I. INTRODUCTION > Technology comparison
II. BatteryMan’s BMS > Cell-integrated topology
> Power Line Communication
IV. BENEFITS
V. APPLICATIONS…
AGENDA
© Power Sources Conference, Herzelia, May 2013
I. INTRODUCTION > Market drivers
II. OBRIST’s HyperHybrid > HICE
> Li-Ion Battery Pack
> E-Drive
> Thermal Management
PROBLEM | UNBALANCED CELLS
Operation mode
Uneven aging
Temperature distribution
in stack
Production tolerance
© Power Sources Conference, Herzelia, May 2013
BMS PRINCIPLE
©
BMS OBJECTIVES
Protection from abuse
Enhancing battery life
Control charge/ discharge
Maintain battery in application-specified state
BMS FUNCTIONS
Retrieve data on cell-level (U, T, I, Z, SoH, SoH)
Data logging for cycle analysis + load strategy optimization
Controlled charging/discharging
Cell-balancing/ Pack balancing
Emergency load shut-off
Keep battery in designated operation conditions
Monitoring in standby-mode
…
Source: Woodbank Communications Ltd
STAR TOPOLOGY (Master/ Slave)
Cells equipped with temperature sensors and
connections to measure the voltage
Multiple cells (module) connected to one slave
Various slaves connected to one master
©
BENCHMARK | Conventional BMS topologies
Power Sources Conference, Herzelia, May 2013
Source: Woodbank Communications Ltd
BENCHMARK | Conventional BMS topologies
RING TOPOLOGY (Daisy Chain)
Slave PCB connected to each cell
Communication transceiver for data
transmission and receipt
Three wire data bus for master/slaves
connection
© Power Sources Conference, Herzelia, May 2013
REAL-LIFE BMS | Complex Wiring & Periphery
Source: BRUSA, 16kWh 400V with fix12cell-module platines Source: Hella & Bender Source: Bundesverband IT-Sicherheit e.V.
Source: EV Power, Australia Source: WatchMojo.com, Bluecar EV pack Source: GreenMicrotech.net
© Power Sources Conference, Herzelia, May 2013
Archive BatteyMan Technology GmbH. Source: PickeringTest.net Source: GreenMicrotech.net
BENCHMARK | Summary Of Classical BMS
© Power Sources Conference, Herzelia, May 2013
Some say, a BMS is a highly
sophisticated and complex system…
DC Power Line
Plus
Minus
BatteryMan Route Map BATTERY CELL MANAGER INSIDE
… we don’t.
We take the direct line.
„The BatteryMan BMS avoids all data-
wiring, connectors, sense calibration
work and significantly simplifies the
integration process resulting in
scalable storage modules for all
battery applications.”
BMS INNOVATION | Cell-integrated BMS
© BatteryMan
conventional Ring topology
conventional Star topology
- +
M
S S
S
S S M
S
- +
1 Master 20 Slaves Cable circuit
1 central Master 5 starform slaves Starform cabling
Cell-integrated sensors Power line communication No cabling on periphery Highest flexibility
topology
BENCHMARK | Now what would you prefer?
© Power Sources Conference, Herzelia, May 2013
CELL-INTEGRATION | BMS Uses DC Power Line
DC/AC Inverter E-motor
Local Monitor Unit LMU per cell measures T, U, SN
Power line communication
CAN, USB,
RS232, RS485…
V
M
DC
AC
X Monitoring in standby mode
Local Monitor Unit (LMU) measures and monitors
U_cell, T_cell
Localization by Serial Number on LMU-MCU
Data transmission over DC power line to master Battery
Control Unit (BCU) via current modulation technique in 24Bit
Code
Microcontroller connects additional load for µs
Decrease of load current
Pulses extracted from DC power line
BCU with digital signal processing (DSP)
Most cost-effective PLUG & PLAY solution
PLC & BMS Cell-Integration
© Power Sources Conference, Herzelia, May 2013
Exceeding voltage
By-passing over shunt
©
CELL-BALANCING
Power Sources Conference, Herzelia, May 2013
NOISE IMMUNITY | DSP
LMU Signal output Cell Voltage under load
© Power Sources Conference, Herzelia, May 2013
REAL-TIME EVENT-DRIVEN UPDATES
Event: „Zone Entry“ Frequent Updates
2,0
2,2
2,4
2,6
2,8
3,0
3,2
3,4
3,6
0% 20% 40% 60% 80% 100%V
olt
age(
V)
Discharge Rate(%)
Discharge Rate Characteristics (LiFeP04 3,2V 10Ah, Type 1865130 by Xinchi)
1C
5C
10C
Individual Trigger Points 3 COMMUNICATION LEVELS
I. Frequent Updates according relevance
II. Real-time event driven updates (redundant zone entry signals, 3-zone priorizing)
III. Synchronous Measurement of all cells at tx at individually set trigger points for crititcal stages
© Power Sources Conference, Herzelia, May 2013
REAL-TIME EVENT-DRIVEN UPDATES
Events: „Zone Entry“
