Periodic Reporting for period 2 - HELIOS (High-pErformance moduLar battery packs for sustaInable urban electrOmobility Services)
Berichtszeitraum: 2022-07-01 bis 2023-12-31
The transition from the internal combustion engines (ICE) age to a fully electric mobility scenario is one of the main challenges to be overcome, to reduce the impact of climate change. The roadmaps and targets for the optimisation of Li-ion technologies and for the development of new chemistries, such as Li-S, Li-air, or solid-state batteries, are then defined in the Integrated SET-Plan (Action 7).
HELIOS addresses the need for increasing the density of battery packs in terms of weight and package space to improve the performance and range of EVs fleets utilised in growing urban electromobility models. A hybrid approach combining different Li-ion modules within the battery pack is developed to maximise energy and power capabilities depending on the application while optimising dimensioning. This hybrid configuration of the battery pack influences the electrical and thermal behaviour of the system. It also affects the design of the thermal management system, as well as the overall configuration of the different components and sub-systems within the battery pack. The proposed battery pack design makes use of advanced materials in the structural components, such as polymers and composites, to enhance mechanical resistance and lightweight, as well as in the thermal management system. Optimised designs for the electric and thermal management systems, casing and insulation, wiring, and other structural components, are reduced within the battery packs.
In HELIOS, the architecture of the different Li-ion modules, the electrical connections, current collectors, and wiring are optimised to ensure high efficiency, cost, and compact design. Advanced concepts of BMS relating to hardware and software enabling cell/module/pack communication need to be developed. IoT technologies connected to the BMS reduce the computational resources significantly, save space and time for data storage, and improves security. Finally, manufacturing processes of modules and their easy and efficient integration into packs need to consider the choice of materials and requirements related to safety, quality, and fast and cost-efficient fabrication.
HELIOS addresses the need for increasing the density of battery packs in terms of weight and package space to improve the performance and range of EVs fleets utilised in growing urban electromobility models. A hybrid approach combining different Li-ion modules within the battery pack is developed to maximise energy and power capabilities depending on the application while optimising dimensioning. This hybrid configuration of the battery pack influences the electrical and thermal behaviour of the system. It also affects the design of the thermal management system, as well as the overall configuration of the different components and sub-systems within the battery pack. The proposed battery pack design makes use of advanced materials in the structural components, such as polymers and composites, to enhance mechanical resistance and lightweight, as well as in the thermal management system. Optimised designs for the electric and thermal management systems, casing and insulation, wiring, and other structural components, are reduced within the battery packs.
In HELIOS, the architecture of the different Li-ion modules, the electrical connections, current collectors, and wiring are optimised to ensure high efficiency, cost, and compact design. Advanced concepts of BMS relating to hardware and software enabling cell/module/pack communication need to be developed. IoT technologies connected to the BMS reduce the computational resources significantly, save space and time for data storage, and improves security. Finally, manufacturing processes of modules and their easy and efficient integration into packs need to consider the choice of materials and requirements related to safety, quality, and fast and cost-efficient fabrication.
• All components for battery modules in variant for HP and HE cells were fabricated.
• Assembly verification and system integration of produced prototypes were performed and detailed documentation was drawn.
• Sub pack structure which accommodates modules were fabricated and modules integration was verified. Detailed documentation was also completed.
• Pending assembly check of the heat exchanger from BTMS and high voltage interfaces to finalize the prototyping task. In fact none or only fine tune changes are expected
• Distinct PCM alternatives were surveyed and supplied to IIT for passive cooling testing.
• Thermal conductivity measurements on 4 PCM (RT42, RT38, RT35HC, SP31) with copper mesh performed at KIT.
• Effect of PCM melting temperature on battery cooling was experimented for various working conditions.
• Effect of copper foam on battery cooling was experimented for various working conditions.
• Effect of implementing PCM block on rest period for a battery was studied.
• Different TMS designs are studied and compared.
• Heat exchanger optimized.
• High energy battery subpack design finalized.
• High Energy Battery subpack BTMS modelled and simulated by IIT.
• Early result database for thermal model is developed.
• Further reference performance, thermal and safety tests have been performed on HP cells at KIT, DTI, ZSW.
• Dynamic performance (compressed real-driving-emissions) cyclic tests have been performed for HP cells at DTI.
• OCV curves have been recorded for HP cells at DTI and KIT
• ZSW has finalized the safety tests for Toshiba and Farasis cells.
• Thermal, electric (ECM) and ageing models have been established for HE and HP cells
• Algorithms for SOC estimation (dual EKF and RLS) and SOH (capacity and internal resistance) established.
• FMEA on cell level was performed, failure dictionary was produced.
• Digital twin: Digital shadow of a hybrid cell model created and run with a simple EMS strategy.
• A simulation of thermal runaway and thermal propagation has been developed at ZSW for Farasis cells applied in the Helios project.
• Balancing system was analysed by UPC and VT and balancing control from the BMS decided.
• Wireless communication between BMU and CMU was performed and tested by VT.
• The development of the back-end and front-end modules of the IoT Platform in T6.3 have been completed too, open to changes in data sets and needs, and deliverable D6.3 was submitted on time.
• DTaaS, the Digital Twin Platform being implemented in T6.4 is successfully advancing in its roadmap and already running a a digital twin consisting of hybrid cell models and a simple EMS that makes the models work together
• Assembly verification and system integration of produced prototypes were performed and detailed documentation was drawn.
• Sub pack structure which accommodates modules were fabricated and modules integration was verified. Detailed documentation was also completed.
• Pending assembly check of the heat exchanger from BTMS and high voltage interfaces to finalize the prototyping task. In fact none or only fine tune changes are expected
• Distinct PCM alternatives were surveyed and supplied to IIT for passive cooling testing.
