Powertrain Strategies for the 21 st Century: Next Generation Electric Vehicle Strategies. Li-ion Batteries for Electrified Mobility

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1 Powertrain Strategies for the 21 st Century: Next Generation Electric Vehicle Strategies Li-ion Batteries for Electrified Mobility Ann Arbor, MI Jacob Bemrich, PE Systems Engineering Manager Robert Bosch Battery Systems LLC

2 Bosch Powertrain Electrification future mobility Worldwide Footprint Cell Development Hayward Detroit (Region) Farmington Hills, local office EM Plant Hildesheim PE Dev & Plant Reutlingen Cell Development Stuttgart BAT Plant Bamberg Headquarter EM, LE, BAT Research & Development Stuttgart (Region) PE Dev. & Plant Budapest &Hatvan BAT Plant Suzhou Cell Dev. & Plant Kyoto & Ritto BAT Plant Springboro BAT Development Orion EM: PE: BAT: CELL: PE SW/HW Develop. Coimbatore, Bangalore E-Motor Power Electronics Battery Pack Battery Cell Shanghai UAES Development & Plant Tokyo (Region) Yokohama, local office ~ 1800 employees working on power train electrification within Bosch group 2

3 R&D and Production Global Locations North America Springboro, Ohio Production plant, (50,000+ vehicle packs built since 2006, Li-Ion SOP Nov 2012) 170,000 ft 2 (16,000 m 2 ) Expandable to 213,000 ft 2 Technical and Product Services in place for Aftermarket to support complete Product Life Cycle Approx. 150 employees Orion, Michigan Engineering facility (several OEM projects since 2005) Mission: Produce and Deliver Zero Defect Battery Packs On-time for Production and Service Customers. Experienced xev battery pack mechanical, HW-, SW- and systems-engineering On-site development labs, test labs, and validation facilities for Li-ion Approx. 100 employees 3

4 Influence variables on emobility Infrastructure User experience UX Business models Legislation Technology EV-train Web 3.0 Megatrends electrified, automated, connected Applications Market volume Customer expectations Requirements KPIs 4

5 Content Market requirements for batteries 2020ff the Bosch view Applications Market volume Customer expectations Battery requirements KPIs Technologies to reach the targets Battery cell technologies until 2020 LIT From 2020: PLIT Summary and prospect Bosch 48V Mild HEV 5

6 Applications Applications HEV PHEV EV BRS Generation 1 (series) Generation 2 (in development) Electrical range Electrical power Challenges High power Low cost High performance Cycle life Cost down High energy density Cost down High power Low cost 6 Technology Li-ion (available) Li-ion (improved) Li-ion (improved) Post Li-ion Li-ion (available)

7 Units [mio. vehicles] Market volume Total vehicle market: , PHEV and EV with strong growth HEV volume declining , HEV Hybrid Electric Vehicle PHEV Plug-in Hybrid Electric Vehicle EV Electric Vehicle Vehicle sales PC incl. LCV<6t: Estimation Bosch 7 BBSD/ENA 7/20/2016

8 Production capacity [GWh/year] Consequences on production capacity Required battery production capacity Li-ion Consumer HEV Hybrid Electric Vehicle PHEV Plug-in Hybrid Electric Vehicle EV Electric Vehicle 8

9 Customer expectations towards an EV Customer expectations Driving range 350 km Good performance Fast charging No battery exchange during vehicle life Reasonable safety Affordable Battery requirements 50kWh 200Wh/kg 400Wh/kg 150kW 250kW P/E ratio km with 15min charge time 80% capacity & 300Tkm, > 10years Safety level equal or higher than in vehicle with ICE Market price target battery: 6,600USD 9

10 KPIs: status 2015, market targets Energy Density Cost Lifetime Performance Quality Safety 10

11 Energy Cost density [EUR/kWh] [Wh/kg] ~ x 2 ~ Factor 3 ~ Factor 1/3 ~ Factor 1/4 KPIs: status 2015, market targets Energy Density EV Cost Cell Pack 11

12 Cost [EUR/kWh] ~ Factor 1/3 ~ Factor 1/4 KPIs: status 2015, market targets EV Cost Cell Pack 12

13 Content Market requirements for batteries 2020ff the Bosch view Applications Market volume Customer expectations Battery requirements KPIs Technologies to reach the targets Battery cell technologies until 2020 LIT From 2020: PLIT Summary and prospect Bosch 48V Mild HEV 13

14 Volumetric energy density [Wh/l] Battery cell technologies LIT Maximum Market until 2020 dominated by Li-ion Technology (LIT) Energy density in 2020 already close to the technical limit of LIT Post Li-ion Technologies (PLIT) with potential for higher gravimetric and volumetric energy densities in combination with improved safety EVs w/ SOP > 2020: PLIT with solid state electrolyte very promising EV with solid state electrolyte, SOP > 2020 Li-S >2025 Conversion cathode > PHEV 2020: ~400Wh/l EV 2020 ~ 800Wh/l Gravimetric energy density cell [Wh/kg] 800 LIT: Li-ion Technology PLIT: Post Li-ion Technology 14

