Design of high-voltage battery packs for electric vehicles
01 Jan 2015-pp 245-263
TL;DR: In this article, the main target of the battery pack design is to reduce the costs of the individual components and increase the energy density on a system level without affecting the safety and lifetime.
Abstract: The bottleneck of electric road vehicles lies in the low energy density, high costs, and limited lifetime of the battery cells contained in a high-voltage battery pack. As the battery pack is a complex system that consists of various components, an efficient design is crucial for the success of electric vehicles. To ensure the safe and reliable operation of the energy storage system, the single components such as the housing, the battery modules, the cooling system, as well as a battery management system have to fulfill challenging requirements. The main target of the battery pack design is to reduce the costs of the individual components and increase the energy density on a system level without affecting the safety and lifetime.
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TL;DR: In this article, the authors presented an impact analysis of a fast-charging station on the grid in terms of power consumption, obtained by the Monte Carlo simulation, showing that it is not economical convenient size the assumed ultra-fast charging station for the maximum possible power also considering its high impact on the Grid.
Abstract: Road transport electrification is essential for meeting the European Union's goals of decarbonization and climate change. In this context, an Ultra-Fast Charging (UFC) system is deemed necessary to facilitate the massive penetration of Electric Vehicles (EVs) on the market; particularly as medium-long distance travels are concerned. Anyway, an ultra-fast charging infrastructure represents the most critical point as regards hardware technology, grid-related issues, and financial sustainability. Thus far, this paper presents an impact analysis of a fast-charging station on the grid in terms of power consumption, obtained by the Monte Carlo simulation. Simulation results show that it is not economical convenient size the assumed ultra-fast charging station for the maximum possible power also considering its high impact on the grid. In view of the results obtained from the impact analysis, the last part of the paper focuses on finding a method to reduce the power installed for the DC/DC stage while keeping the possibility for the electric vehicle to charge at their maximum power. To achieve this goal a modular approach is proposed. Finally, two different modular architectures are presented and compared. In both the solutions, the probability of having EVs charging at limited power is less than 5%.
10 citations
01 Jan 2016
TL;DR: Possible secondary uses ofDecommissioned traction batteries still possess sufficient performance to meet the requirements of other mobile or stationary energy storage applications and their economic potentials are discussed.
Abstract: A fast market penetration of electric vehicles is (among other reasons) currently restricted by the high cost of batteries. Prolonging their life cycle by reusing them in other applications after they are retired from automotive service can be a viable option for addressing this problem. Decommissioned traction batteries still possess sufficient performance to meet the requirements of other mobile or stationary energy storage applications. This paper discusses possible secondary uses and their economic potentials. Keywords—electric vehicle batteries; secondary use; end-oflife-solutions; business models; value networks
9 citations
Cites background from "Design of high-voltage battery pack..."
...This is caused by higher initial investments (respectively depreciations) mainly due to the traction battery as the single most expensive component [1]....
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TL;DR: The critical load limits and failure behavior can be used to improve the prediction accuracy of hazardous situations for the development and design process of high voltage battery systems.
Abstract: As high voltage systems for electrified vehicles and their electronic components exhibit hazardous potential during abuse situations, their development needs special consideration. Battery busbars, representing current-carrying components, pose a special threat in the event of a vehicle crash. While the behavior of Li-Ion cells under different crash loads has already been investigated, there is no detailed knowledge about the electro-mechanical behavior of busbars during crash situations. Therefore, this paper focuses on combining mechanical and electrical loads on thermoplastic-insulated battery busbars. The conducted experimental work includes mechanical penetration of the insulation with various indenter geometries. Simultaneously, a high electrical potential was applied between the indenter and the conducting copper of the busbar. To detect the failure of the busbar, which is considered an electrical short circuit, insulation resistance was measured. Furthermore, the investigation includes the influence of humidity and lower voltage on the electro-mechanical behavior to simulate operating conditions. The results of this paper contribute to current knowledge in meeting the challenges that arise in developing safe vehicle batteries. The critical load limits and failure behavior can be used to improve the prediction accuracy of hazardous situations for the development and design process of high voltage battery systems.
8 citations
TL;DR: The aim of the research was to reveal the correspondences between functions, data groups and system components, to create the concept of a complex, integrated information application and to elaborate its innovative functions.
Abstract: Increasing acceptance of electromobility is an important step towards sustainable transportation. However, besides its obvious environmental and economic benefits, the technology of Electric Vehicles (EVs) still has some significant operational drawbacks (e.g. relatively short driving range, long recharging time). Advanced mobile applications supporting travellers’ decisions, improving predictability and reliability could play a key role in the promotion of a more widespread use of the technology. Mobile applications can serve as a “platform” between the human component and the integrated system. The aim of our research was to reveal the correspondences between functions, data groups and system components, to create the concept of a complex, integrated information application and to elaborate its innovative functions. As a result of our systematic analysis of the most important, currently available applications, it has been found that important, customizable functions (e.g. charger-point reservation, energy-efficient routing etc.) are not yet available, thus our innovation focused on these information management features. Based on our concept, integrated information applications can be developed, providing real-time personalized service for the users and including all functions related to electromobility.
