Lithium-Ionen-Batterien für Elektrofahrzeuge

Transcription

Neue Fahrzeugkonzepte mit dem Fokus Nachhaltigkeit:
Lithium‐Ionen‐Batterien für Elektrofahrzeuge
14. Zulieferforum der Arbeitsgemeinschaft Zulieferindustrie
26. Januar 2010 ∙ Frankfurt Dr. Jörg Kümpers
Johnson Controls Saft Advanced Power Solutions GmbH
Agenda
ge da
Neue Fahrzeugkonzepte:
• Elektrofahrzeuganwendungen:
El kt f h
d
Vom
V
Hybrid
H b id zum El
Elektroauto
kt
t
• Schlüsselfaktoren fortschrittlicher Batterietechnologien
• Aktuelle Trends bei der Entwicklung von Lithium-IonenBatterien
JCS Advanced Power Solutions
2
Johnson Controls – Global Footprint
Global Technology Centers for Development and Manufacturing
Nersac, France
NiMH & Li-Ion
production
Bordeaux, France
Li-Ion Pilot Line
& Research
Global Capabilities
• Product Planning
• Benchmarking
• Consumer Research
• Design Studio
• Advanced Engineering
• Project Management
• Quality Systems
3
Hannover,
Germany
System Integration
•
•
•
•
•
•
•
Milwaukee,
US
Li-Ion Lab
Purchasing
Product Development
Prototype Shop
Chemical Labs
Testing
Production Process/Prove Out
Manufacturing
Cergy, F
C
France
BMS NiMH & Li-Ion
Shanghai, PRC
Development
Facility
3
Johnson Controls SAFT – Global Footprint
Global Technology Centers for Development and Manufacturing
JCS started Li-Ion Cell Production
for Automotive Applications in
Nersac, France in January 2008
Nersac, France
NiMH & Li-Ion
production
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
Investment
I
to the
h H
Holland,
ll d Mi
Mich.,
h ffacility
ili iis app $220 million.
illi
Initial capacity of 15 million lithium-ion cells.
Agenda
ge da
El kt f h
d
Vom
V
Hybrid
H b id zum El
Elektroauto
kt
t
6
There are Multiple Types of Hybrids
Micro HEV (a.k.a Stop/Start)

Low voltage

Shuts down engine at idle to save fuel

Example: BMW 1,3 mini series – JCI is the world leader
in AGM micro hybrid batteries
Mild HEV

Low to medium voltage

Includes stop-start, regeneration braking and acceleration
assist

Example: Saturn Vue, S-class, 7-series
Full HEV

High voltage

IIncludes
l d allll mild
ild HEV ffeatures
t
PLUS electric-only
l ti
l operating
ti
range and optionally, multiple axle electric drive

Example: Ford Escape, Toyota Prius
7
There are Multiple Types of Hybrids
Plug-In Hybrid (PHEV)

High voltage
Includes all full hybrid features PLUS
electric-only operation for ~20 miles
Ability to recharge battery through 120V electrical outlet
((in addition to regenerative
g
braking)
g)
Demonstration vehicles: GM Saturn VUE, Dodge Transit, Ford
Escape
Electric Vehicle (EV)
( )

High voltage
No internal combustion engine
Recharge battery through 120V electrical outlet
Demonstration vehicles : Mitsubishi i-EV
Fuel Cells

