Application of Li Ion Batteries in Industrial Vehicles.

Transcription

1 3 rd Israeli Power Source Conference Application of Li Ion Batteries in Industrial Vehicles. TCO and commercial considerations based on customer business cases. May 29th-30th 2013

2 Agenda 1. LiTHIUM BALANCE A/S. Company profile. 2. Situation Analysis: Case of Toyota Material Handling Europe (TMHE) 3. Solution Description. 4. Measured benefits (TCO, commercial considerations). 5. Conclusion, recommendation.

3 LiTHIUM BALANCE, facts Battery Managment System supplier. Award winning, patented BMS technology (US, China, EU). Founded in 2006 by Danish Technological Institute. 6 meur invested in platform development. Current owners: DONG Energy Power A/S. Power utility supplier. DS 7 Aps (Holding company for business angels) Lars Barkler, CEO Number of employees: 15 Focus on R&D and Sales Direct sales, and through network of distributors Production outsourced BB Electronics Industrial LV BMS platform. Flextronics Industrial and automotive HV BMS platform. 3

4 We serve the large format lithium battery applications with three BMS platforms Integrated (i-bms) Basic BMS for simpler applications (Boat, Scooter, Robot) 12-72V versions Embedded switching RS232 communication TÜV automotive Scalable (s-bms v.6) Advanced BMS for industrial and EV applications Modular V RS485 and CAN-bus Industrial certification High EMI resilience, Networked (n-bms) Automotive grade BMS Modular V 3mV precision Up to 1 temp sensor/cell Analogue redundancy ISO26262 ASIL C CAN-bus board2board 50% size reduction Release for sale Q

5 Market position Our focus: democratising Li-ion battery technology for use in industrial and motive applications (1-3). Our challenge: making good on this goal in a cost effective manner Our solution: flexibility, support documentation and the right product!

6 We have unique integration knowhow from170+ different customer implementations. Major revenue from Industrial. First Li-ion forklift in a cold store No battery swap needed Longer pack life Opportunity charging Maintenance free Lower TCO First Li-ion electric street sweeper No exhaust emissions Low noise emissions Can be used on pavements with pedestrians Can be used at any time of the day or night First Li-ion truck mounted forklift Manageable weight Can also be driven indoor for delivery or pick ups Can be used around food stuffs Can be operated day or night First Li-ion garbage truck compactor Reduces noise and tailpipe emissions No engine revving Can be operated day or night

7 Direct supply to a major battery manufacturer

8 Who are customers today? Key challenge: Winning early majority. Sales Customer Types: Technology fans/hobbyists (at early stages). Technology visionaries (happening now). Those in established companies who see a benefit from an innovation or new technology Early majority Success, mainstream market presence Chasm

9 Crossing the chasm The difficulty of attracting mainstream customers Revolutionary change Productivity improvement New, fast, easy, unique products De facto standard, 3rd party support, low cost of ownership Tolerates in-complete product Expects complete solution Willing to take risk Wants little risk, but willing to learn References other industries Rely references within their industry Buy from new firms Buy from market leaders (like competition) Wants rich tech support Wants one point of contact

10 CASE: Toyota Material Handling Europe TMHE is world s no.1 supplier of Material Handling Solutions, i.e. forklifts and warehouse trucks. Biggest pain: Cost induced by service and maintenance of the machines primarily battery change and pack maintenance. Impact: 1 spent on maintenance translates into ~10 spent on damages* (e.g. lost income due to productivity losses). Reducing negative impact of service and maintenance costs is the gold of the customer. *Håkan Dahllöf, president of TMHE (2011)

11 Situation Toyota asked us to address Battery change is a problem. Production loss. Direct costs are high Production loss due to battery handling. Cost of personnel, replacement packs and equipment. Cost due to a relative short cycle life of the L/A battery. Energy costs. L/A battery has low energy efficiency. Discharge performance of the L/A is a problem. Truck gets slower as it discharges affecting truck performance, productivity and end-user satisfaction. Image. Customers want environmentally friendly battery technology. Design. Customer want smaller machines.

12 TMHE, technical solution. Blackbox Li-ion battery pack (48V 800Ah): Large format prismatic LFP cells sbms # LiBAL Std. LV Switchbox Fast charger (6,4kW). TMHE-specific CAN-bus interface and advanced Error Handling Procedures. Solution tested and approved by TMHE (factory tests, extensive field tests).

13 In field operation, 24/7 since C FACTS: In constant use since Nov shift operation, 24/7. Opportunity charged. No technical problems, breakdowns and/or production stop. Battery SOH near 100%.. No maintenance on battery was performed since Nov Huge savings because no maintenance, no battery change and no production stop. High end-user satisfaction (constant performance).

