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OSEM-EV - Optimised and Systematic Energy Management in Electric Vehicles

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EGVIA - ERTRAC 1st European Conference Results from Road Transport Research in H2020 projects
29 November 2017 to 30 November 2017
Brussels

Published in: Automotive
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OSEM-EV - Optimised and Systematic Energy Management in Electric Vehicles

  1. 1. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 Reiner John Less emissions, and congestion more comfort and safety
  2. 2. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 OSEM-EV is taking a leap towards 3rd and 4th Generation Intelligent Electric Vehicle with a value-based functional integration of electro-thermal energies
  3. 3. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 EGVI GV2-Call 2014 Optimised and systematic energy management in electric vehicles” Concerns and objectives § “Range limitation, due to the limited storage capacity of electric batteries […]” § “In extreme conditions up to 50% of the batteries' capacity is absorbed by [auxiliary equipment]“ Improvements 1. Comprehensive thermal management system 2. Battery life duration enhancement (as a side effect of thermal management) 3. Energy efficiency of electrified accessories 4. Energy harvesting functions and automated and eco-driving strategies
  4. 4. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 Predictable mileage
  5. 5. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 Team and target
  6. 6. 1 Predictable mileage Systematic control of electro-thermal energy flows 2 Driving range increase Intrinsic higher battery performance and capacity, higher powertrain efficiency, energy density at same cost 3 Battery thermal endurance Optimal operating conditions and intersystem operability 4 Battery lifetime prolongation Peak and pulse performances in driving, charging and recuperation phases 5 Affordable battery capacity Downsizing 6 Thermal preconditioning Powertrain and compartment heating/cooling to optimal operation range 7 Thermal insulation materials Reduced thermal energy demand 8 Functional thermal network Integration of subsystems for reduced size, weight and cost 9 Coupled electro-thermal architecture Systematic subsystem electro-thermal management 10 Electro-thermal energy management Control algorithms and computing platform for energy storage, reuse, substitution and harvesting
  7. 7. This is property of Osem-EV
  8. 8. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 OSEM.EV models virtual vehicle of all categories and demonstrates two real vehicles
  9. 9. OSEM-EV-SC2Feb 8th, 2017 9 Direct with dual heat sources Heating mode Waste heat Ambient heat
  10. 10. OSEM-EV-SC2Feb 8th, 2017 10 Indirect with dual heat sources Heating mode Waste heat Ambient heat Integrated heat pump Secondary cabin heating/cooling loop
  11. 11. OSEM-EV-SC2Feb 8th, 2017 11 Different solutions were proposed and analyzed: ØAlternative thermal management architectures with heat pump ØInfluence of thermal mass (direct copper cooling) ØInfluence of coolant management § Maximum coolant flowrate § Reduced flowrate Ø Effect of machine and inverter cooling by AC system in hot weather conditions (on-going) Ø Influence of new cooling methods on lifetime of components (e.g. oil cooling) Thermal management systems for powertrain Q: How can the powertrain help to improve the overall energy management of the EV?
  12. 12. OSEM-EV-SC2Feb 8th, 2017 12 Schematization of the Powertrain TE-MCU VE-MCU Adding computation power to the powertrain for thermal management. Thermal management CPU interfaces with e-motor control Heat pump Battery
  13. 13. Battery System Overview System Architecture n System power and energy n 96 Cells à 94Ah (Geometry: Prismatic BEV4, Chemistry: NMC/Graphite) n Total energy content: 33kWh n Max. continuous power: 120kW 2016-02-08 13OSEM-EV n Battery system thermally insulated for all-time controlled energy exchange with the other components of the car n Battery pack and battery system electronics can be installed separately and connected afterwards leading to a flexible installation of the battery system
  14. 14. Design of the Battery Module 14OSEM-EV Battery module without top frame Fraunhofer IISB Assembled battery module 12s1p battery module without cover lid 2016-02-08 Module overhead: n Weight 5kg / 20% n Volume 3L / 25%
  15. 15. WP 5 WP 3 WP 1 Supply Chain 3 – Tasks 15OSEM-EV WP 3 Requirements • Mechanical requirements and specifications - installing space - vertical and lateral coil offset - structural part requirements • Electrical requirements and specifications - voltage levels - interfaces - switching frequency • EMF • Functionality • Temperatures • Communication protocol System Setup • Magnetic field simulations • Coil parameter - windings - diameter - litz wire • Thermal & Electric Design - currents, losses Mechanical Design • Mechanical design • Embedding process • Materials • Thermal design Electrical Design • Driver stage • Connectors • Circuit Simulation • Control logic and algorithms • Communication interfaces HIL – test bench • HIL test bench with battery as source and sink for application related testing • Efficiency and loss analysis • EMV tests
  16. 16. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 Qualified and quantified targets Competitive Advantage of European automotive industry Increased electro-thermal performance and reduced costs of automotive subsystems and the overall EVs produced in Europe Cost -20% Productivity +5% Value proposition and customer satisfaction drives increased production numbers of European EVs Production volume per year ahead of current track +0.5% Improved usability by range increase and predictable mileage Range +10% Pred. mileage +20% Significant improvement on safety and comfort + 60 % Sustainability Improved total energy efficiency of the EV + 30 %
  17. 17. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 OSEM.EV is focused on 2 real car demonstrators LEV for food delivery Daimler B-class
  18. 18. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 723970 Thank you Enjoy Life with fresh food with less emissions through electrified mobility Acknowledgment: This project has received funding from the European Union's Horizon 2020 Programme under Grant Agreement No. 653514

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