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Commercialization of a battery system for the premium car segment - from digital twin to product
- 1. Commercialization of a battery system for the premium car segment – from digital twin to product 28.04.2021 I Dr. Grzegorz Ombach, EVP at DRÄXLMAIER Group
- 2. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 2 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 3. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 3 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 4. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 4 DRÄXLMAIER – Systems Partner for Electrical Mobility Battery Systems and High Voltage Parts Individually configured products, from development up to production LV Battery Systems HV Battery Systems HV Control Boxes Systems Partner DRÄXLMAIER Group
- 5. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 5 Full speed towards e-mobility In Ten Years from 0 to 800 Volt
- 6. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 6 DRÄXLMAIER HV battery systems DRÄXLMAIER HV switch boxes DRÄXLMAIER charge port DRÄXLMAIER HV harness DRÄXLMAIER HV connectors DRÄXLMAIER HV electronics DRÄXLMAIER HV-systems
- 7. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 7 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 8. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 8 Passenger vehicles Sales Forecast ICE vs. EV worldwide 2020-2032 62.3 66.6 68.4 70.1 71.6 72.7 73.2 73.0 72.1 71.3 69.8 68.2 66.2 6.0 9.4 12.4 14.1 16.0 17.5 19.1 21.0 23.5 25.7 28.2 30.5 33.3 0 10 20 30 40 50 60 70 80 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 Mio. ICE/48V EV Source: LMCA Global Light Vehicle Sales Forecast Q4/2020
- 9. Number of BEV-models available worldwide 2017-2030 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 9 Passenger vehicles Source: LMCA Global Light Vehicle Sales Forecast Q4/2020
- 10. Regional Sales Forecast EV worldwide 2020-2032 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group Overall Sales 2032 2020 6,0 Mio. 33,3 Mio. China 1,8 9,0 Europe 2,0 12,4 North America 0,8 4,4 Japan 0,9 1,6 RoW 0,5 5,9 Passenger vehicles Source: LMCA Global Light Vehicle Sales Forecast Q4/2020
- 11. Production Capacity Battery Cells 2020-2030 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 11 Source: VDI/VDE production capacity growth up to 2100 GWh/a predicted by cell suppliers until 2030 (Europe: 595 GWh/a) Europe 29% North America 10% Asia 60% RoW 1% [GWh/a]
- 12. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 12 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 13. Trends Electric Passenger Vehicles 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 13 Range > 500 km Super Fast Charging 800 V // > 350 kW Second Life and Recycling refurbishment // alternative applications Lifespan optimized cooling configurations Building Blocks degrease in production costs // new production processes Energy Density cell to pack // cell to chassis // new formfactors // new cell chemistries Cost Reduction material costs // volume // production costs Diagnostics and Data data management // digital production twin // digital product twin
- 14. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 14 Trends Electric Cargo Vehicles Fuel-cell-hybrid Trucks • Long haul usage • Heavy duty → Overall design goal for HV-battery: optimum interaction with fuel cell (recuperation, cyclisation etc.) BEV Trucks • Short haul usage (regional distribution, last mile transport etc.) • Light duty → Overall design goal for HV-battery: energy density (gravimetric) Sources: Daimler Trucks, Nikola Motor Company
- 15. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 15 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 16. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 16 From cell-to-module to cell-to-chassis Vertical Integration Material Cell Module Battery System Electric Motor Power Electronics Integrated Powertrain Full Vehicle OEM Cell Supplier Tier1 Supplier Sources: insideEVs, CleanTechnica, Tesla Cell-to-module Cell-to-pack Cell-to-chassis
- 17. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 17 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 18. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 18 All rights reserved. Distribution within DRÄXLMAIER Group, customer and partners. Key development aspects High-Performance HV-Battery Source: Audi Mediacenter Depth of added value • Concept development • Validation, testing • Series development • Industrialization • Production • Spare part service • Recycling
- 19. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 19 Porsche Taycan battery system 800V-Technology in Series made by DRÄXLMAIER 0-100 km/h: < 3,5 s Range: > 500 km Charging Time: 100 km / 4min Source: Bild (Taycan-Forum)
- 20. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 20 ICE vs. 400V-BEV vs. 800V-BEV Charging Time ~ 10 min ~ 30 min ~ 12 min ICE 800 Volt BEV > 150 kW > 300 kW 400 Volt BEV Refueling/Charging Time
