Brief Introduction into e-mobility€¦ · Product Manager Power Supplies ... ICE + XEV 2016 –2031 13 12.06.2020 Brief Introduction into e-mobility AUTOMOTIVE VW plans 150 GWh/yr

Automotive

Ralf Oestreicher

Market Segment Automotive

BRIEF INTRODUCTION INTOE-MOBILITY

Anja Fenske

Product Manager Power Supplies

► Motivation

► Market Outlook

► Major Components

► Market Segmentation

► Take Aways

OVERVIEW

Rohde & Schwarz

MOTIVATION

1. Limited resources

2. Air pollution

3. Restrictions (no allowance to enter cities)

4. CO2 emission target

12.06.2020 Brief Introduction into e-mobility3

AUTOMOTIVE

Rohde & Schwarz

CO2 EMISSION TARGET


AUTOMOTIVE

Average CO2 emission 2019: 121.8 g/km

Penalty: 95 €/g CO2 per car

E.g.: 1 M cars 100 g CO2/km

(100 – 95) x 95€ = 475 M€ penalty

Rohde & Schwarz

HOW TO REACH CO2 EMISSION TARGET?


AUTOMOTIVE

Balancing of different technologies

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MODE OF ELECTRIFICATION

Brief Introduction into e-mobility6

AUTOMOTIVE

12.06.2020

Rohde & Schwarz

BALANCING OF DIFFERENT TECHNOLOGIES


95 g CO2/km

ICE

AUTOMOTIVE

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95 g CO2/km

BEV

ICE

AUTOMOTIVE

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95 g CO2/km

PHEV BEV

ICE

AUTOMOTIVE

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95 g CO2/km

PHEV BEV

ICEHEV

AUTOMOTIVE

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95 g CO2/km

PHEV BEVICE MHEV HEV

AUTOMOTIVE

► Motivation

► Market Outlook



► Take Aways

OVERVIEW

Rohde & Schwarz

GLOBAL OUTLOOKICE + XEV 2016 – 2031


AUTOMOTIVE

VW plans 150 GWh/yr battery capacity

for Europe in 2025 (2.5 Mcars x 60kWh)

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GLOBAL OUTLOOKICE + XEV 2015 - 2050


AUTOMOTIVE

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BEV BATTERY COSTS OUTLOOK 2010 – 2030


AUTOMOTIVE

Source: LMC

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GLOBAL BATTERY CELL PRODUCTION 2019


AUTOMOTIVE

► Motivation

► Market Outlook



► Take Aways

OVERVIEW

Rohde & Schwarz

MAJOR COMPONENTS ELECTRICAL VEHICLE

18

AUTOMOTIVE

12.06.2020

EV blockdiagram 48V MHEV blockdiagram

Brief Introduction into e-mobility

Rohde & Schwarz

MARKET SIZE EV COMPONENTS


AUTOMOTIVE

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MAJOR COMPONENTS – BATTERY


AUTOMOTIVE

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AUDI BATTERY STRUCTURE


AUTOMOTIVE

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CELL / BATTERY OPTIMISATION

Optimisation of battery performance prime target of car manufacturer

Improvement of range longer distances

Improvement of specific energy less weight, more energy

Improvement of costs affordable BEV

Distinguish from other car manufacturers

Comparable with combustion engine car development in the past:


Model: VW Beetle

Year: 1972

Engine: 1600 cm3

Power: 37 kW

Consumption: 15 l/100km

Model: VW Golf

Year: 2019

Engine: 1500 cm3

Power: 110 kW

Consumption: 5 l/100km

AUTOMOTIVE

Rohde & Schwarz

MAJOR COMPONENTS –BATTERY MANAGEMENT SYSTEM


Battery Management System (BMS) will be the key element in future cars such as the Engine

Control Unit (ECU) in today‘s cars

Features

Monitoring of Li-Ion cells

Cell balancing

Monitoring of cell temperatures

Battery current and voltage measurement

State of Charge (SOC) and State of Health (SOH) calculation of battery cells

Controls internal and external actuators like fans for battery cooling, etc.

