Battery Review. Paul Newsome, Chief Technical Officer Okan Tur, Chief Technical Specialist, Williams

Transcription

1 Battery Review Paul Newsome, Chief Technical Officer Okan Tur, Chief Technical Specialist, Williams

2 Williams Advanced Engineering Formula E 28 Feb 2014

3 WILLIAMS ADVANCED ENGINEERING We are a world class engineering company who happen to go racing Sir Frank Williams, Founder and Team Principal

4 WILLIAMS ADVANCED ENGINEERING Engineering Excellence Williams Advanced Engineering apply the skills, intellectual property and experience of the Williams F1 Team to deliver projects in technology areas including: High performance hybrid and EV powertrains and components Aerodynamics Lightweight structures Driving dynamics Specialist low volume manufacture WAE blend the unique motorsport culture of competitiveness, speed and the agility of Formula 1 with engineers recruited from prestigious performance automotive companies to create a 150 strong team to: Engineer and produce high performance, low volume road and race vehicles Develop and manufacture class leading components such as batteries, motors and controllers and vehicle control electronics / software

5 A History of Engineering Excellence WAE is only 3 years old, but Williams has a previous successful history of Engineering beyond Formula 1. Formula 2 Williams developed the car for the revived Formula 2 Championship that began in Group B Rallying The Metro 6R4 rally car was developed by Williams in 1984 in just six months. British Touring Car Championship Williams were Renault s official entry to the BTCC between 1995 and Williams Renault won the Manufacturer s title twice as well as the Driver s title in Le Mans 24 Hours Prior to their F1 Partnership, Williams designed and built Le Mans prototypes for BMW. The V12 LMR won the 24 Hours of Le Mans in Porsche AG 911 GT3R Hybrid Through a subsidiary, Williams Hybrid Power, developed a flywheel based kinetic energy storage system which is in use on a Porsche 911 GT3 R car, which achieved its first victory in 2011 at the forth round of the VLN Endurance Racing Championship held at the Nurburgring.

6 Racing outside Formula 1 Williams partnered with BMW to race the 1999 Le Mans winning V12 LMR Williams Touring Car Engineering were Renault s entry to the BTCC between 1995 and Race Wins 29 Pole Positions 29 Fastest Laps 2 Manufacturer s titles 1 Driver s title

7 The five principles the division stands for High Performance Hybrid and EV Powertrain High specific power output engines, high torque density motors, high power density energy storage Lightweight Structures Carbon composites, metal alloys, intelligent combinations of functionality, appropriate feature specifications F1 Bred Aerodynamics Positive down force, low drag, active solutions High Performance Driving Dynamics Low polar moment of inertia, improved traction, track capability Specialist High Performance Low Volume Product Delivery Total programme solutions from drawing board to manufacture

8 High Performance Hybrid and EV Powertrain Battery Technology 2010 Designed for F1 Flywheel Technology 2012 Developed for Jaguar C-X Produced for Formula E Hybrid Technology Evolution 2009 Formula 1 regulation changes allowed Kinetic Energy Recovery Systems (KERS) Williams evaluated a variety of technologies including electric flywheels although regulation changes meant we developed and raced with a battery energy storage solution flywheel and battery technologies in racing, roadcars, buses and now Formula E Accompanying the Energy Storage Systems has been the development of Battery Management Systems, Inverters, Motors and Vehicle Controllers. Williams continued to develop and apply both the

9 Lightweight Structures Lightweight Vehicle Mentality The ultimate lightweight solution requires the intelligent combination of functions into a single component, sophisticated load case analysis and a comprehensive knowledge of material properties. Composite Material Solutions Williams have industry experts in the use of carbon composites with years of experience in materials, manufacturing techniques and weight optimisation. Metallic Material Solutions Experience in F1 has made Williams an expert in the use of titanium, magnesium and aluminium, both on their own and in combination with other metallic or composite materials. Component Manufacturing Capability Williams have Autoclaves and Machining Centres, that specialise in the low volume manufacture of components in carbon composites, magnesium, titanium and aluminium.

10 F1 Bred Aerodynamics Aerodynamics skills honed in Formula 1 Aerodynamic capability is a key differentiator in Formula 1 performance. Williams has built a core skill in this science over 35 years of competition. Computational fluid dynamics Williams have state of the art tools for CFD and are continually driving to improve those tool s capability and correlation. Wind tunnels Williams have invested millions in two wind tunnels on site at Grove, designed to give the highest level of capability in moving ground test capability for both scale model and full size testing. Effective solutions Williams capabilities allow solutions to be identified to improve stability, target efficiency, deliver down force, achieve cooling requirements and drive lower drag.

11 High Performance Driving Dynamics Holistic process for delivery of the dynamic result Target setting defines the product concept design, analysis evaluates and optimises the base vehicle and the active systems and vehicle development refines the result. Suspension system design and development Expertise in all areas of suspension design and development with experience of a wide range of vehicle types with passive and active technologies. Braking system design and development WAE can develop turnkey attribute-focused performance and refinement brake solutions, correlating subjective and objective targets in cast iron and ceramic solutions. Slip control system analysis and development The Driving Dynamics team have worked independently and with stability system suppliers to develop integrated Slip Control Systems: ABS, Traction Control, Dynamic Control, E-Diff calibrations, re-gen, torque vectoring and other functions.

12 Specialist High Performance, Low Volume Product Delivery The total vehicle solution Williams High Performance Vehicles team can design, develop, procure and manufacture your racing vehicle, or specialist high performance road car. Vehicle integration In addition to the skills required to deliver our four key principles we also have strong capabilities in technical vehicle integration, thermodynamics, and electrical systems. Specialist low volume project management Williams have the tools, systems and people to manage projects to delivery. These include CAD tools, BOM systems, a specialist product procurement team and established links with a supplier base capable of supporting our projects. Specialist vehicle manufacture Williams highly trained technicians manufacture vehicles to meticulous standards in immaculate facilities.