- 21. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 21 All rights reserved. Distribution within DRÄXLMAIER Group, customer and partners. Virtual production launch Porsche Taycan HV-Battery • Production Volume • Production Downtime • Overall Operations Effe ctiveness (OOE) • Overall Equipment Effectiveness (OEE) • Total Effective Equipment Performance (TEEP) https://youtu.be/5qKkv86PJsM
- 22. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 22 All rights reserved. Distribution within DRÄXLMAIER Group, customer and partners. Series production in Sachsenheim Porsche Taycan HV-Battery Automated Connected Flexible Resource-saving Cost-efficient https://youtu.be/QeNl5dM3cSs
- 23. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 23 Agenda DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 24. 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group 24 All rights reserved. Distribution within DRÄXLMAIER Group, customer and partners. Data Backbone Car Floor ((Pre-)Series) Digital Twin Performance Twin Product Twin Shop Floor Office Floor OEM Cloud Telemetry data Manufaturing data DRX Cloud Engineering Data (e.g. CAD) 2-tier Cloud Production Twin
- 25. Agenda 28.04.2021 Commercialization of a battery system for the premium car segment - from digital twin to product | Dr. Grzegorz Ombach I DRÄXLMAIER Group DRÄXLMAIER E-Mobility Portfolio 1. Market Overview 2. Requirements to Create Customer Value 3. End-to-end Value Chain 4. High Performance Battery Systems 5. Digital Twins 6. Summary and Q&A 7.
- 26. www.draexlmaier.com DRÄXLMAIER Group T Dr. Grzegorz Ombach Executive Vice President Head of Group Development Head of Market Battery +49 8741 47-1119 grzegorz.ombach@draexlmaier.com www.linkedin.com/in/grzegorz-ombach
Editor's Notes
- Good morning dear participants virtual batteries event 2020. Thank you for having me. My name is Grzegorz Ombach and I am responsible for battery systems at company DRX. Almost every day we hear news about battery industry. Today Ford announced plans to invest $185 million into a new battery lab as a step toward manufacturing its own battery cells for electric vehicles. The funds will go toward constructing Ford Ion Park, a 200,000-square-foot production "pilot facility" that's expected to open by the end of next year in metro Detroit. Also a few days ago Porsche wants to build its own battery cell factory for the production of “high-performance batteries” in Tübingen, Germany. Although the Stuttgart-based sports car manufacturer plans to purchase batteries for its electric cars from parent company Volkswagen in the future, high-performance cells – that is “a Porsche domain”. A lot of movement in automotive, battery area. Today I would like to exchange with you my experience from a battery system commercialization for high performance vehicle and also touch on digital twin and data. I have a chance to be in this industry for about 20 years. I worked on various aspects like electric powertrain at Siemens VDO and Brose, charging sollutions with wireless charging by Qualcomm and now working on battery systems at Drx. To design and built high performence battery system many parameters have to be taken into account. But there are four main key parameters like Cell, Cooling, Electronics and Data, which in my opinion are the key. Let‘s start our jurney in to the battery world.
- The mobility of the future is one of the greatest challenges of our time. We are continuously developing electrical mobility, with the goal of unlimited, emission-free transportation for all. In the area of battery systems and high-voltage components, the DRÄXLMAIER Group develops and produces the high-voltage battery systems and components, modules for both high-voltage and low-voltage (less than 60 volts) battery systems, and offers tailor-made solutions for this, from development up to production. We meet the highest automotive requirements. Our systems can be designed specifically for each customer, and different performance requirements can be configured individually. We offer integration of complete battery electronics, battery status detection with permanent monitoring for voltage, current, and temperature, as well as vehicle integration optimized for the installation space.
- It was more then 10 years ago where Mr Drx and Dr. Gall our CTO, co CEO decided to invest in this area. Our first E-mobility project entailed developing the overall system for the Audi R8 e-tron. That was followed by a whole series of other projects in which we developed solutions for a wide variety of our customers’ car models. Based on a whole decade of experience and know-how, battery systems have become one of our core competences. Series production of the overall battery system for the Porsche Taycan is another milestone in the history of our E-mobility.
