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GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
Electric Vehicle Batteries: Moving from Research Towards Innovation
Knowledge Transfer from Research to Innovation
System Integration
Ian Faye
10th of April 2013
Brussels
1
GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
Bosch E-Drive Activities
Charging stations for
electric vehicles
Drives for e-bikes Battery: BBS
Electrical drives for
passenger cars
Hybrids, Plug-in & EV
Software for
infrastructure integration
Chargers for EV / PHEV
Hydraulic hybrid system
& electrical drives
for commercial vehicles
Navigation systems
Research and pre-
development for future
electrical vehicle concepts ABS, ESP,
Break-Booster
Starters and generators
for Start/Stop Systems
System integration is more than putting components together in a vehicle
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GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
System Integration Powertrain
Battery Integration Involves Several Interfaces
Mechanical and Environmental
Electrical Power and Recuperation
Thermal Conditioning
Communication and Management
Safety Concept
a
nl INV
CON
EM
ECU
HV
BAT
BMS
CHA AUX
ECU DIF
GET BCM
12V
BAT
VCU ESP PSM
Integration of one component affects interfaces of others
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GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
real vehicle range:
200 km
260 kg
200 km
180 kg
Li-Ion
Li-Ion
Li-x
Optimize Battery PLUS Optimize Vehicle System
200 km
500 kg
250
Wh/kg
22 kWh/100 km 150 Wh/kg 12 kWh/100km
consumption
2010
2015
2010 2020
44 kWh
improved module with intelligent BMS
35
kWh
350
Wh/kg
2020
44 kWh
200 km
100 kg
Li-x
44 kWh
cell level usable
energy
200 km
200 kg
Li-Ion
24
kWh
2015
modular design w/ optimized vehicle integration
Source: Heiko Weller, Bosch
Optimization achieved through synergies between components and vehicle: Vision -> integrated components
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GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
Future Intelligence in System Integration
Optimization achieved through synergies between components and SW
System optimization for Driving Range
System optimization for Life-Time
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GS/EP | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
Volume Bundling
1
100
10,000
1,000 10,000 100,000 1,000,000
Sh
are
of
de
ve
lop
me
nt
co
st
pe
r b
att
ery
[e
uro
s]
Annual battery production volume
Anticipated
development effort
for cells and packs
approximately
1,500 man years
As a result
investment in
development of
approx. 150 m euros
With depreciation
over 10 years and
8 % financing cost,
cost amounts to
25 m euros/year and
manufacturer
Battery manufacturer
with 50,000 to 100,000 EV/year
Additional development
cost for small manufacturers:
500 euros/battery
Battery manufacturer
with 500,000 EV/year
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GS/EP | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
Weight Volume Cost
12% 4%
84%
9% 10%
81%
6% 5%
89%
Battery Power Electronics Electric Motor
Electric motor: 60 kW Battery: 20 kWh
Li-ion battery
Summary
Integrated system must lead to weight, volume and cost reduction.
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GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration
Gasoline Systems
Key Messages
System integration adds additional value to components
Optimization must cover powertrain, communication and whole vehicle concept
System integration must cover safety aspects
for the user
for the service technicians
for rescue forces in case of accidents
To maintain equivalent high safety levels as with today’s conventional vehicles
Support standardization of non competition relevant products for “platform” concept
Research is still needed in key areas:
solutions for product integration
reduced energy consumption of controls, as well as auxiliaries (heating/cooling)
pre-heating/cooling of passenger compartment and temperature sensitive
components (like battery)
second life concepts, reliability and safety and recycling
standardized protocol of SOH for cells and modules
ensure safety level achievement incl. data communication
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GS-EH/PJ-SPE | 4/8/2013 | abl | © Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
smart EV-VC: Battery and System Integration anl
Gasoline Systems
Thank you for your attention!
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