Technologies for Electric Vehicles Land, Water, Air to By Dr Peter Harrop IDTechEx www. electricvehiclesresearch.

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1 Technologies for Electric Vehicles Land, Water, Air to 2021 By Dr Peter Harrop IDTechEx www. electricvehiclesresearch. com

2 Why land, water and air? Most attention is given to electric cars but About 55% of the market value is other electric vehicles up to 2021 Technology trends usually apply to land, water and air eg lithium polymer traction batteries, brushless motors. The world s largest electric vehicle business is Toyota and it makes electric forklifts, buses, trucks, cars etc and their batteries and motors and shares the knowhow between these divisions

3 EV superlatives Largest batteries 400 kwh in swimmer Autonomous Underwater Vehicles AUVs Use of multimode energy harvesting glider AUVs solar + wave power First use of third generation lithium sulphur batteries Unmanned Aerial Vehicles UAVs Largest supercapacitor banks buses Fastest acceleration motor bike First commercial use of fuel cell scooter

4 Technical challenges Traction batteries Cost(up to 50% of vehicle cost), energy storage = range km today safety, life Supercapacitors ie ultracapacitors energy density Traction motors cost, cooling, in wheel Electronic controls including Vehicle Management System VMS, Battery Management Systems BMS cost, performance move to printed electronics, cell sensors etc Range extenders cost, life, performance, start up time Energy harvesting photovoltaic (light & IR), thermoelectric (heat), electrodynamic (regen. braking, shock absorbers etc), piezoelectric (movement/ vibration) cost, life, performance, trend to multi mode harvesting Charging stations cost, speed, safety, standards

5 1 Hybrid with conventional engine not designed for the purpose usually parallel hybrid

6 2 As batteries improve, the trend is to series hybrid with range extender

7 Trend for hybrids to be plug in HYBRID ALL ELECTRIC RANGE km 300 km with help from better batteries, tiny range extenders and energy harvesting Regenerative braking, shock absorbers, thermoelectric, photovoltaic PURE ELECTRIC VEHICLE RANGE 250 km 1000 km

8 Hybrids become more like pure electric vehicles Amazingly quiet,super efficient, single cylinder range extender for light trucks etc. from Switzerland

9 Fuel cells no longer seen as battery replacements but as small range extenders Fuel cell sizes in 98 bus trials in 20 years Red largest Green smallest

10 Tata road map India

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12 Traction battery chemistry changes Lead acid is low cost for low energy storage. Its weight is beneficial in mobility for disabled and forklifts. Toxic but recycling is thorough except in China and Third World Nickel metal hydride is used for hybrids because of good cycle life but lithium ion is taking over Lithium ion is taking over most applications as cost comes down because it has excellent energy density, good power density, little self discharge, no memory effect, abundant materials etc.

13 Traction batteries The decade of lithium ion NiMH being phased out because of poor lanthanum supplies, self leakage and energy density vs lithium ion Lead acid hangs on for most Mobility for disabled Heavy Industrial Surface boats Electric bikes Golf cars

14 Three generations of lithium ion battery GEN USE CHEMISTRY TECHNICAL FEATURES First Tesla car Lithium cobalt oxide cathode, wet electrolyte, carbon cathode Second Most e car, bus, truck, boat AUV, planes Third UAVs, military Less cobalt or no cobalt in cathode (Lithium iron phosphate popular). Sometimes a solid polymer with gel as electrolyte Lithium sulphur, lithium air, lithium water. Often a solid inorganic electrolyte printed reel to reel High energy density, relatively unstable cell, relatively poor temperature tolerance. Safety by fuses, trips, cell temperature sensors, very small modules that cannot trigger a runaway in adjacent modules. Inherently safer, cheaper cells with better temperature tolerance and sometimes light weight containment but usually poorer energy density. Flammable organic electrolytes Highest energy density but problems of life and sometimes safety as yet

15 Lithium ion traction battery cathodes trend to less cobalt or no cobalt save cost, improve safety Nothing is inherently safe With laptop Li ion quality, one car in 70K will explode

16 1000 $K Lower upfront cost than ICE version Higher cost than ICE kwh CHEAPER BATTERIES WILL MAKE MORE EVS CHEAPER TO BUY THAN ALTERNATIVES

17 Purpose of supercapacitors in EVs Protect the battery during fast charge and discharge used in e bikes and buses Do some or all of the storage work longer life, faster charge discharge, no cooling, lower cost? Elon Musk of Tesla says supercapacitors are the future not batteries Some experimental supercapacitors now have the energy density of lead acid batteries Some buses now run on supercapacitors alone

18 Trend to higher voltage systems to improve efficiency and drive latest motors This is not a universal trend

19 100 Energy kwh Lead NiMH Acid PURE ELECTRIC ON ROAD Lithium MILD HYBRIDS 1 NEV GOLF 24 VOLTS 700

20 Different motors for the same type of vehicle there is a shakeout coming!! Brushed motors replaced by brushless Battle of the brushless motors Asynchronous AC induction motor Tesla Roadster car EZGO golf car DesignLine and Orion hybrid bus WheelTug/ Boeing airliner electric nosewheel Synchronous permanent magnet motor Most other electric cars Club Car golf car Some other buses DLR/ Airbus airliner electric nosewheel

21 Battle of the brushless motors Type Good Bad Best for Asynchronous Synchronous ie AC induction PMAC sinusoidal BLDC trapezoidal Switched reluctance Ruggedness, easy cooling, life Efficiency, size No magnet, cost Size, efficiency Magnet problems temperature, cost, assembly Close tolerance, efficiency, noise, vibration Military, bus, truck, forklift Bikes and small vehicles. Favoured for cars and other mid sized vehicles for now but under threat from asynchronous. Small market share so far but being tried for medium to large EVs

22 Heavy duty and large vehicles g y g y p Heavy industrial ie heavy lifting Military Asynchronous No magnets gaining market share Large bus Light Commercial/ Industrial category Aircraft and other Marine Car Small bus Large trucks Smaller vehicles Large car Small car Synchronous Permanent Magnet AC PMAC or the closely related brushless DC BLDC all gaining market share Small and light duty vehicles Large two wheel & allied ie motor cycles & 3 wheel Small two wheel and allied eg E bikes Mobility for disabled Synchronous Permanent Magnet DC with Brushes losing market share

23 Evolution of range extenders piston Rotary ICEgen Free piston gen ICE Mini turbine Fuel cell gen

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25 Propulsion-system architecture: Fuel Fuel-cell Fuel-cell Fuel Battery Battery Reformer Motor controller Reformer Motor controller IDTechEx 2011 Motor Motor Propeller

26 KEY ENABLING TECHNOLOGIES Batteries Gen 2/ Gen 3 Li ion Electric motors Watch asynchronous Electronics/ electrics Printed & laminar ADD Range extenders Turbine, fuel cell. Supercapacitors & supercabatteries Energy Harvesting PV & electrodynamic

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