• Thermal conductivity measurements on 4 PCM (RT42, RT38, RT35HC, SP31) with copper mesh performed at KIT.
• Effect of PCM melting temperature on battery cooling was experimented for various working conditions.
• Effect of copper foam on battery cooling was experimented for various working conditions.
• Effect of implementing PCM block on rest period for a battery was studied.
• Different TMS designs are studied and compared.
• Heat exchanger optimized.
• High energy battery subpack design finalized.
• High Energy Battery subpack BTMS modelled and simulated by IIT.
• Early result database for thermal model is developed.
• Further reference performance, thermal and safety tests have been performed on HP cells at KIT, DTI, ZSW.
• Dynamic performance (compressed real-driving-emissions) cyclic tests have been performed for HP cells at DTI.
• OCV curves have been recorded for HP cells at DTI and KIT
• ZSW has finalized the safety tests for Toshiba and Farasis cells.
• Thermal, electric (ECM) and ageing models have been established for HE and HP cells
• Algorithms for SOC estimation (dual EKF and RLS) and SOH (capacity and internal resistance) established.
• FMEA on cell level was performed, failure dictionary was produced.
• Digital twin: Digital shadow of a hybrid cell model created and run with a simple EMS strategy.
• A simulation of thermal runaway and thermal propagation has been developed at ZSW for Farasis cells applied in the Helios project.
• Balancing system was analysed by UPC and VT and balancing control from the BMS decided.
• Wireless communication between BMU and CMU was performed and tested by VT.
• The development of the back-end and front-end modules of the IoT Platform in T6.3 have been completed too, open to changes in data sets and needs, and deliverable D6.3 was submitted on time.
• DTaaS, the Digital Twin Platform being implemented in T6.4 is successfully advancing in its roadmap and already running a a digital twin consisting of hybrid cell models and a simple EMS that makes the models work together
Progress beyond state of the art:
• Hybrid module configuration battery packs, integrating LFP and NMC cells
• Advanced polymers and composite material for structural components, housing and insulation
• Hybrid thermal management system integrating tab and surface cooling with PCMs
• Multilevel converters for the efficient management of energy and power
• Multilevel converters for modularity, scalability and adaptability to the powertrain
• In-vehicle AC-DC converters for ultra-fast charge
• Improved charging protocols and communications
• Improved state estimation methodologies, SOC and SOH
• Improved control and health management strategies
• Development of BMS with enhanced functionalities for state estimation and connectivity
• DC-DC converter for cell balancing
• AI algorithms for improved PHM embedded in the datAssistTM IoT software platform
• Digital twins for performance and process circularity optimisation
• LCCA tool for circular economy of Li-ion battery packs
• V2G communication protocols for 1st and 2nd life battery pack utilisation
• Big data analysis and IoTs applied to the management of performance and carbon footprint of EV fleets
• Multisensing units integrated in the BMS for measurement of multiple parameters
• Gas sensors for early detection of CO, VOCs, etc
• Active and passive balancing system
IMPACT-1: Considerably improved performance of the EV through reduced battery system weight by 20% at constant electric vehicle range for mid-size battery electric car
IMPACT-2: Overcome the uncertainty of range by achieving 25% shorter recharging time with a 150kW charger compared to the best-in-class electric car available on the market in 2018. The demonstrator must have the same battery capacity as the reference car and meet the useful battery life mentioned below
IMPACT-3: Improved attractiveness of the EV through achieving extended useful battery life to 300 000 km in real driving[1] referring to a mid-size passenger car using improved battery management, balancing and thermal management during high-power charging/discharging
IMPACT-4: Contribution to Circular Economy goals through a minimum 20% Life Cycle Analysis improvement compared to existing products
IMPACT-5: Considerably improved knowledge on the module and pack sensorisation and thermal management
• Hybrid module configuration battery packs, integrating LFP and NMC cells
• Advanced polymers and composite material for structural components, housing and insulation
• Hybrid thermal management system integrating tab and surface cooling with PCMs
• Multilevel converters for the efficient management of energy and power
• Multilevel converters for modularity, scalability and adaptability to the powertrain
• In-vehicle AC-DC converters for ultra-fast charge
• Improved charging protocols and communications
• Improved state estimation methodologies, SOC and SOH
• Improved control and health management strategies
• Development of BMS with enhanced functionalities for state estimation and connectivity
• DC-DC converter for cell balancing
• AI algorithms for improved PHM embedded in the datAssistTM IoT software platform
• Digital twins for performance and process circularity optimisation
• LCCA tool for circular economy of Li-ion battery packs
• V2G communication protocols for 1st and 2nd life battery pack utilisation
• Big data analysis and IoTs applied to the management of performance and carbon footprint of EV fleets
• Multisensing units integrated in the BMS for measurement of multiple parameters
• Gas sensors for early detection of CO, VOCs, etc
• Active and passive balancing system
IMPACT-1: Considerably improved performance of the EV through reduced battery system weight by 20% at constant electric vehicle range for mid-size battery electric car
IMPACT-2: Overcome the uncertainty of range by achieving 25% shorter recharging time with a 150kW charger compared to the best-in-class electric car available on the market in 2018. The demonstrator must have the same battery capacity as the reference car and meet the useful battery life mentioned below
IMPACT-3: Improved attractiveness of the EV through achieving extended useful battery life to 300 000 km in real driving[1] referring to a mid-size passenger car using improved battery management, balancing and thermal management during high-power charging/discharging
IMPACT-4: Contribution to Circular Economy goals through a minimum 20% Life Cycle Analysis improvement compared to existing products
IMPACT-5: Considerably improved knowledge on the module and pack sensorisation and thermal management