Battery Gen II
PHEV Battery
Pack Gen II
48 V System
Gen II (specific cells)
PHEV/EV
Systems based on:
• Improved Battery management
• Integrated sub components
• Next generation cell technologies
HEV Truck
Gen II
Diversification of product portfolio beyond vehicle industry
Author: Klaus Grieshofer Disclosure or duplication without consent is prohibited 13 March 2015