Battery Management System Development For Evolving Hybrid Markets from ISG Imagine Your Future Workshop for Manufacturing Enterprises

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Proprietary and Confidential. No part of this document may be reproduced in any form or by any electronic or mechanical means,
including information storage and retrieval devices or systems, without prior written permission from Information Services Group, Inc.
19 November 2015
Alind Saxena
Business Head, Transportation, Americas from L&T Technology Services
Hurley Davis
Director Software Development from A123 Systems
Battery Management System
Development
For Evolving Hybrid Markets
#ISGSmartalks @ISG_News

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1. About Hybrid Electric Vehicles Market
2. How we Help our Customers
3. And Who we are…!
Agenda

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Of the 4,192 cars produced
in the United States 28 %
were Electric Vehicles
Did you Know ?
La Jamais Contente
An Electric vehicle &
The First automobile to
reach 100 km/hr in 1899
The Fastest land vehicle % Electric vehicle
Till 1900 AD was… produced in 1900 in USA

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Demand for Electrified Propulsion is Increasing
2.5% 2.6% 2.8% 2.9% 3.0% 3.0% 3.0%
0.2%
0.4%
0.5% 0.7% 0.8% 0.9% 1.0%
0.3%
0.4%
0.4%
0.5%
0.6% 0.6% 0.6%0.01%
0.01%
0.01% 0.01%
2014 2015 2016 2017 2018 2019 2020
Full/Mild Hybrid Plug-in Hybrid Battery EV's Fuel Cell
Electrified Powertrain Production
forecast 2011-2020
4.6% of total powertrain production worldwide to be ELECTRIC
Source: KPMG
90
95
100 104 107 111
2015 2016 2017 2018 2019 2020
Outlook on worldwide
light vehicle sales (Mn)
Source: Statista

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What are the key Challenges in EV’s Today ?
Time to Fully charge a EV
Weight to Wattage Ratio
Minimise power loss in
Conversions
Safety and battery protectionOverall System Cost
1 2
3
4 5

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How are we helping to address these challenges?
• Develop low-voltage batteries
(12V, 48V) for micro-hybrids
• UltraPhosphate™ Lithium-Ion
Technology enables 60%
weight reduction over lead-acid
• Technology Support across
the product life cycle
A123 Systems L&T Technology Services
• Safety Standards Complaint
Design Frameworks (e.g.,
SafeX ™)

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Electric Vehicle Critical Systems
Battery & Management Systems
 Need for Greater Energy Efficiency
 High Power to Energy Ratio
Inverter
 Adoption of new materials and control
algorithms for greater performance
Infrastructure
 Need for affordable, convenient, and
compatible options for charging
Stations
DC/DC
 High efficiency, compact size,
lightweight and reliability of
converters

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1. About Hybrid Electric Vehicles Market
2. How we Help our Customers
3. And Who we are…!
Agenda

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A123 Designs & Engineers Leading Edge Battery Systems
► Scalable Prismatic and Cylindrical Modules
► Battery Control Module (BCM)
► Electrical Distribution Module (EDM)
► Current Sense Module (CSM)
► Battery Management and Controls
► Pack Enclosure Systems with Integrated Cooling
PHEV/EV & HEV Modules EDM+CSMBCM
A123 designs battery systems that push the envelope on efficiency

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Technology Solutions leading to more benefits
►UltraPhosphate™ Lithium-Ion Technology
 Outstanding cold cranking power
 Outperforms lead-acid technologies
 Exceptional cycle-life
 High charge acceptance
 60% weight reduction over lead-acid
 Solution for start-stop and
recuperation demands
 Compact solution
 Supports fuel savings initiatives
 Powerful charge acceptance
 Potential to eliminate cooling system
 Supports engine downsizing and
electric supercharging
 Solution for start-stop and
recuperation demands
12V Starter Battery 48V Battery

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L&T TS is Fully aligned with the right Technology
 Software design / development / Maintenance
 Software FMEA, Code optimization
 Model based design & development
 Diagnostics – UDS, OBDII, J1939
 Hardware & EMC design / development
 DFMEA, Hazard Analysis,Worst case circuit analysis
 Value engineering for combining PCBs, cost reduction in each
board
 PSPICE simulation and verification for complex circuits and
transient immunity analysis
 Safety critical projects - SIL, ISO 26262
 Independent testing/validation
 Verification & Validation – Unit Testing, Software Testing, System
Testing
 Hardware Testing – Module testing, environmental testing
 Test Automation
 Complete Product Development from Concept to Prototype
 CAD – Modeling, Drafting,
 CAE – FEM, FEA,Thermal Analysis
 CFD – Cooling Analysis
Software
Development
Hardware
Development
Testing
Mechanical
Engineering
Battery Management System

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L&T TS BMS Functional Safety Framework (SafeX ™)
Functional Safety ISO 26262 Framework
Design partner for functional safety ASIL B/C/D Compliance.
SafeX
Battery pack system level
Experience
Analog signal conditioning
Adherence to SAE and OEM
standards for Hybrid Electric
Vehicles
High Voltage and High Current
Experience
Battery Technology ( Lead Acid ,
Li-ion, NiMH, NiCD)
Functional Safety ISO26262
compliant Designs

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1. About Hybrid Electric Vehicles Market
2. How we Help our Customers
3. And Who we are…!
Agenda

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14
About us: A123 Systems LLC
► Corporate headquarters: Livonia, Michigan
► Approximately 2,000 employees worldwide, $250M+
revenue
► Mass producing millions of batteries per year since 2006
► 1.5 GWh of manufacturing capacity by 2018
► 400+ patents and patent applications
A123 Systems is a worldwide leader in providing complete
Lithium-ion Energy Storage Solutions

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About Us: L&T Technology Services
Industrial/
Medical
Transportation
Process
Industries
Telecom/
Hi-Tech
Major Verticals Connected VehicleADAS &
Infotainment
AUTOSAR &
Functional Safety
Hybrid Electric
Vehicle
SOLUTIONS FOR TRANSPORTATION
Our Offerings for EV ‘s
 Battery management Systems
 Charging Electronics
 Thermal management
 Converters & Invertors
A wholly-owned subsidiary of L&T providing end-to-end
Engineering R&D services to clients

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excellence. ISG supports private and public sector organizations to transform and optimize their operational environments through research, benchmarking, consulting and managed services,
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