14 TMHE: Factors affecting TCO* In order of significance: 1. Resources spent on maintenance, i.e. Manpower, infrastructure, battery storage and charging rooms, water. 2. Time and money spent on battery change, i.e. spare packs, equipment, personnel. E.g.: 36min./truck/day because no battery change (6x6min) 180h/year, i.e. 24 working days saved per truck/year! 3. Energy savings. Li-ion is ~20% more efficient than the L/A (measured by Toyota) 4. Loss of productivity due to operation stop for battery change or maintenance. Remember: 1 spent on maintenance =~ 10 damage! 5. Cycle life. The cycle life can be affected by temperature, DOD%, charging discipline. 6. Longevity (years in service of the machine) 7. Battery purchasing price *TCO Total Cost of Ownership Pic. 1 LiBAL performing situational analysis with Toyota, Exide and SuperGros

15 Cost of ownership over 5 years Li-ion is estimated to be ~1,68 times cheaper than the corresponding L/A solution over a 5 years period in a heavy duty professional application, i.e. battery/maintenance cost and energy savings taken into account. The potential derived benefits, e.g. due to increased productivity, simplified logistics etc. make the Li-ion solution even more interesting. Reference parameters L/A Li-ion 1 Truck lifetime Number of battery packs per truck needed to ensure smooth operations Battery cost per pack Number of packs needed during the 5 years period 7,68 1,71 5 Longevity of a single battery 1,3 years 2,91 years 6 Total battery purchasing cost over the 5 years period Time spent on battery change over the 5 years period [days] Time spent on battery maintenance [days] 15, Total days spent 135, Cost of maintenance [man-day, 350 /day] Energy throughput [kwh/truck over the 5 years] kwh kwh 12 Energy cost [ ] TCO N.B. All prices in the below table are are based on 2010 prices.

16 Conclusion Relatively high purchasing price of Li-ion compared to L/A should not be a show stopper. Li-ion technology is economically justified in the heavyduty professional applications. The best suited for Li-ion are*: 1. Professional industrial application. 2. Heavy usage with high charge/discharge rates and capacity. 3. Multiple shift operation where battery change is required. 4. Large energy throughput / consumption. 5. Maintenance cost is high. 6. Machine is applied in a harsh environment, e.g. cold or hot ambient temperatures. 7. Where there is a need for simplified logistics, cost reduction, productivity increase. 8. High focus on design, machine size, ergonomics and environment, i.e. noise and emission control. * The projects must score high on at least 2 of the above factors.

17 APPENDIX

18 Our customers are primarily industrial, automotive and battery manufacturers Industrial Forklifts, cleaning, lifts Automotive Truck, bus, car Battery Batteries, integrators but we have also done marine, military, storage, agricultural, aerospace applications CONFIDENTIAL

19 Toyota introducing Li-ion to the market. CeMAT exhibition in Hannover, 2011.

20 CASE 2: Tennant Company Tennant Leading supplier of cleaning machines and street sweepers. Key drivers for change: Legal constraints and costs. EU directive on emission standards for non-road and commercial vehicles (EURO 6) drive conversions from diesel to electric. Direct costs are high: Cost induced by maintenance of diesel engine. Fuel price. Environmental nuisance: Pollution. Noise. Restricted access to urban areas due to noise.

21 Tennant. Solution overview. Dual Li-ion battery pack (72V 400Ah), i.e. cells (LFP), BMS (sbms, #100160), switchbox (LiBAL Std. LV Switchbox) and a fast charger (6,4kW). Solution is in production. Dual pack: 1. Drive 2. Vacuum cleaner and tools

22 Tennant: Factors affecting TCO In order of significance: 1. Resources spent on maintenance of the current diesel engine. 2. Energy savings. Diesel vs. electricity. 3. Gain in productivity due longer/earlier operating hours. 4. Cost savings due to fewer machines. 5. Battery purchasing price. 6. Low noise. Less complaints. *TCO Total Cost of Ownership

23 CASE 3: Banke Accessory Drive Revolutionary idea for reducing noise and tailpipe emissions during garbage collection. 700volt system powering an electric power take off (e-pto) to drive the compactor. No engine revving and one battery charge lasts all day.

24 CASE 2: Cargotec truck mounted forklift Replacement of existing internal combustion engined solutions with Li-ion battery powered solutions 1. Price premium offset against continually more stringent exhaust emissions legislation 2. Ability to operate 24/7 low noise emissions 3. Ability to operate indoors/outdoors or around foodstuff 4. On truck charging, always ready for deployment 5. Reduced service costs electric vs ICE technology

25 CASE 3: Banke Accessory Drive Reduces noise and tailpipe emissions No engine revving One battery charge lasts all day

26 Banke Accessory Drive. Solution. 700V system powering an electric power take off (e-pto) to drive the compactor no engine revving and one battery charge lasts all day.

27 Banke: Factors affecting TCO In order of significance: 1. Energy savings. Diesel vs. electricity. 2. Gain in productivity due longer/earlier operating hours. 3. Cost savings due to fewer machines. 4. Battery purchasing price. 5. Low noise. Less complaints. *TCO Total Cost of Ownership

28 Additional things to consider What problem(s) are you solving with your product? What are the markets? Original chosen market segment too small The product must be fit for purpose What would represent the total solution and how do you provide it? How do you get to your customers Start small and stay small until you have a reason to be big How much do you think it will cost, then triple it! To succeed, you must survive What would success look like? It always takes longer and costs more... Professional management essential