Lithium-Ionen-Batterien für Elektrofahrzeuge

Neue Fahrzeugkonzepte mit dem Fokus Nachhaltigkeit:Lithium‐Ionen‐Batterien für Elektrofahrzeuge

14. Zulieferforum der Arbeitsgemeinschaft Zulieferindustrie

26. Januar 2010 ∙ Frankfurt

Dr. Jörg KümpersJohnson Controls Saft Advanced Power Solutions GmbH

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Neue Fahrzeugkonzepte:

El kt f h d V H b id El kt t

Neue Fahrzeugkonzepte: Lithium-Ionen-Batterien für Elektrofahrzeuge

• Elektrofahrzeuganwendungen: Vom Hybrid zum Elektroauto

• Schlüsselfaktoren fortschrittlicher Batterietechnologien

• Aktuelle Trends bei der Entwicklung von Lithium-Ionen-Batterien

JCS Advanced Power Solutions2

Johnson Controls – Global FootprintGlobal Technology Centers for Development and ManufacturingGlobal Technology Centers for Development and Manufacturing

Bordeaux, FranceNersac, France Hannover, Milwaukee, C FBordeaux, FranceLi-Ion Pilot Line

& Research

Nersac, France NiMH & Li-Ion

production

Hannover, Germany

System Integration

Milwaukee, US

Li-Ion Lab

Cergy, FranceBMS NiMH & Li-Ion

Global Capabilities• Product Planning• Benchmarking

• Purchasing • Product Development

Shanghai, PRCDevelopment

Facility

• Consumer Research• Design Studio• Advanced Engineering

• Prototype Shop • Chemical Labs• Testing

• Project Management• Quality Systems

• Production Process/Prove Out• Manufacturing


Johnson Controls SAFT – Global FootprintGlobal Technology Centers for Development and Manufacturing

JCS started Li-Ion Cell Production for Automotive Applications in

Global Technology Centers for Development and Manufacturing

for Automotive Applications inNersac, France in January 2008

Nersac, FranceNersac, France NiMH & Li-Ion

production

JCS Advanced Power Solutions

Johnson Controls SAFT – Global Footprint – Manufacturing

Holland, Michigan USA

Li-Ion production

Johnson Controls-Saft announced plans to build its first U.S. cell manufacturing facility for lithium-ion hybrid batteries in Holland, Michigan

The plant will start production in 2011

I h H ll d Mi h f ili i $220 illiInvestment to the Holland, Mich., facility is app $220 million.

Initial capacity of 15 million lithium-ion cells.


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There are Multiple Types of Hybrids

Micro HEV (a.k.a Stop/Start)Low voltage Shuts down engine at idle to save fuelExample: BMW 1,3 mini series – JCI is the world leader in AGM micro hybrid batteries

Mild HEVLow to medium voltageIncludes stop-start, regeneration braking and acceleration assist Example: Saturn Vue, S-class, 7-series

Full HEVHigh voltageI l d ll ild HEV f t PLUS l t i l tiIncludes all mild HEV features PLUS electric-only operating range and optionally, multiple axle electric drive Example: Ford Escape, Toyota Prius


There are Multiple Types of Hybrids

Plug-In Hybrid (PHEV)High voltage Includes all full hybrid features PLUSelectric-only operation for ~20 milesAbility to recharge battery through 120V electrical outlet(in addition to regenerative braking)( g g)Demonstration vehicles: GM Saturn VUE, Dodge Transit, Ford Escape

Electric Vehicle (EV)( )High voltageNo internal combustion engineRecharge battery through 120V electrical outletDemonstration vehicles : Mitsubishi i-EV

Fuel CellsHigh VoltageHigh VoltageNo internal combustion engine Full gas hybrid functionalityDemonstration vehicles: Daimler, Ford, Honda, Toyota, GM


y

8

Fuel Economy can be enhanced by increasing electric Power

Electric Power

Full HybridFull Hybrid

Electric Power

15 kW15 kW• > 200V• Electric propulsion

R ti B ki

Mild H b idMild H b id10 kW10 kW

• Regenerative Braking• Boost• Start/Stop

Mild HybridMild Hybrid10 kW10 kW• 42V – 150V• Combined Starter/Alternator• Limited Boost / Regeneration• Start/Stop

• 42V – 150V• Combined Starter/Alternator• Limited Boost / Regeneration• Start/Stop