13 Projects

14 Recent Projects - Jaguar C-X75 Hybrid Super Car, Technology Prototype Nismo GT-R Nurburgring Time Attack 7mins 8secs, fastest production road car Audi E Tron Hybrid Energy Storage System Electric Flywheel KERS Technology

15 Other Projects in Public Domain - Battery Manufacture - Evoque E - Jaguar Land Rover Wind Tunnel 1 Caterham F1 F1 KERS Marussia F1 Electric Pedelec System Brompton Bicycles

16 What Williams Advanced Engineering Offers Our Partners Williams Advanced Engineering is a high technology Engineering Consultancy that provides its business partners: The application of Formula 1 technology and techniques into other industries. The Complete Design, Development and Manufacture of products for use in all types of motorsport. The complete Design, Development and Manufacture of specialist road products. The engineering of very high efficiency technical solutions. Access to all of Williams state of the art facilities for marketing, manufacturing, test and development. Agility and speed to market.

17 Williams Advanced Engineering Formula E Energy Storage System

18 Formula E Battery In June 2013, Williams Advanced Engineering was announced as the Formula E Technical Partner to supply the Energy Storage System, the Battery. Battery Technology Evolution Battery Technical Description Cooling System Battery Safety Battery Transportation

19 WILLIAMS ADVANCED ENGINEERING Formula E Battery Technology Evolution 2010 Formula Jaguar C-X Formula E WAE BMS Hybrid Battery KERS Battery EV Battery

20 KERS Hybridisation of Formula 1 cars Technology 2009 regulations permitted maximum power of 60 kw, 400 kj per lap Extremely high power density KERS battery, motor, power and control electronics Lithium battery with integrated Williams battery management system High system voltage selected to minimise weight Background 2009 Formula 1 regulation changes allowed Kinetic Energy Recovery Systems (KERS) Williams evaluated a variety of technologies and whether to in source or outsource development Results and achievements Technology developed for Formula 1 KERS has been used in other applications including hybrid buses and supercars Battery, motor, electronic and control technology developed in house Manufactured by Williams Williams KERS system has been supplied to another team in 2013

21 Jaguar C-X75 Project A hybrid supercar Technology Powertrain uses two electric motors in conjunction with the 500PS, 10,000 rpm 1.6 litre turbo charged and supercharged engine The rear electric motor drives into the rear 7 speed transmission alongside the engine Can be driven electrically or as a hybrid in 4WD Performance is 0-160kph < 6s, top speed > 320kph, C02 < 99g/km Background Results and achievements A collaboration between Williams and Jaguar to design, develop and build the Jaguar C-X75 Hybrid Supercar. Project led by Williams and staffed by a combined Williams and Jaguar team High level of technology leveraged from Formula 1 including engine, battery / BMS, hybrid control system, aerodynamics 5 high quality prototypes suitable for external demonstration manufactured and showing key vehicle attributes Williams provide expertise in hybrid propulsion systems and control, aerodynamics, chassis systems and vehicle dynamics, and specialist build operations Williams are supplying the vehicle control module with software and the battery

22 BATTERY PACK DEVELOPMENT AND MANUFACTURE Scope Different size packs from <1 to 35 kwh 48V to 800V system voltage Technology Patented thermal technology provides indirect cell liquid cooling In house Williams BMS In house build and test facilities High discharge rates, up to 60C Results and Achievements Manufactured packs perform to simulation Battery packs have proven reliable in race and road car applications Effective implementation of low volumes in challenging environmental conditions Variety of alternative cell sizes and chemistries engineered

23 Formula E Battery Technical Requirements The requirements of the battery were identified as: 200kW maximum, 90kW average power 32kWh stored energy 610V nominal battery voltage Indirect liquid cooling

24 Formula E Battery Safety Cell Structural Cell located between the tub and the motor/trans HV Isolation through organ stops Burst disks on underside Safety construction utilising Williams proven material sandwich Confidential and proprietary information of Williams Grand Prix Engineering Limited

25 WILLIAMS ADVANCED ENGINEERING Battery Content 165 Lithium Pouch Cells held in 5 modules 15 CMUs individually monitoring Voltage, Cell Temp, etc Battery voltage disconnect through organ stops, in addition to contactors Cell cooling over the body of the pouch and the tabs 3459 individual parts Confidential and proprietary information of Williams Grand Prix Engineering Limited

26 Formula E Battery Cooling System The battery cooling system: Patented thermal technology provides indirect cell liquid cooling Coolant is dielectric (non electrical conducting) Cooling system is to be used to pre and post condition the battery temperature Both the pump and heat exchanger are external to the battery pack

27 Formula E Battery Safety The battery safety is of primary consideration: The BMS primary safety features Individual Cell Voltage monitoring Individual Cell Temperature monitoring Isolation monitoring Battery Current monitoring HV Interlock System monitoring Power Limit De-ratings BMS has internal datalogger and will log all battery and cell data during the race day On Track Safety Procedures Crash Testing Shock Testing

28 Formula E Battery Transportation A Legal Framework (UN38.3) exists for Transportation of Batteries by Air, Sea and Road: Altitude Simulation Thermal Tests Vibration Shock Short Circuit Impact Overcharge

29 ENERGY STORAGE SYSTEM PARTNERS TO FORMULA E In Shanghai, September 2014, ten teams will commence in the first race of this exciting new series, all with a WAE battery in their cars

30 Williams Advanced Engineering Technology Partner