development and production of li-ion battery packs for ... · development and production of li-ion...
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Development and Production of Li-Ion Battery
Packs for Transport Application. An Industry Perspective.
Herbert Josef ThannerDirector Research Programm CoordinationMAGNA STEYR Battery Systems GmbH & Co OG
8th A3PS Conference
Eco-Mobility 2013
2 locations in Europe
1 location in North America
North America
Auburn Hills
Austria
Graz
Zettling
(Status Q2 2013)
Production Engineering Services & Production Engineering Services
Battery Systems / Worldwide Presence
33rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
Battery Systems / Locations Europe
• Austria (Europe)
Employees: 171 (Status Q3 / 2013)
Products: Li-Ion PHEV Battery Pack, 12V Li-Ion Batteries
Production cap. PHEV: >35.000 Units / year (2 shifts)
Plant Size: 14,000 m²
• Functions
Battery Pack Engineering
Prototype Battery Builds
Battery Pack Assembling
Zettling (HQ)
43rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
Battery Systems / Locations Europe
• Austria (Europe)
Employees: 25, Total 6,500 (Status Q1 / 2013)
Plant Size: 800,000 m²
• Functions
Battery Testing
Material Testing
Battery Pack Assembling
Graz
53rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
• Michigan (USA)
Employees: 48 (Status Q3 / 2013)
Testchannels: >400 (pack/module/cell)
Plant Size: 7,630 m²
• Functions
Battery Pack Engineering
Battery Testing
Material Testing
Battery Systems / Location North America
Auburn Hills
63rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
Battery Pack Applications
TRUCK/BUS HEV*
HEAVY DUTYPOWER BATTERY PACKS
FULL HEV*POWER BATTERY
PACKS
PHEV*
ENERGY BATTERY PACKS
50
Tota
l E
nerg
y [kW
h]
0
1
10
Power [kW]
1 10 100 1000
EV* Electric VehiclePHEV* Plug In Hybrid VehicleHEV* Hybrid Electric Vehicle
12 / 48V SYSTEMS POWER BATTERY
PACKS
MILD HEV*
POWER BATTERY
PACKS
EV*ENERGY
BATTERY PACKS
Battery Packs Portfolio for Automotive Market
12V48V
(micro HEV)Hybrid PHEV/REX BEV
Truck HEV
Truck / Constr. PHEV
energycontent
~ 300 Wh 0,25 -1 kWh 0,2-3 kWh 6-18 kWh 16-36kWh 2 - 16 kWh 8 - 14 kWh
power ~ 3 kW 8 - 11 kW 10-50 kW 50-120 kW50-120 kW 50 - 120
kW100 - 170 kW
voltage 12 V 44 V 120/400 V 400 V 400V 400 / 700 V 400 / 700 V
weight ~ 5 kg ~10 kg 10-40 kg 80-200 kg 200-400 kg 60 - 180 kg 120 - 220 kg
cooling ----- AC cooling/liquid air/liquid liquidliquid
(optional)liquid liquid
SOP 2014 2015 2015 2014 2010Gen 1 2009Gen 2 2011Gen 3 2013
2015
manuf. capacity
> 1000/a 100.000/a 50.000/a > 35.000/a 3000/a 3,000/a 3,000/a
73rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
83rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
Components and Systems
Current sensor:
Hall Sensor
Accuracy ±0,5%
ASIL B able
Shunt basedAccuracy ±0,5%Redundant power measurementASIL C
CSC:
Daisy Chain
Accuracy ±2mV
ASIL B
Daisy Chain (differential)
Accuracy ±2mV
ASIL C
BMU:
2 µP
750V
ASIL B
AUTOSAR
Dual Core µP
450V
ASIL C
AUTOSAR
EMV measures:
Filter components
Harness measures
Housing measures
Fail-safe communication
Disconnection system:
Qualified components
Fuses and relays for different loads and voltage levels:
Housing:
Steel welding
construction
Steel thermoforming
Aluminum cast /
thermoforming
plastic
Busbars:
Cells alu/alu welded
Cells alu/Cu welded
Ni-Cu screwed
Cooling:
Liquid
Air
Refrigerant
In-House Development
Mechanical Integration of Cells
9
• Fallbeispiel + BilderSteel metal can based
Self supporting module structure
Cell is used as mechanical structural part
Reduced weight of cooling ���� air cooled system
Integration cells for leightweight materials
Weight: 110 kg (10,5kg/kWh)
Dimensions: 1000 x 250 x 600mm (b x h x t) mm
Wh/kg on cell level
liq
uid
liq
uid
air air
Pouch housing Steel metal can housing Al can housing
liq
uid
liq
uid
air
Package demanding Standard Modules
High density package due to efficient thermal concept
���� liquid cooling but increased gravimetric Energy2011
2012
3rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
Gra
v.
En
erg
y [
Wh
/kg
]
Future Trends
Improvements: Cathode, Package, Electrolyte
New technologies: Li/S; Li/Me; Li/Polymer; New Cathode storage mechanisms
Li/ Air
02010 2015 2020 2025 2030
500
1000
1500
Theoretical LIB [Wh/kg]
Gra
v.
En
erg
y [
Wh
/kg
]
Lithium Ion
Improvements: better algorithms, leightweight materials
Improvements mainly based on cell technology
02010 2015 2020 2025 2030
100
200
300
Cell
Le
vel
Pack L
evel
3rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited 10
113rd October 2013 Herbert Josef Thanner – Battery Systems Disclosure or duplication without consent is prohibited
Current Products
Innovation Fields
New Products
���� 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2020
From 12V systems up to high energy BEV applications
Product diversification driven by matching market needs
BEV
Battery Pack
Battery Systems / Product Roadmap
HEV Truck
Gen I
12V Light Weight
Li-Ion Battery
PHEV
Battery Pack
HEV Truck
Gen III
PHEV / HEV
Truck Gen IV
48 V System
Gen I
High Power
HEV Battery
12V Light
Weight Li-Ion
Battery Gen II
PHEV Battery
Pack Gen II
48 V System
Gen II (specific cells)
HEV/PHEV/EV
Systems based on:
• Improved Battery management
• Integrated sub components
• Next generation cell
technologies
HEV Truck
Gen II