7 citations
TL;DR: New methods are necessary to identify and handle uncertainties of complex product systems within requirements engineering and an approach towards comprehensive uncertainty management is taken within this publication.
Abstract: Electric mobility is on the verge of becoming a mass market. Major automotive OEMs have initiated programs to electrify their product portfolio. This transition poses new challenges and requires new innovative concepts in automotive development processes, especially for battery systems as the key component within electric powertrains. Battery system costs account for up to 40% of the electric vehicle’s total costs. Additionally, development cycles of battery systems for automotive applications are characterized by long development periods. Hence, the initiatives to advance electrification result in numerous development projects affiliated with significant development expenses. Battery systems can be referred to as mechatronic and electrochemical systems. They require a complex interaction of diverse scientific and engineering disciplines. Fast innovation cycles have effects regarding product requirements and assumptions towards their allocation. Hereby, uncertainties can lead to risks within development projects, especially in terms of time and costs. In current development processes, necessary changes are only dealt with reactively, causing unplanned additional expenses and delays. Thus, there is need for handling potential changes proactively, i.e. managing uncertainties leading to those changes as early as possible. New methods are necessary to identify and handle uncertainties of complex product systems within requirements engineering. An approach towards comprehensive uncertainty management is taken within this publication.
6 citations
References
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Patent•
11 Jan 2010TL;DR: In this paper, a battery system including a plurality of subunits each of which has a heatsink and a battery cell and two voltage terminals symmetrically positioned with respect to a centerline of that battery cell, where all the battery cells are arranged so that their voltage terminals are aligned along two rows.
Abstract: A battery system including: a plurality of subunits each of which has a heatsink and a battery cell and two voltage terminals symmetrically positioned with respect to a centerline of that battery cell, wherein all of the battery cells are arranged so that their voltage terminals are aligned along two rows; a plurality of identical busbar supports equal in number to the plurality of subunits, each having two slots and mounted on a corresponding different one of the subunits with each of the terminals of the battery cell extending up through the two slots; and a plurality of bimetallic busbars, each one supported by a different corresponding subset of the busbar supports and electrically connected directly to either a first or second terminal of each of the battery cells of each of the modules on which those busbar supports are mounted.
39 citations
Patent•
05 Dec 2011
TL;DR: In this article, an improved integration system for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the system utilizing at least one insulating layer interposed between the battery pack enclosure and the vehicle floor panel.
Abstract: An improved integration system for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the system utilizing at least one insulating layer interposed between the battery pack enclosure and the passenger cabin floor panel, where the insulating layer provides noise isolation, thermal isolation and vibration damping, and where the insulating layer is compressed when the battery pack enclosure is mounted to the vehicle.
32 citations
Patent•
10 Jul 2012TL;DR: In this article, a pressure compensation device for compensating an internal pressure in a housing of an electrochemical device is provided, including at least one gas through-opening and a membrane element with a gas-permeable membrane, which is deformable depending on a change in the internal pressure and by which the gas throughopening is blocked.
Abstract: A pressure compensation device for compensating an internal pressure in a housing of an electrochemical device is provided, including at least one gas through-opening and at least one membrane element with a gas-permeable membrane, which is deformable depending on a change in the internal pressure and by which the gas through-opening is blocked, and a protective degassing element, which is configured and arranged in such a way that when a critical deformation of the membrane is reached, it damages the membrane in such a way that the membrane at least partially opens the gas through-opening for protective degassing of the housing. The pressure compensation device allows both reliable pressure compensation between the interior of the housing and the exterior of the housing of an electrochemical device during normal operation of the electrochemical device and also ensures reliable bursting protection in the event of excess internal pressure in the housing.
19 citations
Patent•
27 Apr 2011
TL;DR: In this article, an energy storage module for supplying voltage, in particular to a motor vehicle, was characterized in that each row (60, 61) of storage cells is separated from the end plates (30, 35) and the tension rods (40, 41, 42) by an insulating jacket (50, 55) that completely encircles the row of stored cells and that has electrical insulation properties.
Abstract: The invention relates to an energy storage module (1) for a device for supplying voltage, in particular to a motor vehicle, said device being constructed from a number of energy storage modules (1), said energy storage module (1) being constructed from several prismatic storage cells (10), which are arranged one behind the other so as to be stacked in at least one row (60, 61) and which are clamped between two end plates (30, 35) by means of tension rods (40, 41, 42). The energy storage module according to the invention is characterized in that each row (60, 61) of storage cells is separated from the end plates (30, 35) and the tension rods (40, 41, 42) by an insulating jacket (50, 55) that completely encircles the row (60, 61) of storage cells and that has electrical insulation properties. The electrical insulation properties of the insulating jacket (50, 55) are such that the insulating jacket provides contact protection regarding a voltage obtained by serially connecting all storage cells (10) of the energy storage module and/or regarding a voltage obtained by serially connecting the energy storage modules (1).
12 citations