Electric Vehicle Batteries: Moving from Research Towards Innovation Knowledge Transfer from Research to Innovation System Integration Ian Faye 10 th of April 2013 Brussels 1
Bosch E-Drive Activities Drives for e-bikes Electrical drives for passenger cars Hybrids, Plug-in & EV Battery: BBS Navigation systems Chargers for EV / PHEV Charging stations for electric vehicles Software for infrastructure integration Hydraulic hybrid system & electrical drives for commercial vehicles Starters and generators for Start/Stop Systems ABS, ESP, Break-Booster Research and predevelopment for future electrical vehicle concepts 2 System integration is more than putting components together in a vehicle
System Integration Powertrain Battery Integration Involves Several Interfaces Mechanical and Environmental Electrical Power and Recuperation Thermal Conditioning Communication and Management Safety Concept VCU ESP PSM BCM AUX 12V BAT ECU CHA BMS HV BAT ECU INV CON EM GET DIF a nl 3 Integration of one component affects interfaces of others
4 smart EV-VC: Battery and System Integration Optimize Battery PLUS Optimize Vehicle System 22 kwh/100 km 150 Wh/kg real vehicle range: 12 kwh/100km cell level 250 Wh/kg 350 Wh/kg 2010 2015 2020 260 kg Li-x 180 kg Li-Ion 500 kg Li-Ion 44 kwh 44 kwh improved module with intelligent BMS 44 kwh usable energy 2010 2015 2020 consumption Li-Ion 200 kg Source: Heiko Weller, Bosch 35 kwh Li-x 100 kg 24 kwh modular design w/ optimized vehicle integration Optimization achieved through synergies between components and vehicle: Vision -> integrated components
Future Intelligence in System Integration System optimization for Driving Range System optimization for Life-Time Optimization achieved through synergies between components and SW 5
Share of development cost per battery [euros] smart EV-VC: Battery and System Integration Volume Bundling 10,000 Additional development cost 100 for small manufacturers: 500 euros/battery Battery manufacturer with 50,000 to 100,000 EV/year Battery manufacturer with 500,000 EV/year 1 1,000 10,000 100,000 1,000,000 Anticipated development effort for cells and packs approximately 1,500 man years As a result investment in development of approx. 150 m euros With depreciation over 10 years and 8 % financing cost, cost amounts to 25 m euros/year and manufacturer Annual battery production volume 6 GS/EP 4/8/2013 abl Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
Summary Li-ion battery Battery Power Electronics Electric Motor 12% 4% 6% 5% 9% 10% 84% 89% 81% Weight Volume Cost Electric motor: 60 kw Integrated system must lead to weight, volume and cost reduction. Battery: 20 kwh 7 GS/EP 4/8/2013 abl Robert Bosch GmbH 2013. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
Key Messages System integration adds additional value to components Optimization must cover powertrain, communication and whole vehicle concept System integration must cover safety aspects for the user for the service technicians for rescue forces in case of accidents To maintain equivalent high safety levels as with today s conventional vehicles Support standardization of non competition relevant products for platform concept Research is still needed in key areas: solutions for product integration reduced energy consumption of controls, as well as auxiliaries (heating/cooling) pre-heating/cooling of passenger compartment and temperature sensitive components (like battery) second life concepts, reliability and safety and recycling standardized protocol of SOH for cells and modules ensure safety level achievement incl. data communication 8
anl Thank you for your attention! 9