Modular structure including Battery Management Controller and Cell Monitoring Controller

AUTOMOTIVE

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MAJOR COMPONENTS –BATTERY MANAGEMENT SYSTEM


AUTOMOTIVE

Cell 1

Cell 2

Cell n

Module 1

Cell 1

Cell 2

Cell n

Module n

Cell

Monitoring

Unit / Controller

(CMU / CMC)

Slave 1

Cell

Monitoring

Unit / Controller

(CMU / CMC)

Slave n

Battery

Management

Controller

(BMC)

Master

Battery Management System (BMS)

Rohde & Schwarz

MAJOR COMPONENTS –INVERTER / CONVERTER


Modern power modules use

wide-bandgap materials such

as silicon carbide (SiC)

high switching frequencies

steep rising edges

high voltages

AUTOMOTIVE

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MODE OF ELECTRIFICATIONINCLUDING 48V FULL HYBRID

26 Brief Introduction into e-mobility

AUTOMOTIVE

12.06.2020

Rohde & Schwarz

48V MARKET


48V MHEV (and 48V HEV) will dominate the market for the next years due to:

Less safety regulation (< 60V)

AUTOMOTIVE

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48V MARKET




Moderate additional costs for large benefit

AUTOMOTIVE

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48V MARKET





Covering additional applications

AUTOMOTIVE

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48V MARKET






With battery shortages ongoing, you can make at least

twenty 48V full hybrids for one Tesla

AUTOMOTIVE

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48V MARKET






With battery shortages ongoing, you can make at least

twenty 48V full hybrids for one Tesla

No government incentives required

AUTOMOTIVE

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48V BMS MARKET


Major player in 48V BMS:

Continental:

2020 4 Million MHEV.

2025 15 Million MHEV.

Already received

orders worth 1B€ for

48V systems.

Bosch:

2025 15

Million MHEV.

AUTOMOTIVE

Rohde & Schwarz

R&S SOLUTION48V BATTERY MANAGEMENT SYSTEM► Function: Monitor, control and manage various functions and parameters such as:

interconnection of multiple low voltage battery cells (e.g. 3.7V) that form a 48V battery pack

voltage, current and temperature of the battery cells

state of charge (SOC) and state of health (SOH) of the battery cells

thermal management, energy management, cell balancing and performance of the battery pack

► Test issue:

Emulation of single battery cells in R&D (upto 16 cells with approx. 3.7V per cell)

Debugging of Cell Monitoring Controller (HW)

► R&S products:

Power Supply: 8 x NGL200 / NGM200

RTO, RTP


AUTOMOTIVE

► Motivation

► Market Outlook



► Take Aways

OVERVIEW

Rohde & Schwarz

AUTOMOTIVE

35 Brief Introduction into e-mobility

► Voltage level will go up from 400V to ≥ 800V to increase driving range and improve charging efficiency

► Wireless connection between cell management controller and battery management controller under

development; reduction of weight (cables) and price

► Cloud based BMS data and control management (e.g. Bosch)

► Customer specific design of battery cells driven by OEMs; production mainly at cell manufacturer;

differentiation and further improvement of specific energy and SoC/SoH; Cell To Pack (CTP)

► Li-Io batteries dominant, solid state batteries and fuel cells not relevant before 2030,

electrical drivetrain architecture remains unchanged

► Wireless in-wheel-Motor (W-IWM): inductive charging during driving

► Further integration of modules (e.g. converter and inverter)

► HV Inverter/Converter: IGBT, MOSFET; SIC more mature than GaN

► Wireless Power Transfer (WPT) / Inductive Charging:

standardization in advanced status (Standardisation Roadmap)

test phase started (e.g. BMW 530e + WiTricity)

TECHNOLOGY TRENDS

12.06.2020

https://www.bosch-mobility-solutions.com/en/products-and-services/mobility-services/battery-in-the-cloud/

https://www.din.de/resource/blob/235254/a0d14b63b9685859b1c0c297827e50f8/roadmap-en-2020-data.pdf

Rohde & Schwarz

FURTHER QUESTIONS

Contact:

Ralf Oestreicher

Market Segment Automotive

[email protected]

Phone: +49 89 4129 14540


AUTOMOTIVE

mailto:[email protected]

Webinar

Anja Fenske

Product Manager Power Supplies

POWER SUPPLIES OVERVIEW AND TEST OF BATTERY MANAGEMENT SYSTEMS AND CELL MANAGEMENT CONTROLLERS

► R&S power supply portfolio

► R&S®NGL/M200 power

supply series

Common features

NGM200 exclusive

features

► Battery management

system testing

AGENDA

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R&S POWER SUPPLY CLASSES

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HMP2030HMP2020

HMP4040HMP4030

HM8143

NGL202NGL201

NGM202NGM201NGP802

NGP822

NGP804

NGP814

NGP824

B A S I C P E R F O R M A N C E S P E C I A L T Y

1 output 2 outputs 3 outputs 2 outputs 3 outputs 4 outputs1 output 1 output 2 outputs 3 outputs