15 PLIT cell technologies Terminology Anode Separator Electrolyte Cathode Li-ion Technology (LIT) Lithium in both electrodes mainly intercalated Structure of electrodes hardly changed due to intercalation Li-ions migrate free via (liquid) electrolyte Discharging Li + Li + Charging Li Graphite Lithium-metal-oxide Post Li-ion Technology (PLIT) At least one electrode not intercalating lithium Acronym PLIT often used as synonym for Li-Sulfur and Li-Air technologies Cells with metallic Lithium anode are counted among PLIT 15

16 PLIT cell technologies, examples Li-Sulfur Technology Li-Air Technology Anode Separator Electrolyte Cathode Anode Separator/Electrolyte Cathode Discharging Li + Li 2 S Binder Discharging Li + Li 2 O 2 Discharging O 2 Li + Charging S 8 C Li + Charging O 2 Charging Metallic lithium Mixture of sulfur and carbon particles with binder Metallic lithium Solid state electrolyte Mesoporous carbon Solid State Cells Cells with conversion cathode Anode Separator Cathode Anode Separator Electrolyte Cathode Polymer Discharging Discharging Li + Li + Li + Charging Active material Li + Charging FeF 2 Metallic lithium Solid state electrolyte with active material Metallic lithium Metal fluoride 16

17 Solid state cells, status Bosch Bosch acquired Californian battery technology company Seeo Engineering prototype cells available Seeo DryLyte TM Technology Anode Lithium Foil Separator Cathode Dry Solid Dry Solid Polymer Composite Electrolyte Dry Solid Technology very promising: Lifetime > 1000 cycles reached with LFP cathode, operating temperature C 17

18 Solid state cells, Safety Safety test results (LFP cathode, Li metal anode) Crush test Test Crush Result No smoke or flames Penetration test No smoke or flames X-Axis Short circuit test No smoke or flames Thermal shock No smoke or flames Y-Axis Over-discharge No smoke or flames Overcharge No smoke or flames Z-Axis Thermal stability Stable up to 180 C Intrinsic safety of Seeo technology is a big advantage 18

19 Summary and prospect Li-ion technology will dominate the market until 2020 Li-ion technology technical feasible for EV and PHEV Technical limit of automotive Li-ion ~ Wh/kg Post Li-ion with potential to further increase energy density and to reduce cost Solid state cells for EV expected to be ready for series past 2020 PLIT with high chance for game changer 19

20 Content Market requirements for batteries 2020ff the Bosch view Applications Market volume Customer expectations Battery requirements KPIs Technologies to reach the targets Battery cell technologies until 2020 LIT From 2020: PLIT Summary and prospect Bosch 48V Mild HEV 20

21 Innovation line Bosch 48V Mild HEV Evolution of Electrification ICE Dominant HEV Dominant 2 0 x Baseline: Start/Stop / min 6 Start A Stop km/h Advanced Start/Stop Start A Stop x 1000 / min km/h Start/Stop Coasting 2 4 x 1000 / min 6 Start A Stop 40 Coasting km/h V Systems 4 x 1000 / min 6 Start A Stop Coasting km/h - Recuperation Boost e-drive entry CO 2 potential x 1000 / min shev 6 Start A Stop 40 Coasting 80 - km/h Recuperation Boost e-drive x 1000 / min 6 PHEV Start A Stop Coasting km/h - Recuperation Boost e-drive Further improvement of cost-benefit ratio plus feeling of electric driving shev: Strong Hybrid Electric Vehicle ; electric motor operation independent of engine state; typically operating at VDC>

22 Units [mio. vehicles] Powertrain Scenarios 48V BRS 48V shows considerable market growth Vehicle sales PC incl. LCV<6t 1) total market 85 mio. 112 mio. 125 mio BRS 48V ) Estimation Bosch 22 BBSN/ENA1 7/20/2016 BRS 48V Boost Recuperation System

23 Increasing Power Needs for Individual Components Bosch 48V HEV Power-Net Redundancy Autonomous Functions Time to Stop Limited Change wrt. Today Brake Actuation Electrical Power Increased EPS Power Increased in coord. w/ Brakes Further EPS Power Increase Longer Duration Increasing Total System Power Required to Achieve Operation Duration after system electrical failure 23 Robert Bosch Battery Systems BBSN/ENA1 7/20/2016

24 Bosch 48V HEV Summary 48V seen as a bridge to a higher voltage future Main focus is on easy to integrate belt-machines Other topologies considered, but with a later implementation (post 2021) Cost effective CO 2 reduction the main driver Power-net requirements may drive manufacturers towards 48V solutions Highly Automated Driving will require redundant and powerful actuation systems pushing charging systems to their limit New concepts may change the landscape SSC could be one path where a non-traditional strategy that delivers real-world fuel savings may also drive the need for redundant power-net capability 24

25 THANK YOU