Individual Trigger Points possible
3 COMMUNICATION LEVELS
I. Frequent Updates according relevance
II. Real-time event driven updates (redundant zone entry signals, 3-zone priorizing)
III. Synchronous Measurement of all cells at tx at individually set trigger points for crititcal stages
Voltage Sensor signal
© Power Sources Conference, Herzelia, May 2013
REAL-TIME UPDATES
Charging
& Balancing 3,3V
Balancing 3,0V
Balancing 3,24V
Charging
Balancing 3,24V
No charging
Load
Balancing 3,24V
Charging
© Power Sources Conference, Herzelia, May 2013
PLUG & PLAY | Fastest Pack Design
SMART CELLS | Cell-integrated BMS for modular composition
SCALABLE | Easy upscaling & individual design (Plug & Play)
UNIVERSAL | 1 BMS for all chemistries, forms, sizes and interfaces
FLEXIBLE | Avoids data lines, connectors, BMS design, installation of
sensors and cabling for modifications + variations
LOWEST-COST | Enables adequate battery dimensioning with smart cell
© Power Sources Conference, Herzelia, May 2013
CELL-INTEGRATION | The Cost Saver
COST
REDUCTION
MATERIAL SAVING
© Power Sources Conference, Herzelia, May 2013
BMS MARKET | Application Fields
EV, HEV, PHEV
Electric Bikes (two-wheelers)
Forklift Trucks
Medical Devices
Robots/ Automation
ESS for Renewables
Off-Grid ESS
Prototyping
©
Source: BatteryMan archive
Power Sources Conference, Herzelia, May 2013
Continuous Progression 3rd generation BCU master board with DSP processor for optimized noise filtering, with standard USB and RS485 plus optional CAN interface.
ESS Energy Storage System| Module 2,5 kWh Ready to install packs with isolated MC4 connectors, for households and industry
Plug&Play Energy Storage System (ESS) First BMS using power line communication for cell data monitoring!
“Smart Solar Manager” | Off-grid system 48V Solar battery pack as off-grid ESS Including PV string monitoring and energy management for solar towers
APPLICATION: EV Li-Ion Battery Pack
©
OBRIST Powertrain Pack
Capacity 10.1 kWh
Voltage nominal 360 V (250V-420V)
Output 100 kW (peak 150 kW)
Number of cells 1400
C-rate discharge 10 C (15 C – peak)
C-rate charge 10 C (15 C – peak)
Weight w/o fluids 84 kg
Power Sources Conference, Herzelia, May 2013
Customized product development LMU adoptions for powerline communication for customer-specific product developement.
I. INTRODUCTION > Technology comparison
II. BatteryMan’s BMS > Cell-integrated topology
> Power Line Communication
IV. BENEFITS
V. APPLICATIONS…
AGENDA
© Power Sources Conference, Herzelia, May 2013
I. INTRODUCTION > Market drivers
II. OBRIST’s HyperHybrid > HICE
> Li-Ion Battery Pack
> E-Drive
> Thermal Management
BMS
Thermal management
Packaging interface
Durability tests
Power Sources Conference, Herzelia, May 2013 ©
Customized Battery Adaptation
Driving of HyperHybrid System:
Acceleration
Deceleration
Charging
Discharging
Constant drive
Hybrid controller settings and
algorithms adaptation
Power Sources Conference, Herzelia, May 2013 ©
Hybrid Controller Development
60
80
100
120
140
160
180
200
220
2008 2010 2012 2014 2016 2018 2020 2022 2024 2026 2028
Year [ - ]
CO2 emission
[ g/km ]
2,5
3,3
4,2
5,0
5,9
6,7
7,6
8,4
9,3
EU (NEDC)
Expected for 2025
US (CAFE)
Japan (10-15 Mode)
Gasoline
[ l / 100km ]
120g/km (FE: 130g/km, complimentary: -10g/km
EU
Japan
US
Power Sources Conference, Herzelia, May 2013 ©
Market Drivers
Legislation
High Fuel prices
Peak oil
Social
Reduce carbon
footprint
City EV
III. High-performance E-drive
IV. Smart Thermal Management
II. Optimized high power Li-Ion battery
I. Development of an ultra-compact & high
efficient internal combustion engine
Lowest cost | Best fuel efficiency | +1000km driving range
HyperHybrid (HH) Innovative serial plug in hybrid (PHEV) powertrain
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain
Combustion Engine (HICE) with generator and inverter
Motor with energy recovery
Downsized Li-Ion battery
Power Electronics
Charger
Power Sources Conference, Herzelia, May 2013 ©
Highly compact 1098cc 2 cylinder 4 stroke engine with generator
Power: 40kW generator @ 400V (or 60kW @ 600V)
Noise: Twin crankshaft for total mass balancing
Efficiency: Spec. fuel consumption 215g/kWh (test result)
Fuel: unleaded, ethanol, LNG, CNG
Thermal management: Heat storage
Operation: Full load condition
Weight: 76kg with generator