NGE103BNGE102B

HM7042-5

HMC8041 HMC8043HMC8042

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Basic Power Supplies

Economical, quiet and stable

Manual and simple PC-controlled operation

In education, on the bench and in system racks

B A S I C

1 output 2 outputs 3 outputs

NGE103BNGE102B

HM7042-5

HMC8041 HMC8043HMC8042


HMP2030HMP2020

HMP4040HMP4030

NGP802

NGP822

NGP804

NGP814

NGP824

P E R F O R M A N C E

2 outputs 3 outputs 4 outputs1 output

Performance Power

Supplies

Speed, accuracy and advanced

programming features

Features such as DUT

protection, fast programming

times and downloadable V and I

sequences

Used in labs and ATE

applications

more

channelsmore

power

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HM8143

NGL202NGL201

NGM202NGM201

NGM201S P E C I A L T Y

1 output 2 outputs 3 outputs

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Specialty Power Supplies

Tailored to specific applications

Unique capabilities such as

• Emulating the characteristics of a battery

• Electronic load to sink current and dissipate

power in an accurate and controlled

manner

Used in labs and ATE applications

more

functions

Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILYINNOVATIVE OPERATING CONCEPT

Rotary Knob

fast adjustment of all values

Home Button

return to channel view at any time

User Button

set your preferred shortcut, e.g. screenshot

Output On/Off

easily switching on/off the output

Power On/Off Button

USB Interface

plug in USB stick to save e.g. log data

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5” Capacitive Touch Screen

intuitive user interface

Menu Button

all settings in one place

Channel Buttons

quickly switching on/off the channels

Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILYKEY SPECIFICATIONS

R&S®NGL200 and R&S®NGM200 Specifications

Number of channels 1 or 2

Voltage per channel 0 V to 20 V

Max. current per channel ≤ 6 V: 6 A, > 6 V: 3 A

Max. output power per channel 60 W

Load recovery time < 30 µs

Ripple and noise < 500 μV (RMS) / < 1 mA (RMS) (meas.)

Programming resolution 1 mV / 0.1 mA

Max. Readback resolutionR&S®NGL: 10 µV / 10 µA

R&S®NGM: 5 µV / 10 nA

Electronic load 60 W / 3 A

Data LoggingR&S®NGL: 10 sample/s

R&S®NGM: 500 ksample/s

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Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILY

Source and sink operation

Minimum ripple and noise

Fast load recovery times

6 ½ digit resolution

High speed data acquisition

Battery simulation

Multiple measurement ranges

Digital voltmeter input

NGL200 & NGM200 common features and NGM200 exclusive features

NGL200 & NGM200 common features NGM200 exclusive features

COMPANY CONFIDENTIAL

Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILYTWO-QUADRANT OPERATION

NGL200 & NGM200 common features

Operates as source and sink

The R&S®NGL200 power supplies automatically

switch from source mode to sink mode.

As soon as the externally applied voltage exceeds

the set nominal voltage, current flows into the

power supply.

Customer benefits►Simulates loads and batteries

►Charging and discharging of batteries


Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILYMINIMUM RIPPLE AND NOISE


Linear regulation

Advanced electronic circuitry is often very

sensitive to interference on the supply lines.

The R&S®NGL200 power supplies provide

extremely stable output voltages and currents.

Specifications (20 Hz to 20 MHz)

►Voltage ripple and noise:

< 500 µV (RMS)

< 2 mV (peak-to-peak) (meas.)

►Current ripple and noise:

< 1 mA (RMS) (meas.)Customer benefitsSupports power amplifiers and MMIC development


Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILYFAST LOAD RECOVERY TIME


Best load recovery time in its class

During challenging load conditions most power supplies

react with slow recovery time and overshoot.

Optimized control loop design in the R&S®NGL200

achieves a load recovery time of < 30 µs with

minimum overshoot.

Customer benefits►Perfect when testing IoT and battery powered devices

►Qualifying of sensitive designs, e.g. semiconductors


Rohde & Schwarz

R&S®NGL200 AND R&S®NGM200 POWER SUPPLY FAMILY6 ½ DIGIT RESOLUTION


Customer benefits►Perfect for characterizing devices with low standby power consumption

and high full load current

►Saves bench space and needs less connections to the DUT

►Replaces an additional DMM in many applications.