High Voltage
No internal combustion engine
Full gas hybrid functionality
y
GM
Demonstration vehicles: Daimler, Ford, Honda, Toyota,
8
Fuel Economy can be enhanced by increasing electric Power
Electric Power
Full Hybrid
15 kW
10 kW
5 kW
Mild H
Hybrid
b id
Micro Hybrids
• > 200V
• Electric propulsion
• Regenerative
R
ti B
Braking
ki
• Boost
• Start/Stop
• 42V – 150V
• Combined Starter/Alternator
• Limited Boost / Regeneration
• Start/Stop
• 12/42V
• Combined Starter/Alternator
• Start/Stop
•
Fuel Economy
5%
10%
15%
20%
25%
9
Fuel Efficiency & C
CO2 Reducttion Benefit
Battery Innovation “fuels” the Drive to sustainable Transportation
Micro
Hybrid
Vehicle
Fleets
Mild
H b id
Hybrid
Vehicle
Fleets
Full
Hybrid
Vehicle
Fleets
PHEV
Vehicle
Fleets
Pure
Electric
Vehicle
Fleets
100%
60%- 100%
Commercially Available
25-40%
12-20%
Under Development
5-8%
Phased Technology Roll-out and Commercialization
10
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 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
y
Prius Plug-In
g
Toyota
SoP 2010 PHEV
PEVE
Azure Dynamic’s Balance HEV
SoP 2010 HEV
Johnson Controls Saft
Ford’s first PHEV
SoP 2012 PHEV
Johnson Controls Saft
11
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)
Boost, Recuperation, Stop-Start, (no EV mode)
35 cells each 6.5 Ah
SoP in 2009 ((MY 2010))
Cooperation : Daimler / Continental / JCS
Battery located in Engine Compartment : A/C – cooled
Agenda
ge da
El kt f h
d
Vom
V
Hybrid
H b id zum El
Elektroauto
kt
t
13
The Pentagon of Virtues displays the main parameters of an
automotive battery
y for advanced automotive applications
pp
POWER
SAFETY
ENERGY
LIFE
COST
14
The Battery for automotive Applications is a complex System
Mechanical Subsystem
Electrochemistry/Cell
Cell Manufacturing
Electronics
Software
System Assembly
Electrical Subsystem
Thermal Management Subsystem
15
Design Ù System Characteristics
Design:
Characteristics:
-Cell Type
-Size / Dimensions / Volume
- Number of Cells
- Weight
g
- Architecture
- Energy Content
- Cooling System
- Power capability
- Electronics
- Life Expectance
- Housing
- Robustness
- Vehicle Integration
- Safety Level
JCS Technology Scope
Milwaukee US
- NA Applications
Mechanical
Subsystem
S. Suckow, 19.06.2009
Electrochemistry Milwaukee
Cell Design
US
Hanover DE
Bordeaux FR
- EU Applications
Shanghai CN
Cergy FR
- Asia Applications
- Core
- Applications
Thermal
Subsystem
Electronics Hardware
Low Level Software
Electrical
Subsystem
Application
Software
Confidential 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
e
Be
B
C
N
O
F
Ne
e
Na Mg
Al
Si
P
S
Cl
Ar
As
Se
Br
Kr
In
Sn Sb
Te
I
Xe
Tl
Pb
Po
At
Rn
Li
K
Ca
Sc
Ti
Rb
Sr
Y
Zr
Nb Mo Tc
Cs Ba
La
Hf
Ta
Fr
Ac
Ra
V
Cr Mn Fe Co
W
Cu Zn
Ru Rh Pd Ag Cd
Re Os
Reducing elements
1
8
Ni
Ir
Pt
Au Hg
Ga Ge
Bi
Oxidizing elements
Maximum theoretical specific
energy is reached
for the Li/F pair: 6085 Wh/kg
Battery Technologies: Specific energy of (electro)chemical storage
In practice only a small part of theoretical energy can be realized for
rechargeable battery applications
for the express purpose of quoting General Motors
19
Battery Technologies: Comparison of various Technologies
20
Agenda
ge da
El kt f h
d
Vom
V
Hybrid
H b id zum El
Elektroauto
kt
t
21
Battery Technologies: Voltage Characteristics
VL41M Typical continuous discharge at +23°C
4.0
Voltag
ge (V)
36
3.6
3.2
C/5
C/3
1C
2C
150A
2.8
2.4
2.0
0
5
10
15
20
25
30
35
40
45
Discharged Capacity (Ah)
22
Battery Technologies: Cycle Life
VL45E (High Energy) cells @ C/3 during 80%DOD (DST) cycling
Specific Energy @ C/3, (Wh
h/Kg)
200
180
About 5 years continuous cycling
160
140
120
100
80
60
40
20
0
0
500
1000 1500 2000 2500 3000 3500 4000 4500 5000
Cycles
Protected 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)
Projected Ca
alendar Life (years)
100
Projection:
10

20 years lif
life att 30°C

10 years life at 40°C

2.7 years life at 60°C
1
Storage @ 60%SOC
EOL projected for 100% increase of impedance
Tested on VL7P & VL20P products
Actual data at 20
20, 40 60°C
60 C - Tests in progress
0.1
0
20
40
60
80
100
Temperature (°C)
24
Energy Throughput is a key Parameter of Battery Technologies
45000
40000
Capacity Turnover / NC
C
35000
30000
Pb-flooded
Full HEV
operation range
25000
Pb-AGM
Pb
AGM
NiMH
20000
Li-Ion
15000
Plug-In HEV
operation range
10000
Full EV
operation range
5000
0
0
10
20
30
40
50
60
70
80
90
100
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
today
s battery technology
Li-Ion is the target of every
OEM as the obvious next step
battery solution
WHY?
{
30% Smaller
50% Lighter
More Powerful
Faster
Recharge
Enhanced
Cycle Life
More Energy
26
JCI is committed to support of R&D activities along the entire chain
•Basic research
•Applied
research
•Development
•Production
•Cathode
C th d
•Anode
•Electrochemistry
y
•Materials
Discovery
•Energy Storage
•Energy
•Separator
p
•Cell
•Life
•Mass
production
•Electrolyte
•Safety
•Other (Inerts)
•Cost
Cost
•Cell
•Fuel Cells, Caps
•Scale Up
Continuous feedback of market needs and technology possibilities
27
Lithium Ion Cells for various Applications
Electrochemistry
Li-Ion
Li Ion cells
Positive material: NCA
Negative material: Graphite
Electrolyte: blend of solvent with dissolved LiPF6
Construction
Cylindrical,
C li d i l spiral
i l wound
d ttype
Aluminum case
Can to cover assembly through laser welding
2 Terminals located at the same end
Safety Features
Overpressure release through rupture area
Integrated current interrupt
28
JCS Li-ion Cell Products – PHEV and EV
Diameter 54 mm /
VL45E
VL41M
VL22M
VL30P
45
41
22
30
Dia. (mm)
54
54
54
54
Length (mm)
222
222
145
222
Weight (kg)
1.07
1.07
0.65
1.1
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
Capacity (Ah)
C/3 @ 4V
Power (W)
30 – 50%SOC
30s
Note:
•
•
•
•
•
Standard mechanical parts
Standard chemistry (NCA/Graphite)
Standard assembly processes
Flexible height to various capacities
3 different electrodes types “E” / “M” / “P”
for various Power to Energy ratios
2300
V limit, 2.5 V
•
Energy-Power Applications EV or PHEV
10s –
50%SOC
characteristics at 25°C
JCS Battery System – Internal Perspective
S. Suckow, 19.06.2009
Mechanical & Electrical Integration
•Communications Interfaces
•Packaging
•High Voltage Connectors
•Power Interface
Thermal Management
•Air Cooled
•Liquid
Li id C
Cooled
l d
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
Electrical System
Thank you for your attention !
Vielen Dank für Ihre Aufmerksamkeit !
In case of questions / Bei Rückfragen
Dr. Jörg Kümpers
Johnson Controls Saft Advanced Power Solutions GmbH
Am Leineufer 51
30419 Hannover
Tel. +49 (0) 511 975 1870
[email protected]