Micro HybridsMicro Hybrids5 kW5 kW

••

• 12/42V• Combined Starter/Alternator• Start/Stop

• 12/42V• Combined Starter/Alternator• Start/Stop

Fuel Economy5% 10% 25%20%15%

Fuel Economy5% 10% 25%20%15%


Battery Innovation “fuels” the Drive to sustainable Transportation

ittio

n B

enef

Pure Electric

MildH b id

FullHybrid Vehicle Fleets

PHEV Vehicle Fleets

CO

2R

educ

t

Vehicle Fleets

100%MicroHybrid Vehicle Fleets

Hybrid Vehicle Fleets

Fleets

cien

cy &

C

25-40%

60%- 100%

Commercially Available

Fuel

Effi

5-8%

12-20%

Under Development

Phased Technology Roll-out and Commercialization


Li-Ion Battery Automotive Commercialization

Li-Ion Technology in series production:

Vehicle SoP Type Battery súpplier

Mercedes S-Class hybrid, SoP 2009 Mild - HEV Johnson Controls Saft / Conti

GM Volt Plug In Hybrid SoP 2010 PHEV CPI / LG chemGM Volt – Plug In Hybrid SoP 2010 PHEV CPI / LG chem

Mitsubishi i-MiEV SoP 2010 EV GS Yuasa

BMW 7 Series ActiveHybrid SoP 2010 Mild-HEV Johnson Controls Saft / Conti

Nissan LEAF SoP 2010 EV AESC

BYD SoP 2010 PHEV BYD

Toyota Prius Plug-In SoP 2010 PHEV PEVEy g

Azure Dynamic’s Balance HEV SoP 2010 HEV Johnson Controls Saft

Ford’s first PHEV SoP 2012 PHEV Johnson Controls Saft


Li-Ion for Mild Hybrid Application – Example Daimler S-class :

New S-class S400 Blue-hybrid with JCS Li-Ion technology

Mild Hybrid Battery System (19 kW boost)Mild Hybrid Battery System (19 kW boost)Boost, Recuperation, Stop-Start, (no EV mode)35 cells each 6.5 Ah

SoP in 2009 (MY 2010)( )Cooperation : Daimler / Continental / JCSBattery located in Engine Compartment : A/C – cooled


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The Pentagon of Virtues displays the main parameters of an automotive battery for advanced automotive applicationsy pp

POWER

SAFETYENERGY

SAFETY

LIFE COST


The Battery for automotive Applications is a complex System

Mechanical Subsystem Electrochemistry/Cell

Cell Manufacturing

Electronics SoftwareElectronics Software

System Assembly

Electrical Subsystem Thermal Management Subsystem


Design System Characteristics

Design: Characteristics:

-Cell Type

- Number of Cells

-Size / Dimensions / Volume

- Weight

- Architecture

Cooling System

g

- Energy Content

Power capability- Cooling System

- Electronics

- Power capability

- Life Expectance

- Housing - Robustness

- Vehicle Integration

- Safety Level


JCS Technology Scope S. Suckow, 19.06.2009

ElectrochemistryCell Design

MechanicalSubsystem

Milwaukee US- NA Applications

Milwaukee US

Hanover DE- EU ApplicationsShanghai CN- Asia Applications

Bordeaux FR

Cergy FRCore

Thermal Electronics Hardware

- Core- Applications

Subsystem Low Level Software

ElectricalSubsystem

ApplicationSoftware

JCS Advanced Power SolutionsConfidential and Proprietary 17

Energy of Battery Systems is strongly related to the chemical Energy

The laws of nature have fixed limits to specific energy of electrochemical systems from the periodic table of elements

Li-Ion battery technology offers low weight, high reduction potential chemistry.

- High voltage due to high chemical energy:

- Low weight of Lithium metal

- High mobility of Li-Ions in solid state materials

H He

Li Be B C N O F Ne

Maximum theoretical specific energy is reachede C O e

Na Mg Al Si P S Cl Ar

K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr

Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe

Cs Ba La Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn

energy is reached for the Li/F pair: 6085 Wh/kg

Cs Ba La Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn

Fr Ra Ac

Reducing elements Oxidizing elements


Battery Technologies: Specific energy of (electro)chemical storage

In practice only a small part of theoretical energy can be realized for rechargeable battery applications

JCS Advanced Power Solutionsfor the express purpose of quoting General Motors 19

Battery Technologies: Comparison of various Technologies


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Battery Technologies: Voltage Characteristics

VL41M Typical continuous discharge at +23°C

3 6

4.0

3.2

3.6

ge (V

)

2.8Volta

g

C/5C/3

2.41C2C150A

2.00 5 10 15 20 25 30 35 40 45

Discharged Capacity (Ah)