Mounting position: any
215
510
HICE
590
Power Sources Conference, Herzelia, May 2013 ©
I. Innovative HICE For Serial Hybrid and REX
OBRIST Powertrain Pack
Capacity 10.1 kWh
Voltage nominal 360 V (250V-420V)
Output 100 kW (peak 150 kW)
Number of cells 1400
C-rate discharge 10 C (15 C – peak)
C-rate charge 10 C (15 C – peak)
Weight w/o fluids 84 kg
A „C“ discharge rate of 10 means that an 8 kWh battery can be discharged with 10 times 8 kW hence 80kW c
Power Sources Conference, Herzelia, May 2013 ©
Li-Ion Low Cost Battery System
HV Li-Ion Battery Key Target Data
Modular high power battery system with 10-17kWh (400V)
High power cylindrical 18650 cells; 8,5C discharge (15 C peak)
Liquid cooling for homogenous temperature (max ΔT = 2-3 K)
Regular 20% DOD during operation
L x W x H: 589 x 312 x 320mm
Few mounting restrictions
Innovative internal cell fixation system
Compact system, Plug-In chargeable
External interface for cooling and heating
Variable design options
High power and high energy application applicable
Integrated BMS with PLC, no wiring for modularity
Power Sources Conference, Herzelia, May 2013 ©
Li-Ion Low Cost Battery System
25
2m
m
twin motor design with 2x60kW (peak)
continuous power 2x40kW
weight approx. 101kg
PM e-motor with hybrid technology *
inverter with torque vectoring left/right
2 integrated sets of gear wheels
2 integrated inverters left/right
2 coolant loops left/right
* PM hybrid technology: rotor with embedded permanent magnets
hybrid technology generates reluctance at failure mode
with hybrid technology save e-motor operation
Ø 2
20
mm
809mm
38
6m
m
Power Sources Conference, Herzelia, May 2013 ©
Key Data Twin Electrical Motor
Surface Temperature:
Average tap surface temperature spread below 2K over the whole battery pack
Coolant Temperature:
Average coolant temperature increase below 1,5K over the whole battery pack
Power Sources Conference, Herzelia, May 2013 ©
Battery Thermal Management CFD Results
Innovative “HICE” insulation
use of the HICE as a “Energy Storage Unit”
improved compartment heating
emission reduced warm start up
Battery insulation system
minimization of energy demand for thermal management
extension of battery operating range (Hot and cold application)
optimization of battery lifetime
simplified cooling architecture for high and mid temperature loops
Interior thermal management
more effective heating and cooling system to maximize mileage
Power Sources Conference, Herzelia, May 2013 ©
Innovative Thermal Management
Power Sources Conference, Herzelia, May 2013 ©
Thermal- and Noise Insulation
Customized vibration absorbers
Customized thermal and noise insulation
INV
_M
1
INV_HICE BMS/ISO PDU
Charger
Power Train Bus System
Vehicle Safety Bus System
ESP / ABS
r1
r2
a
a
CAN 500kB/s (10ms)
ECU
CAN 500kB/s (1ms)
CAN 500kB/s (100ms) Hyperhybrid
Controller
HVAC
Vehicle Bus System
T
Screen
Ele
ctr
ic m
oto
r
Power Sources Conference, Herzelia, May 2013 ©
Customized System Structure
Power Sources Conference, Herzelia, May 2013 ©
System Efficiency @ Constant Speed 60kph
Combustion Diesel
h=20% h=93% Diesel
79,29g/kWh
250gCO2/kWh
430g/kWh
h=19 113g CO2/km
HyperHybrid Gasoline h=41% h=81% Gasoline
82,85g/kWh
257gCO2/kWh
279g/kWh
h=33 73gCO2/km
*1
*2
*3
*4
*5
Legend: *1 Specific calorific value *2 Specific CO2 emission per kWh *3 Specific fuel consumption *4 CO2 emissions per km
Prius Gasoline h=31% h=93% Gasoline
82,85g/kWh
257gCO2/kWh
290g/kWh
h=19 75g CO2/km
Controller
HICE 40kW Battery
11kWh
Electric front drive (85kW)
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain eFWD
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain eFWD
Controller
HICE 40kW Battery
11kWh
Electric front drive (85kW)
All components are mounted to a car specific frame which uses
the existing mounting points
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain eAWD
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain eAWD | Alternative configuration
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain eAWD | Alternative configuration (Underfloor)
Battery 17kWh
HICE 60kW
Twin electrical front and rear motor (4x85kW)
HyperHybrid power controller with charger and DC/DC
E-Torque vectoring for all wheels
Power Sources Conference, Herzelia, May 2013 ©
HyperHybrid Powertrain eAWD | 340kW