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Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 1
1 CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Energy Storage System EVSmart Battery Management System
BOSCHCorporate Research
2
Energy Storage System EV
CR/PJ-LIB | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Lithium Ion Technology at Bosch
BoschPower Tools
Bosch
Corporate Research
Bosch/Samsung
� New High Energy Lithium Ion Cells
� Safe Lithium Ion cells
� Energy storage and battery
systems for HEV/EV vehicles
� Power Tools powered by Lithium
Ion cells
Bosch eBikes
� Closed System (Battery, Charger,
Drive Unit) for electric bikes
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 2
3
Energy Storage System EV
CR/PJ-LiB | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Lithium Ion Technology at the Bosch Research Department
Materialresearch
Lithium Ion Cell manufacturing
� Module Design
� Battery Management Algorithms
� High Energy Cells: LiS & Li-Air
� Safe Lithium Ion Cells
� New Materials for High Energy
Lithium Ion cells
System development
4
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Development Roadmap E-Mobility
HEV PHEV EV11. Generation
SOP 2018
EV22. Generation
SOP 2012SOP 2010
System EV GS-EH
Organization SB Limotive
Development Roadmap E-Mobility
Bosch
Research
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 3
5
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Innovation for higher performance (specific energy & power)
Prismatic cell design for highest safety & lifetime
Focus on high quality plus cost-efficient & innovative system solutions
World-wide spare part support by Bosch Aftermarket
Recycling w/ support of partners
6
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Cooling SystemBMS Software
Cells Modules BMS Pack
� SB LiMotive offers flexible business models
Products
� In connection with hardware also development services, e. g.
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 4
7
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Vehicle
System
Sub-System
Component
Future (E)- Mobility Demand
Requirements Engineering EV
8
Energy Consumption and Weight Reduction EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Energy Storage System EV
8
0
10
20
302010:
22 kWh/100km
Target 2020: 12 kWh/100km
Mech. Brakes (0,5 kWh)
Aerodynamic (7 kWh)
Roll-Resistance (4 kWh)
Drive Train Losses (5 kWh)
Accessories (1,5 kWh) &
Thermo (3,5 kWh)
Aerodynamic (5-6 kWh)
Roll-Resistance (2-3 kWh)
Drive Train Losses (2 kWh)
Accessories (1 kWh) &
Thermo (1,5 kWh)
400 kg weight reduction, Frontal
Area und cw reduced
Consumption kWh/100km real cycle (CADC)
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 5
9
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
real vehicle range:
200 km
260 kg
200 km
180 kg
Li-Ion
Li-Ion
Li-x
Optimization Battery Optimization Vehicle and System
200 km
500 kg
250 Wh/kg
22 kWh/100 km150 Wh/kg 12 kWh/100km
consumption
2010
2015
2010 2020
+
44 kWh
improved module with intelligent BMS
35 kWh
350 Wh/kg
2020
44 kWh
200 km
100 kg
Li-x
44 kWh
cell levelusable
energy
200 km
200 kg
Li-Ion
24 kWh
2015
modular design w/ optimized vehicle integration
10
Energy Storage System EV
CR/PJ-LiB ARC-137 CR/ARC-Liedtke | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
> 64 %
> 18 %
> 13 %
> 3 %
> 2 %
Market acceptance EV *)
*) from magazine Auto-Motor Sport , ** Total vehicle weight incl. battery = 1000 kg ) , Energy consumption : 16 kWh/100km
600 W
h/k
g
220
Wh/k
g
300
Wh/k
gTarget WindowFull EV
LiS
& L
iAir
cells
160 W
h/kg
130 Wh/kg
**)
Mitsubishi MiEVUrban electric vehicle
Tesla RoadsterEV Sport Car
BMW Mini EUrban electric vehicle
GM VoltPlug In
HV-N
CM
Li-I
on c
ell
Phosphate b
ased Li-I
on cell
260
Wh/
kg
LiFePO4
Li(Fe,Mn)PO4
NCM
HV-NCM
LiS
Li-Air
130 Wh/kg
150 Wh/kg
160 Wh/kg
220 – 260 Wh/kg
Energy density (1C-rate)
Energy density (0.1 C-rate)
300 Wh/kg ***)
600 Wh/kg ***)
***) values vary in dependence of
selected cell design
Estimation for cell level
Research / development status
Conventio
nal NCM
Future Cell Technology for EV
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 6
11
Energy Storage System EV
Corporate Research | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Battery Management System (BMS)
BMS FUNCTIONSSingle Cell Sensing
Battery Diagnosis
Main Contactor Control
Temperature Prediction and Management
Isolation Failure Detection
Current and Voltage
Limitation
Battery Cell Balancing
Power and restenergy prediction
Identification of Safety Events
is part of the battery system intended to ensure safe and optimal battery operation, as well as provides information for the other components of the BEV.
12
Energy Storage System EV
Corporate Research | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial property rights.
Energy storage system - requirements pyramid
Co
sts
Weight
Safe
ty
Efficiency
Lo
ng
lif
eti
me
Lo
w p
ac
k c
os
ts
Low internal resistance
Light battery
components
High specific energy
Active balancing
Cell a
nd
desig
n s
pecif
ic s
afe
ty
BM
S s
afe
ty f
un
cti
on
s
BMS
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 7
13
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
2,00
2,10
2,20
2,30
2,40
2,50
2,60
2,70
2,80
2,90
3,00
3,10
3,20
3,30
3,40
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
t [min]
U0
U1
U2
U3
U4
U5
U6
U7
U8
U9
2,00
2,10
2,20
2,30
2,40
2,50
2,60
2,70
2,80
2,90
3,00
3,10
3,20
3,30
3,40
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
t [min]
U0
U1
U2
U3
U4
U5
U6
U7
U8
U9
2,00
2,10
2,20
2,30
2,40
2,50
2,60
2,70
2,80
2,90
3,00
3,10
3,20
3,30
3,40
3,50
3,60
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
t [min]
U0
U1
U2
U3
U4
U5
U6
U7
U8
U9
2,00
2,10
2,20
2,30
2,40
2,50
2,60
2,70
2,80
2,90
3,00
3,10
3,20
3,30
3,40
3,50
3,60
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
t [min]
U0
U1
U2
U3
U4
U5
U6
U7
U8
U9
46 min
54 min + 17 %
Active Balancing
No Balancing
Range test with differently aged cells.V
olts
Vo
lts
14
Energy Storage System EV
CR/PJ-EV2 | 11/30/2010 | © Robert Bosch GmbH 2009. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Optimized Solution future EV
Volume
Function
Cost
Efficiency
Weight
EV2
Overall Optimum
Volume
Function
Cost
Efficiency
Weight
EV2
Overall Optimum
„The optimum of each subsystem and component is not necessarily the
overall optimum of the entire system“
Electrical Vehicle Batteries Made in Europe
30.11.2010
Joint EC / EPoSS / ERTRAC Expert Workshop 2010 8
15 CR/PJ-EV2 | 16.09.2010 | © Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Thank you for your attention !
BOSCHCorporate Research
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