Battery Technologies: Cycle Life

VL45E (High Energy) cells @ C/3 during 80%DOD (DST) cycling

160

180

200

h/Kg

) About 5 years continuous cycling

120

140

160

@ C

/3,

(Wh

60

80

100

c Ene

rgy

@

0

20

40

Spec

ifi

00 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Cycles

JCS Advanced Power SolutionsProtected Battery Information 23

Life Projection of Lithium Ion Batteries

Cycle Life Expectancy for Li-Ion Batteries:Arrhenius plots based on 100% increase of resistance:

Projection based upon various test results(up to 4 years observation)

100

(yea

rs)

Projection:

20 lif t 30°C10

alen

dar L

ife 20 years life at 30°C

10 years life at 40°C

2.7 years life at 60°C

1

Proj

ecte

d C

a

Storage @ 60%SOCEOL projected for 100% increase of impedanceTested on VL7P & VL20P productsActual data at 20 40 60°C Tests in progress

0.10 20 40 60 80 100

Temperature (°C)

Actual data at 20, 40 60 C - Tests in progress


Energy Throughput is a key Parameter of Battery Technologies

45000

35000

40000

25000

30000

nove

r / N

C

Pb-floodedPb-AGM

Full HEV operation range

15000

20000

Cap

acity

Tur

Pb AGMNiMHLi-Ion

operation range

5000

10000

C

Plug-In HEV operation range Full EV

operation range

00 10 20 30 40 50 60 70 80 90 100

DOD %


DOD %

25

Li-Ion is a Enabling Technology for the next Generation of HEVs

Li-Ion Battery Technology Advantages for HEVs

Nickel Metal Hydride is today’s battery technologytoday s battery technology

Li-Ion is the target of everyLi-Ion is the target of every OEM as the obvious next step battery solution

{ 30% Smaller 50% Lighter More Powerful

WHY? { More EnergyEnhanced Cycle Life

Faster Recharge


JCI is committed to support of R&D activities along the entire chain

•Basic research •Applied •Development •Production

C th d

•Basic research research •Development •Production

•Electrochemistry

•Cathode

•Anode

•Separator•Energy

•Cell

y•Materials Discovery

•Energy Storage

p

•Electrolyte

•Other (Inerts)

•Life

•Safety

Cost

•Mass production

•Cost•Cell

•Fuel Cells, Caps •Scale Up

Continuous feedback of market needs and technology possibilities

JCS Advanced Power SolutionsConfidential and Proprietary 27

Lithium Ion Cells for various Applications

ElectrochemistryLi Ion cellsLi-Ion cellsPositive material: NCANegative material: GraphiteElectrolyte: blend of solvent with dissolved LiPF6

ConstructionC li d i l i l d tCylindrical, spiral wound typeAluminum caseCan to cover assembly through laser weldingCan to cover assembly through laser welding2 Terminals located at the same endSafety FeaturesOverpressure release through rupture areaIntegrated current interrupt


JCS Li-ion Cell Products – PHEV and EV

Diameter 54 mm / Energy-Power Applications EV or PHEV

VL45E VL41M VL22M VL30P

Capacity (Ah) C/3 @ 4V 45 41 22 30

• Standard mechanical parts• Standard chemistry (NCA/Graphite)• Standard assembly processes

Dia. (mm) 54 54 54 54

Length (mm) 222 222 145 222

Weight (kg) 1.07 1.07 0.65 1.1

• Flexible height to various capacities• 3 different electrodes types “E” / “M” / “P”

for various Power to Energy ratios

Volume (dm3) 0.51 0.51 0.33 0.51

Energy (Wh) 160 146 78 107

Power (W) 710 850 700 1520( )Current limit (A) 250 300 300 500

Power (W) V limit, 2.5 V 2300

30 50%SOC 10s –

• Note: characteristics at 25°C

30s – 50%SOC 10s 50%SOC

JCS Advanced Power SolutionsConfidential and Proprietary

JCS Battery System – Internal Perspective S. Suckow, 19.06.2009

Mechanical & Electrical Integration•Communications Interfaces•Packaging•Packaging•High Voltage Connectors•Power Interface

Thermal Management•Air CooledLi id C l d•Liquid Cooled

Cells and Cell Modules•Li-Ion (Lithium-Ion)•NiMH (Nickel Metal Hydride)

Hybrid System Electronics•BMS (Battery Management System)•CSC (Cell Supervisory Controller)•Software•Electronics•Power Interface•Electrical System


Electrical System

Thank you for your attention !Thank you for your attention !

Vielen Dank für Ihre Aufmerksamkeit !

In case of questions / Bei Rückfragen

Dr. Jörg KümpersJohnson Controls Saft Advanced Power Solutions GmbHAm Leineufer 5130419 Hannover30419 HannoverTel. +49 (0) 511 975 [email protected]


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Lithium-Ionen-Batterien für Elektrofahrzeuge