Readings with 6½ digit

resolution

Voltage, current and power measurement

values are shown with up to 6½ digits

resolution.


Rohde & Schwarz

BATTERY BASICS

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Battery modelling►Real batteries show different

characteristics depending on the

type of battery and its charging

condition.

►Capacity, open circuit voltage

(Voc) and equivalent series

resistance (ESR) are important

battery characteristics that depend

on its state of charge (SoC).

►Example shows typical

characteristics of a AA type battery 0 %80 % 20 %30 %40 %50 %60 %70 %100 % 90 % 10 %0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Internal resistance

Open circuit voltage

[V] [Ω]

State of charge

Application

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BUILDING BATTERY MODELS WITH THE R&S®NGM200

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Application

Versatile battery simulation► Capacity, Open Circuit Voltage (VOC) and

Equivalent Series Resistance (ESR) are

important battery characteristics that

depend on its State of Charge (SoC)

► To define a battery model, the battery’s

data can be entered in a pre-defined table

► Running a battery in discharging mode, the

real output performance can be simulated

► On the other side, also the charging

behavior of a battery can be simulated

► Using an R&S®NGM202, even two

batteries can be simulated at the same

time


Battery capacity testing and discharging curve

►For the battery capacity test the R&S®NGM power supply is connected as load to the charged

battery of the mobile phone under test.

►An application note is available to perform the measurement automatically

►Start measurements with a fully-charged battery

►The application software will discharge the battery and display the capacity

► The discharging curve can be compared to the reference curve

BATTERY INCOMING INSPECTIONApplication

BATTERY CELL SIMULATION FOR BATTERY MANAGEMENT SYSTEM TESTS

BMS Testing

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BATTERY MANAGEMENT SYSTEMS ARE USED IN MOST DEVICES THAT USE RECHARGEABLE BATTERIES

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BMS Testing

Electric vehicles

Consumer

electronics

Healthcare

All lithium-ion (Li-ion) batteries require a BMS. This is due to the fact

that all Li-ion batteries will fail if overcharged, completely discharged

or operated outside their safe temperature window. Each Li-ion cell

type has its own safe operating area, which makes it necessary to

program the BMS accordingly.

Rohde & Schwarz

BATTERY MANAGEMENT SYSTEMS

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Battery management system ►Intelligent Battery Management Systems (BMS) are required to actively ensure

the monitoring, controlling and managing of various battery cell parameters

such as

voltage, current, thermal and energy management,

cell balancing

state of charge (SOC) and state of health (SOH) of

the battery cells

►A typical BMS consists of one or more Cell Monitoring

Controller (CMC) and a Battery Management

Controller (BMC) depending on the voltage level of the

battery pack;

BMC and CMC are set up in a master & slave architecture

BMS Testing

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TEST CASES

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Battery management system requirementsTo optimize the monitoring, controlling and managing of the battery cells is a great challenge in

BMS development and validation.

Testing includes:

► Protection: Protect the cells from being operated outside the threshold

conditions

► Cell balancing: Balance the charge in the individual cells to maintain symmetry

between the cells

► Aging: Continuous change of voltage level per cell

► Mission profile: Customized profile simulating different scenarios

► Error simulation: Disconnect the battery during emergency conditions in a safe way

► Communication: Communicate relevant data for the driver displays and alarm

functions

BMS Testing

Rohde & Schwarz

► Support in every step of BMS development

► Customizable test system scalable to the needed number of cells

► Simulation and control of single battery cells with multiple power supplies:

set up of pre-defined and programmable cell models (e.g. Li-Ion)

real time monitoring of battery cell parameters:

terminal and open circuit voltage

charge and discharge current

state of charge (SOC)

internal resistance

► Fast regulation of output impedance (adjustable from -50 mOhm to 100 Ohm)

► Data acquisition with 500 ksample/s for in depth analysis and documentation

► Digital I/O interface ensures synchronous and fast control of all battery cells

57

BMS Testing

R&S SOLUTION

Rohde & Schwarz

The R&S®NGL200 and

R&S®NGM200 power supplies

meet your battery testing

challenges ;)

6/12/202058

summary

Documents

Brief Introduction into e-mobility€¦ · Product Manager Power Supplies ... ICE + XEV 2016 –2031 13 12.06.2020 Brief Introduction into e-mobility AUTOMOTIVE VW plans 150 GWh/yr