Saft battery system for electric and hybrid vehicles: Technical challenges. Tekes EVE Electric Vehicle Systems Seminar Helsinki, 18.

Transcription

1 Saft battery system for electric and hybrid vehicles: Technical challenges Tekes EVE Electric Vehicle Systems Seminar Helsinki, 18. November 2014

2 Agenda Saft in a nut shell Saft experience in electric and hybrid vehicles Market Challenge: Diversity of commercial vehicles Technical Challenges > Challenge 1: What is the customer need? > Challenge 2: Development of the battery system > Challenge 3: Integration, Commissioning and Maintenance Conclusion 2

3 1 Saft in a nut shell 3

4 The Saft Group in Key figures Industrial standby Defence Telecommunication Space Specialty Battery Group 256.3m 41 %* High performance primary and rechargeable lithium and silver batteries for the electronics, defense and space industries. Sales ,2m Industrial Battery Group 367.9m 59 %* Rechargeable nickel and lithium-based batteries for demanding industrial applications. Clean energy storage Vehicles Metering and Professional Electronics Emergency Lighting Rail and Mass Transit Aviation Joint-Ventures: -- ASB Group Thermal batteries Equity accounted 444

5 2 Saft experience in electric and hybrid vehicles 5

6 Key accomplishments over the last 20 years in EV s Ni-Cd - STM5-100 ( ) > More than e-cars e-scooters on the road in Europe equipped with Saft batteries (PSA Peugeot-Citroën + Renault + Th!nk (Ford) ) Ni-MH technology ( ) > Chrysler EPIC Minivan EV development and fleet (200 Ev s) Li-ion - Demo cars & Fleet vehicles since 2000 > Various EV fleet programs with major European & US car manufacturers > More military hybrid energy storage programs than any other company 6

7 A true serial automotive experience from millions Lithium-Ion cells manufactured with Saft technology used in serial vehicle programs in Europe and US Hybrid Electric BAT Plug-in Hybrid Nersac Full Electric 7

8 Racing Applications Extreme Performance Formula 1 KERS Kinetic Energy Recovery System Very High Power Weight Crticial Supplying major teams since 2009 ANDROS ice racing series First World wide EV race With Saft energy storage since 2009 European Electric F3 Championships High Class Sport GT EV 8

9 Saft Strategy Focus on selected major electric and hybrid applications Buses and public transportation vehicles Commercial delivery trucks Industrial and Special vehicles > Material handling > Construction and mining > Airport GSE, Seaport > Agriculture and forest 9

10 An industrial Li-ion footprint in EU and USA Europe Bordeaux (France) Pilot line in operation for more than 12 years Research & Development Center for Europe Nersac (France) World s 1 st facility for Li-ion automotive batteries Large volume, automotive ISO/TS Qualified Capacity installed : ½ million energy cells Cockeysville (MD) Research & Development Center for North America Multi technology cells and systems manufacturing USA Jacksonville (FL) Opened since September 2011, eligible to BAA requirements Large volume, include manufacturing line for prismatic cells Capacity installed : 2 millions energy cells 10

11 3 Market challenge Diversity of commercial vehicles 11

12 A wide diversity of applications 200kWh On-Road & Off-Road Vehicles EV PHEV 150kWh EV 100kWh EV HEV HEV EV EV 50kWh HEV HEV 20kWh PHEV HEV HEV V 350V 400V 600V 630V 750V

13 leads to a wide diversity of requirements! Vehicle category Micro HEV (µhev) Mild HEV (MHEV) Strong HEV Plug-in Hybrid (PHEV) EV Stop/Start Main attribute Regen Brake Power Assist Electric Drive +/- 100m +/- 10km Up to 200km Electrical specifications Operating Voltage Energy level 12V 0,3kWh 750V 200kWh 4 main voltage ranges for industrial and commercial vehicles 12-48V 72-96V Light duty vehicle V Medium and Heavy duty V vehicle 13

14 4 Technical challenges 1. What is the customer s real need? 14

15 Customer inputs Energy or autonomy «Automotive» RFQ process / Very detailed specification Said or not, always needs or constraints for: Energy level Voltage range Power level Continuous Peak Charging constraints Mechanical integration Safety & Reliability Life duration Operating conditions 15

16 Customer inputs Weight & Volume Lower Lower Lower Efficiency & usage ratio Higher Higher Higher 16

17 Battery Sizing Strategy What customer wants «State of the art» of battery design To what battery manufacturer can offer 17

18 5 Technical challenges 2. Development of the battery system 18

19 The technical choice Energy Power Physics Aging Budget SIZING THE BATTERY Techno & Cell Cooling Need Basis Modules BMS Housing 19

