AABC 2012. AABTAM Symposium: Advanced Automotive Battery Technology, Application and Market - Session 3

There is only one significant obstacle to widespread commercialization of plug-in hybrids and all-electric vehicles: the energy-storage device known as the battery. In this session we will review the latest progress in PHEV and EV-battery technology as well as the cost, logistics, and infrastructure aspects of vehicle electrification to assess how close EV/PHEV technology is to offering acceptable value to the market.

Elmar Hockgeiger completed his studies in electrical engineering at the Technical University of Munich in 1988 and started at the BMW Group in Munich soon after. He first worked in test engineering before becoming responsible for the development of transmission electronics. In 2004, he became head of the department of electrical machines and storage systems within the Powertrain Development division of the BMW Group. Since 2008, he is responsible for the development of high-voltage battery systems, including in-house battery development.

1. Lithium-Ion Battery for BMW Active E
   Elmar Hockgeiger, Department Manager Electrical Storage Systems, BMW Group
   Abstract 

   

   No compromises: The BMW Group has a clear sustainability strategy. As a car manufacturer, putting sustainable individual mobility on the road is one of the major challenges. In a three step approach the BMW Group is taking a giant step in this direction:

   • MINI E was the first step to understand EV customer behavior.
   • BMW ActiveE is the second step with improved battery integration in a conversion design with in-house developed and produced electric powertrain components.
   • BMW i3 Megacity Vehicle is a 'Purpose design EV' and will allow ideal integration of the electric drivetrain. The integration of the battery into the vehicle structure is a precondition for low weight and low cost solutions.

   This presentation outlines the project targets and concepts for the BMW ActiveE battery. It also highlights some basic battery concepts for future cost down solutions.

   • Project Targets for the BMW ActiveE battery:
     • In-house development and production of the electric powertrain components.
     • First approach to a modular battery kit.
     • Qualification and validation of the battery concepts and subcomponents for the BMW i3 Megacity Vehicle.
     • Further understanding of customer behavior.
      
   • The Battery concept of the BMW ActiveE:
     • 3 housings (tank/tunnel/front) connected via HV-and cooling lines.
     • 25 modules with 2p x 96s cells. Parallel connection on cell level.
     • Battery system voltage of 355 V.
     • Energy content of about 32 kWh.
     • High power performance up to 147 kW.
     • Battery conditioning via water cooling and heating.
     • Sophisticated battery management system in a 3 ECU Master-Slave architecture.
     • High level and proven safety architecture.
      
   • Future cost down measure: battery construction kit for multi project reuse:
     • Cell standardization: prismatic hard-case cell types based on VDA standard for HEV, PHEV1, EV1 and EV2 cells.
     • Modules for HEV, PHEV and EV applications with integrated CSC's.
     • ECU, connectors, degassing as identical parts in each pack.
     • Packs with high reuse of subcomponents: only housing, cooling and wiring harness is specific.
      
   • Summary:
     • Standardization and a modular battery construction kit is the main measure for cost reduction.
     • An ideal battery package space is a precondition for low weight and low cost battery.
      

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2. Battery Development for Plug-in Hybrid Vehicles
   Hiroyuki Obata, Battery Evaluation ＆ Analysis Dept., Battery Material Engineering Div., Toyota Motor Corporation
   Abstract 

   

   The upcoming Prius PHV is Toyota's first production vehicle for US to include Li-ion battery. Toyota has developed the battery and its system for the new PHV. The safety and reliability evaluation was thoroughly conducted for the launch of the vehicle. This presentation will discuss the development status of the Li-ion battery for Toyota's PHV, including results from safety testing and reliability testing.  

   • What is Plug-in Hybrid Vehicles(PHV)？
   • Advantages of PHV
   • Lithium-ion battery adopted for PHV power system
   • Toyota's safety and reliability concept for traction batteries
   • Acquiring the safety and reliability of the battery cell and pack for PHV
   • The results of the battery life verification from HV and PHV field tests
   • The introduction of new PHV

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3. Energy Storage System Design for Performance Extended Range Electric Vehicles
   Kevin Konecky, Supervisor, Fisker Automotive
   Abstract 

   

   Fisker Automotive launched the Fisker Karma; its first performance luxury Electric Vehicle – Extended Range (EVer) in 2011. At the core of its technology is the Energy Storage System (ESS). This presentation will discuss:

   • Introduction of Fisker Automotive
   • Challenges of Performance EVER Architecture
   • Energy Storage System (ESS) Requirements & Needs
   • Fisker ESS Development Process
   • Fisker ESS Design Aspects for Safety

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4. Developing the EV Battery Market: Technology and Cost Challenges
   Shoichi Matsumoto, President, Automotive Energy Supply Corporation
   Abstract 

   

   • Nissan and NEC established JV as Automotive Energy Supply Corporation (AESC), automotive Lithium ion battery design and manufacturing company in 2007.
   • AESC first launched series production Lithium ion battery pack for Nissan Leaf, first volume production EV.
   • AESC battery has been applied to four volume production vehicle models today.
   • Over 40,000 battery packs has been produced to date.
   • This success has been built up with our partners' cooperation and quality-first technology development.
   • In order to expand the newly created market, AESC is trying to challenge drastic cost reduction and performance enhancement at the same time.

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5. High-Performance Lithium-Ion Batteries for Electrified Vehicle Applications
   Takefumi Inoue, Manager Engineering Department, Lithium Energy Japan
   Abstract 

   

   GS Yuasa and its manufacturing subsidiaries, Lithium Energy Japan (LEJ) and Blue Energy Ltd. (BEC), have been competent to proceed wide-range development and commercial mass production of large-size Li ion cells for electrified vehicles. Various models of prismatic-type cells have been developed by GS Yuasa for application of EV, HEV and PHEV. The cells have been flexibly designed so that the cells fulfill each specific requirement by applying our characteristic cell format such as solid mechanical structure as well as best matching among the cell components. The performance of those cells has been evaluated in tests required for automotive use such as input/output capability of power and energy in various ambient conditions, life time under storage or cycling, robustness and safety in abuse cases, etc. Moreover, future technologies providing further improvement of cell performance have been also investigated in terms of higher energy, longer life, better safety and greater stability.

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6. Infrastructure and Logistics in Support of Plug-in Vehicles
   Mark Duvall, Director, Electric Transportation and Energy Storage, Electric Power Research Institute (EPRI)