- It is also important to mention that we delivered more then 1 Million parts in area of e-mobility from battery systems, switch boxes, BMC and CMC, connectors, HV harness and very important charging ports.
- Today we know that e-mobility is a fact and we hear and see all various annoucments from various global OEMs, like BMW Daimler VW JLR And others, moving during next decade towards pure EV and closing 100 years of combastioon era. Very exciting times for all involved. Around 2028 about 100 milion cars on the road
- This is a good example where we see that many new EV models are coming and with this also many new batteries
- If we look from regional perspective EU will be the biggest market for Evs with about 12M cars in 2032 and China 9 and NA 4.4
- Europe wants to mirror the supply chain in Asia, where battery producers and auto manufacturers are in regional proximity. This ensures timely deliveries, reduced costs, closeness to the consumer and less risk of disruption to supply. There are many new electric battery - gigafactories which are planned in EU and should reach capacity of about 600GWh /a, which would put the battery production closer to car manufacturers as well as closer to a large market where the vehicles will be sold. One important aspect is sustainability in supply chain. It is also translated into regulations determining how batteries are manufactured, material sourcing practices, using green power in production, or mandatory recycling targets. European EV manufacturers are reliant on raw material imports. Most raw materials come from outside of Europe - mainly Asia, Africa, Australia - while the main battery production facilities are today in Asia. All of these separate moving parts have created a long supply chain with an equally heavy carbon footprint. And this has to be optimized. Wir wissen dass die Anzahl der angebotenen BEV-Modelle weltweit bis 2030 stark steigen wird Laut der neusten LMCA Ermittlung ist es mit dem stärksten Anstieg zwischen 2021 und 2023 zu rechnen
- Let’s look from end customer perspective, he needs by EV: range 500+km faster charging – high power life span Safety Continued advancements in cell technology will allow EVs to gain traction. It is expected about 100 million EVs installed by 2028. Recent research around lithium-based chemistries where focused on providing better fire resistance, higher energy density, higher power density, and longer life spans. Li-ion battery will still continue to progress, but it will be solid-state and lithium-silicon technologies that will be the real game changer. And we see that numerous investments from OEMs such as Volkswagen, BMW, Daimler and Tesla, in solid-state technology and lithium-silicon technology companies, including QuantumScape, Solid Power, Enevate and Sila Nanotechnologies. The only way to significantly advance energy density is to add silicon to the Li-ion battery and today it is incremental improvement what will enable energy density increases to 300 Wh/kg over the next 3-5 years On the other hand Silicon-dominant batteries e.g. with nanowire technology would enable energy densities of up to 400 Wh/kg by 2025 with very good high power charging capabilities more than 300 kW Therefore I think, Silicon dominant anodes will be the primary solution until 2025 when solid-state battery will start to be deployed and reach commercialization. Solid-state batteries will enable energy densities of at least 500 Wh/kg and will offer very high charging power over 500 kW+ Lithium-silicon and solid-state are the future technologies that will improve performance, hold more energy, and last longer at a lower cost. And all of this we will see during the next decade.
- BEV is all about energy density FC is about power, importatnt for recuperation capability
- What we see today is that car manufactures are following Tesla/BYD model with downstream integration, with own battery fabs or close collaborations, e.g. Porsche, VW, BMW… And Cell suppliers upstream integration, from cell to module to pack, In 2020 about 80% batteries are from Asia and in 2030 this will be still above 65%.
- System Know-how needed to develop battery system for high performance vehicle Stuctural, Vibration, Crush and Crash Electric Electronics EMI EMC NVH Thermal Safety and Security Data
- Cell Cooling Electronics Data https://www.taycanforum.com/threads/our-2020-porsche-taycan-preview-renderings.16/
- Production Volume. Production Downtime. Production Costs. Overall Operations Effectiveness (OOE) Overall Equipment Effectiveness (OEE) Total Effective Equipment Performance (TEEP) Capacity Utilization. AGV
- GAIA X EU data infrustructure
- To summerize, market is very volatil and will remain so for the next few years. Role of Cell suplier, Tier 1 and OEM is changing and new structure of supply chain will be created. The key aspects which drive perfomrence of battery systems are Cell, Cooling, Electronics and Data. In addtion, industralization concept, repair concept and recycling concept are the key to build sustainable battery for the future.