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Vehicle Electrification by Society of Automotive Engineers International. Focus on Lithium battery technologies.

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vehicle

ELECTRIFICATIONevsae.com

Lithium in the limelightLi-ion battery research heats up around the globe

EV evolution Power grid changes needed

Brushless motor Open-poles motor winding conceptJune 26, 2012

NEVERY CONNECTION COUNTS

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2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. AMP+, TE Connectivity and TE connectivity (logo) are trademarks. Other logos, product and/or company names might be trademarks of their respective owners.

USA: 1-800-522-6752 Canada: +1-905-475-6222 Mexico: +52 (0) 55-1106-0800 Latin/S. America: +54 (0) 11-4733-2200

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Contents4 Battery standards work is real workVolunteers work geared to helping engineers design safe products for all.

18 Tech ReportEnergy EV evolution will require changes in nations power distribution grid Energy Rough road ahead for EV battery costs Energy SAE J1772 combo connector inches closer to adoption Simulation A new approach to Li-ion battery modeling Powertrain Marsilli advances open poles motor winding for hybrids

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Argonne heats up Li-ion battery researchThe U.S. Department of Energy lab near Chicago is using federal stimulus money to dive deeper into lithium battery research.

12 Lithium-ion battery industry moves forwardFrom technology advances to manufacturing capacity expansions, the foundation of the lithium-ion battery industry is becoming stronger and more viable.

29 Whats on evsae.com Cover: Li-ion cell production atJohnson Controls plant in Holland, MI.

Brine, lithium carbonate, lithium hydroxide. (Rockwood Lithium)

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SAE Vehicle Electrification evsae.com

Electrifying SuccessCD-adapco has embarked on a journey of collaboration to create a simulation system which is relevant and focused on todays trends within the automotive marketplace. The journey so far has taken in energy storage technology, electric machines analysis, electro-thermal behaviour and continues apace to deliver engineering success to all our users. The system is built around the class-leading CAE tool STAR-CCM+, a tool which deals with complex, heavy weight 3D resolved physical phenomena. These could include a tightly coupled thermal-electromagnetic problem or an electrochemical-thermal process, all solved within one code, STAR-CCM+. Aligned to this complex heart of the solution are specific design level tools which are focused on the problems design engineers face in the early part of a project. Such tools allow a subsystem to be developed which parachutes the user into the correct design space before deploying STAR-CCM+ to gain those final few percent that make the difference. The value of such a simulation ecosystem is that there is no duplication. Information entered at the component level is directly interpreted into the complex 3D simulation, allowing a range of engineering groups to use the same models in differing circumstances. This is evident in electric machines design where the upfront analytic tool is used to create a machine which delivers the required torque/speed characteristics. The model is then passed to a thermal group who seamlessly transfer it into a detailed 3 dimensional analysis, adding surrounding cooling systems and componentry, which is used to understand local maximum temperatures within the proposed machine under previously defined operating loads. Such a tight integration between design tools and analysis tools provides the most value from a groups investment in analysis while avoiding redundant calculations.

For more information on this growing simulation system designed by world-renowned leaders in analysis with the simple aim to solve your engineering problems and ensure you achieve engineering success, please visit: www.cd-adapco.com. Follow us online. For more information: info@cd-adapco.com www.cd-adapco.com/automotive

Patrick Ponticel SAE Associate Editor

Editorial

Battery standards work is real workSAE Internationals battery standards committees are doing important work in advancing the cause of vehicle electrification. Their nearly 500 members deserve accolades for taking on responsibilities above and beyond those related to their regular jobs. It is vital to safety and to limited costs of electrified vehicles that a group of engineers and related professionals is dedicated to standards responsibilities. Its the right thing to do, the Chairman of the fast-growing SAE Battery Standards Steering Committee told me in a recent phone interview. That was not a pat on the back Bob Galyen was giving himself; just an acknowledgement of the truth. As President of Magna E-Car Systems Battery Business Unit, he speaks from a position of authority in saying SAEs standards work is extremely beneficial to the young electrification-of-the-automobile sector because there are people out there who do not understand batteries, who do not understand electrified systems. And in order for the technical community to protect itself and for it to flourish, it has to have documentation written by a large cross section of professionalsThere will be a lot of guys out there who dont know what theyre doing who can cause physical damage to themselves or others because theyre not designing safe and effective systems. Aside from safety, standards address costs. Great reductions are possible if automakers can agree on a standard battery module or cell size, which would offer manufacturing economies of scale. Galyen is temporarily serving as Chair of the Battery Size Standardization Committee, the focus of which is now on the cell (vs. the module). No standardization results are imminent as automakers want to retain as much packaging flexibility as possible, said Galyen. A much more imminent standard is J2936Vehicle Battery Labeling Guidelines, from the Battery Standards Labeling Committee. This SAE Recommended Practice provides labeling guidelines for any electrical storage device at all levels of sub-component, component, subsystem, and system-level architectures describing content, placement, and durability requirements of labels. It addresses dimensional, positioning, and copy nomenclature, product description, voltage and manufacturing information, as well as end-of-life disposal, shipping, and electrical connection data. J2929Electric and Hybrid Vehicle Propulsion Battery System Safety Standard - Lithium-based Rechargeable Cells should be ready by about years end.

Ad IndexCD-adapco UK 3 dSPACE Inc 5 TE Connectivity cover

Resource LinksSales Force Contact Us Archives SAE Board of Directors SAE Membership

SAE Vehicle Electrification, June 26, 2012, Volume 3, Number 3, (ISSN 2159-4279) is published 6 times a year by SAE International. SAE International is not responsible for the accuracy of information in the editorial, articles, and advertising sections of this publication. Readers should independently evaluate the accuracy of any statement in the editorial, articles, and advertising sections of this publication that are important to him/her and rely on his/her independent evaluation. For permission to use content in other media, contact copyright@sae. org. To purchase reprints, contact advertising@sae.org. Copyright 2012 by SAE International. The SAE Vehicle Electrification title is registered in the U.S. Patent and Trademark Office.

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SAE Vehicle Electrification evsae.com

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