AABC 2014 - AABTAM Symposium: Advanced Automotive Battery Technology, Application and Market - Session 3

Lithium-Ion Batteries for High-Voltage Hybrids and PHEVs

Lithium Ion is increasing its market share in conventional high-voltage hybrids and has become the predominant battery technology to power the emerging plug-in hybrids. Cell chemistry and mechanical design vary among developers as they try to balance safety, durability, performance, and cost to improve the value proposition of the technology. In this session, automotive battery technology specialists will present design and performance data from their HEV and PHEV offerings and discuss the chosen designs.

Session Chairman:

Dr. Matthias Ullrich manages advanced battery technology at Volkswagen AG where he is in charge of the predevelopment of battery technology and development of battery modular concepts with a focus on management system, safety, and life. From 1994 to 2000 he was with VARTA where he worked on lithium ion cells development and automotive battery systems.
 

1. Toyota Batteries for HEV and PHEV Applications
   Hitoshi Sakai, Assistant Manager, and Kazuo Tojima, Senior Staff Engineer - Energy Device Dept., Battery Material Engineering Div., Toyota Motor Corp.
   Abstract 

   

   Toyota Motor Co. launched the Prius in 1997.  Since this launch, we have focused significant efforts into better understanding the performance required from a battery for hybrid applications and designing a battery to match these requirements.  As a result, the NiMH battery pack has gone through iterative design changes with every new generation of vehicle.  Now, we are on a similar trajectory for Li-ion battery. By using demonstrations fleets, we acquired some fundamental understanding of the performance of Li-ion batteries in vehicle applications.  This work resulted in the launch of Toyota HV, PHEV and EV models with Li-ion batteries.  This presentation will discuss the development status of Li-ion battery for Toyota’s hybrid vehicles, including our development of the safety evaluation methods and evaluation results.

   1. Development of TMC’s Hybrid and electric Vehicle
   2. Introduction of the Lithium-ion cell and the battery pack
   3. Toyota’s safety concept for traction batteries
   4. Safety evaluation method for Li-ion cell and battery pack
   5. Results of the Lithium-ion cell and battery pack safety evaluation
   6. Collection and ecology method for after used battery

   Close Abstract
2. Battery System for the Accord HEV and PHEV
   Ryoji Takenawa, Assistant Chief Engineer, Automobile R&D Center, Honda R&D
   Abstract 

   

   A highly efficient two-motor SPORT HYBRID i-MMD system is developed to satisfy the global demands of CO₂ reduction. In order to fill the vehicles demand as the SPORT HYBRID i-MMD, the battery which secures larger capacity and higher output as compared to previous HEV is installed in 2014 Accord Hybrid and Accord plug-in Hybrid. This battery pack which is carried out the weight reduction has attained high durability and safety in consideration of the characteristic of a lithium-ion battery. The new battery system has contributed to achieving the superior fuel economy and the sufficient driving performance.

   • Summary of Battery System for HONDA Accord Hybrid and plug-in Hybrid
   • Lithium-ion Battery System
     • SPORT HYBRID Battery Pack
         -Pack Design
         -Module Design
     • Plug-in HYBRID Battery Pack
         -Pack Design
         -Cooling System
     • Battery Cell
         -Cell Design
         -Durability Management
     • Safety Management
      
   • Conclusion

   Close Abstract
3. Providing EV Value to EREV and PHEV Vehicles
   Andy Leutheuser, Engineering Group Manager – Battery Systems, General Motors
   Abstract 

   

   While the industry makes progress developing lower cost, lower mass, and smaller batteries for the plug-in vehicle market, the vehicles must be developed and tuned to capitalize on the inherent benefits and customer satisfying characteristics that electric vehicles enable. Playing up the vehicle traits that excite and delight customers in addition to the more traditional value, political, and environmental reasons for consideration and purchase can help accelerate market acceptance. The presentation will touch upon the customer loss functions for electric range, power, instant response, linearity of acceleration, noise vibration and harshness, and engine/generator moding. Examples from the “Best of Both Worlds” Chevrolet Volt and the “Pure.Electric.Fun” Chevrolet Spark will be reviewed.

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4. xEV Battery Technology and Market
   Menahem Anderman, President, Advanced Automotive Batteries
   Abstract 

   

   This presentation will provide a brief overview of battery storage requirements and solutions for the key xEV architectures including:

   1. 14V micro-2 hybrids
   2. 48V mild-1 hybrids
   3. 40V to 120V mild-2 hybrids
   4. Moderate and strong hybrids at over 120V
   5. PHEVs (including extended-range EV)
   6. Low-range EVs (up to 100 miles)
   7. Longer-range EVs (150 miles and over)

   The presentation will end with vehicle- and battery-market forecasts by key supplier.

   Close Abstract
5. Battery System for the Porsche Panamera Plug-in Hybrid
   Juergen Hofmann, Head of Energy Management and High Voltage, Porsche
   Abstract 

   

   The Plug-In-Technology is the next key aspect of the E-Mobility-Strategy at Porsche. The Panamera Plug-In-Hybrid is a parallel Plug-In-Hybrid and promises one thing above all: sporty performance with utmost efficiency. The synchronized interaction of the combustion engine, electric machine and high-voltage battery guarantee smooth processes to concentrate what matters the most: driving.

   The main component for hybrid technology is the high-voltage lithium-ion battery with 104 cells. This battery is recharged in around 2.5 hours via direct connection to a 240 Volt household socket. Beyond that recharging can be effected whilst driving through the process of braking energy (recuperation) or via the combustion engine. The innovative lithium-ion technology stores energy with its capacity of 9.4 kWh.

   This presentation outlines the importance of the Plug-In-Concept at Porsche and illustrates the mechanical components as well as the functionality of the battery system for the Porsche Panamera Plug-In-Hybrid.

   • Porsche Plug-In-Concept
   • Porsche Panamera Plug-In-Hybrid
   • Battery system
     • Battery concept and subcomponents
     • Modular battery set-up
     • Key functionalities of the battery system
      

   This presentation concludes with a short summary and discussion about the battery system for the Porsche Panamera Plug-In-Hybrid.

   Close Abstract
6. Safe Batteries? How to Tell
   Ted Miller, Senior Manager of Energy Storage Strategy and Research, Ford Motor Co.
   Abstract 

   

   Vehicle electrification is an important means of reducing transportation fuel consumption and greenhouse gas emissions.  Powertrain electrification can not only improve efficiency, it can also capture otherwise lost vehicle energy. It is obvious that advanced lithium ion rechargeable energy storage systems (RESS) are critical to vehicle electrification. This talk will consider an approach to assessing RESS safety performance within the context of vehicle safety qualification, and the need for design tools to inform the same in the future. The efforts undertaken by the Ford Energy Storage and Materials Research Team on several parallel fronts will be discussed in detail.

   Key topics to be presented include:

   • RESS project overview
   • RESS fault analysis update
   • Test method update
   • Test hardware description
   • RESS project status and plans
   • Ford battery safety research
   • Battery safety performance assessment tools

   Close Abstract