Clean and energy-efficient vehicles Advanced research and testing Battery systems

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1 Clean and energy-efficient vehicles Advanced research and testing Battery systems

2 Flanders DRIVE Index: Flanders DRIVE 1 Optimising power / energy ratio of energy storage systems 4 Battery ageing research 6 Battery modelling 8 Thermal management 11 Lightweight / structural solutions for battery casing 12 Homologation and certification of battery cells / packs 13 Advanced research and test facilities 14 Partner for innovation and development in the automotive industry Flanders DRIVE is a research institute for the vehicle industry situated near the Lommel Proving Ground in Belgium. Together with leading companies and research institutions, Flanders DRIVE works on high-tech, application-oriented research into the green and smart vehicle of the future. Flanders DRIVE supports the automotive industry through a wide range of activities, focusing on Clean & Energy-Efficient Vehicles Lightweight Solutions Intelligent Driver & Traffic Systems Advanced Manufacturing Processes Intelligent Development Tools Flanders DRIVE is supported by the Flemish Government and offers its expertise to European projects 1

3 Vehicle systems integration Body Clean & Energy- Efficient Vehicles Lightweight Intelligent Driver... Solutions... & Traffic Systems... Drivetrain integration & system architectures Battery pack design & development Module design & development Advanced Manufacturing Processes Thermal management Chassis Powertrain Structured V-model development Electrical testing E/E Electrical powertrain Energy management Electrical testing Lightweight structures Thermal management Rational material selection 2 Cell characterization & selection Wide value chain Durability testing Durability testing Functional safety Safety Electrical testing Intelligent Development Tools Safety Structured V-model development 3

4 Optimising power / energy ratio of energy storage systems Pros and cons of lithium-ion cell chemistry types energy energy energy Selecting the right cell chemistry Defining battery pack power / capacity requirements Cost optimisation cost C + NMC power cost LTO + NMC power cost C + LFP power life span safety life span safety life span safety performance performance performance cost energy C + NCA power cost energy C + LMS power C + NMC LTO + NMC C + LFP C + NCA C + LMS Carbon + Nickel Manganese Cobalt Titanate + Nickel Manganese Cobalt Carbon + Iron Phosphate Carbon + Nickel Cobalt Aluminium Carbon + Manganese 4 life span safety life span safety 5 performance performance

5 Battery ageing research Investigation into: Calendar ageing Cyclic ageing Battery characterization Accelerated cell testing Real-life behaviour 6 7

6 Battery modelling 8 Real-time models used in in-house developed battery management system Experience in use of different battery models Using model-based battery cell simulation Measure <it> <SOC (%)> <Current (A)> <Voltage (V)> <OCV (V)> <Ip (A)> <Vp (V)> <Temp> <Eff> <SoH> <Nc> <Power> Predict Battery model can be used for real-time battery management system functions: On open source platform Can be used for any flexible battery configuration Using a real-time model-based and in-house optimised battery model measuring: temperature effects calendar and cyclic ageing effects effect of high-frequency loads 9

7 Battery management system software Individual battery cell model: cell characterization at different temperatures, charging states and currents voltage prediction state of charge calculation Thermal management Low-energy thermal preconditioning towards an effective and efficient use of the battery Battery cell internal heat production and battery pack thermal management simulation Safety functions Balancing control balancing methods Information on vehicle controller area network: maximal charge current, maximal discharge current for inverter state of charge, state of health 10 11

8 Lightweight / structural solutions for battery casing Advanced simulation techniques Finite elements analysis Weight and stress optimisation tools Module and pack optimisation Advanced joining technologies Lightweight solutions using suitable materials (selection process) Certification of battery cells / packs Safety, performance and abuse testing Prototype evaluation Benchmarking Certification on cells: e.g. UN 38.3 / IEC & 2 Certification on modules/packs: e.g. UN 38.3 / ISO & 2 12 Side impact simulation on crashed truck 13

9 Advanced research and test facilities 14 15

10 24-channel battery cell tester Voltage range: 6V Current range: 50A charge and discharge Parallel operation up to higher power (600A max) Impedance spectrometer / electrochemical workstation Frequency range from 10 μhz to 1 MHz Voltage ranges: 10V Current ranges: 1A to 10nA; with boosters, current: 20A Frequency range from 18 khz (potentiostatic mode) to 40kHz (galvanostatic mode) Battery cell climate chamber Internal dimensions: 0.8m x 0.8m x 0.8m Temperature range: -40 C up to180 C Humidity controlled Battery pack climate chamber Temperature range: -60 C up to 130 C Connection for external battery cooling device Humidity controlled Protection against EUCAR Hazard Level 4 9-channel battery module tester Voltage range: 8 and 80V Current range: 50A charge and discharge Parallel operation up to higher power (450A max) 2-channel battery pack tester Voltage range: up to 1000V; 200kW max Current range: up to 1000A; 200kW max Continuous power rating of 100kW 16 17

11 Contact information Flanders DRIVE Oude Diestersebaan Lommel Belgium tel fax

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