20 Cell & Technology Wide range of cells > From 3Ah > To 41Ah Several abilities > «E» as Energy > «M» as medium > «P» as Power > «H» as High Power Several available technologies > SLFP «Super Phosphate» > NMC > NCA / Small Cells Several form factors > Cylindrical > Prismatic «VDA» or others SLFP is Saft patented technology NCA: Nickel Cobalt Aluminum NMC: Nickel Manganese Cobalt 20

21 The Duty Cycle Can be determined > from a rough estimation > power recording on real vehicles Is the basis to any battery design > significant influence on sizing > will impact the business case 21

22 Using simulation tool It requires: Knowledge of Cell performance research, tests & field experience has realized models based on more than 15 years of Li-ion experience Duty cycle as relevant as possible Choice of battery configuration and cooling parameters 22

23 Simulation Output Power in/out of the battery Current in/out of the battery State of Charge evolution during cycle Here correctly balanced Battery behavior for temperature Here significant rise Batt voltage range during cycle Cell voltage range during cycle 23

24 The Sizing process NO! Define cycle and battery typical use OK Performances & Business Case? Size battery xsyp Cell Cooling efficiency More than «I need a battery for my bus» Run simulations Extract results Development Project Starts Specification can be fixed 24

25 Additional Requirements Some additional parameters 25

26 Structured Development Process Full Performance Management Rational arrangement of components Fully Operational System 26

27 Example 1: City truck Li-ion battery system 605V 50kWh & 150kWh 82 Ah 49 kwh - ~700kg X 2 XX strings of packs in parallel 1 BMS per pack 1 MBMM (Master BMM) 1 BTMS 246 Ah 148 kwh - ~1900kg X 6 27 VBU - The Battery Show (Novi) - EVT Track 3 - September 17th, 2014

28 Example 2: City bus Module EV BUS PHEV BUS Single pack configuration Technology 8 x Energy Packs 1 x Power Pack Lithium-ion IRON PHOSPHATE Saft SUPERPHOSPHATE TM Cell VL41M Fe VL30P Fe System configuration CEI [(12S) 16S] 8P [(12) 16S] 1P Voltage Nom Voltage Max Voltage Min 634 Vdc 730 Vdc 480 Vdc Power-Box (Electro-technical components: BMU, fuse, contactors, current sensor ) Service Disconnect Capacity BOL 328 Ah 30 Ah Energy BOL 208 kwh 19 kwh CHARGE Continuous 25 C 300 A / 200 kw 140 A / 88 kw CHARGE Max 10s / 25 C 700 A / 440 kw >200 A / > 120 kw DISCHARGE Continuous 25 C >1000 A / > 600 kw >200 A / > 120 kw DISCHARGE Max 10s / 25 C >1000 A / > 600 kw >200 A / > 120 kw 28 VBU - The Battery Show (Novi) - EVT Track 3 - September 17th, 2014

29 Example 3: Industrial vehicle TBL 800 : World 1 st hybrid electric tractor for wide body aircraft (A380) Energy Storage Solution Medium Power Cell VL41M Fe 224S6P configuration 740 V 180 kwh 100 kw continuous charge 400 kw continuous discharge Business case on Fuel Saving Typical operation: 2,500 hours / year Fuel consumption : 35 liter / hour > Annual : 87,500 liters Expected yearly saving : > 40% or 35,000 liters Reducing Airport taxes for emissions rights Full 8h shift without re-charge Lower maintenance cost Reduce Operating Cost 40% fuel saving Better vehicle efficiency 29 VBU - The Battery Show (Novi) - EVT Track 3 - September 17th, 2014

30 6 Technical challenges 3. Integration, Commissioning and Maintenance 30

31 Battery System Integration and Commissioning 31 Needs to be a structured and detailed activity Has already to be part of the system specification => Should result in an Integration and Commissioning Plan Several Steps > Functional and Safety test of the Battery System > Integration of the Battery System inside the Vehicle Test Bench > Integration and commissioning inside the real vehicle Several activity levels > Check of electrical, mechanical and communication interfaces > Validation of basic performances > Expansion of the functional operation range > Test and validation of failure effects May need several optimizations cycles

32 Battery System Maintenance Needs to be a structured and detailed activity Has already to be part of the system specification => Should result in an Maintenance Concept Plan Questions to be asked > Which preventive and corrective maintenance activities are necessary? > Which of those maintenance activities should be performed by whom? > Which kind of technical qualification of the service technicians is required? > What are the training and service documentation requirements? > What is the resulting spare part concept? Implementation of the necessary service actions 32

33 7 Conclusion 33

34 Conclusions Saft does have : Experience with Automotive programs Automotive Development and Production capabilities > From the cell to the complete system Products for vehicle applications Commercial successes > On-road vehicles > Off-road vehicles > Forklift > Sport vehicles >. Saft : the partner of choice for your vehicle program 34

35 Thank You! Which Questions do you have?