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ADVANCED ENGINEERING
Strictly Private & Confidential © Williams Advanced Engineering Ltd 2017
EV MOTORSPORT DERIVED ADVANCES IN AUTOMOTIVE BATTERY SYSTEM DESIGN
AUTHOR: DR WASIM SARWARFPC 2018
ADVANCED ENGINEERINGStrictly Private & Confidential
© Williams Advanced Engineering Ltd 2017
CONTENTS
2
>Introduction to Williams Advanced Engineering
>The Allure of EV Motorsport
>Key Differentiators - Motorsport vs Automotive Battery Packs
>Transferring Motorsport Developments to Automotive
>Conclusions
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WILLIAMS PROFILE
ABOUT US
• Williams founded in 1997
• Williams Advanced
Engineering formed in 2010
• Public Limited Company
• £150m per year turnover
• 900 employees
CORE COMPETENCIES
• Design
• Data capture and analysis
• Simulation
• Assembly
• Testing
WAE BUSINESS AWARDS
• MIA Business of the Year 2012
• Oxford Brookes Innovation Award 2013
• British Renewable Energy Pioneer 2014
• Race Tech Most Innovative New Motorsport Product Award 2015
• The IET Horizontal Innovation Award 2016
• British Engineering Excellence Award for Consultancy of the Year 2016
• MIA Business Award for Technology and Innovation
• ISO9001 awarded July 2017
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BATTERY SYSTEM DEVELOPMENT AT WAE
4
Fundamental Science Multi-Scale Virtual Engineering Multi-Disciplinary Design
Battery Management System Physical Testing Manufacturing
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H1PERBAT OVERVIEW
5
Flexible battery manufacturing facility in Coventry, UK
Focus on build of bespoke, high performance and low volume battery packs
Collaboration between WAE, Unipart, Warwick Manufacturing Group, Coventry University,
Productiv, MCT ReMan & the NCC
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AUTOMOTIVE OEMS FLOCKING TO EV MOTORSPORT
6
Current OEM Formula E Involvement Future OEM Formula E Involvement
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KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TIME
8
Hong Kong ePrix – Circuit Layout
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KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TIME
9
Tesla Supercharger Network – Western Europe (Left), North America (Right)
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KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TEMPERATURE
10
Monaco ePrix
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KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – OPERATING TEMPERATURE
11
Bjorn Nyland – Model X Off-Roading in Norway
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KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – DEPTH OF DISCHARGE
12
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KEY DIFFERENTIATORS BETWEEN USE OF AUTOMOTIVE & MOTORSPORT BATTERIES – DEGRADATION
13
Vehicle Period Capacity
BMW i3 8 Years / 100k Miles 70%
Chevrolet Bolt 8 Years / 100k Miles 60%
Kia Soul EV 10 Years / 100k Miles 70%
Mercedes
B250e8 Years / 100k Miles 70%
Nissan Leaf
24kWh5 Years / 60k Miles 9 Bars
Nissan Leaf
30kWh8 Years / 100k Miles 9 Bars
Tesla Model
S/XDegradation specifically excluded
Tesla Model 3
8 Years /
100k Miles (SR)
120k Miles (LR)
70%
VW e-Golf 8 Years / 100k Miles 70%
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22.4
7.911.0
4.37.2
5.95.0
35.8
0.4
147.8
100
120
140
160
180
200
220
240
Ene
rgy
De
nsi
ty (
Wh
/kg)
High Performance BEV Energy Density Walk
AUTOMOTIVE BATTERY ENERGY DENSITY WALK
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TRANSFERRING MOTORSPORT INNOVATIONS - OVERVIEW
Dynamic Thermal Limits
Dynamic Electrical Limits
Thermal Interface
BMS Platform Module Mechanical Design
Integrated Composite Case
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DYNAMIC THERMAL LIMITS
Dynamic Thermal Limits – Requirements:
Very low pack thermal distribution
Increased temperature sensing
Sophisticated SoH observation
< -30℃ -30 to -5℃ -4 to 35℃ 36 to 55℃ > 55℃
< -30℃ -30 to -5℃ 36 to 50℃ > 62℃51 to 62℃-4 to 35℃
Static Upper Thermal Limit
Dynamic Upper Thermal Limit
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DYNAMIC ELECTRICAL LIMITS
17
Advanced diagnostics techniques including Differential Thermal Voltammetry (DTV)
and Differential Resistance Analysis (DRA) enable SoH observation and electrode
capacity loss estimation
Enable dynamic voltage limits to compensate for stoichiometric drift
Y. Merla et al, Extending battery life : A low-cost practical diagnostic technique for lithium-ion batteries, 331 (2016) 224–231
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DYNAMIC ELECTRICAL LIMITS
18
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THERMAL INTERFACE
19
Tab CoolingMinimizing Footprint
Integrated liquid cooled cell-
to-cell bus bars
Effective Bus Bar Thermal
Mass Tuning
Conduction CoolingLow cost, package efficient
solution with low complexity
Novel interfacial materials -
↑ Thermal Conductivity &
Isolation Resistance
Combine with tab cooling
Face CoolingMaximum heat rejection
Novel interfacial materials -
↑ Thermal Conductivity &
Isolation Resistance
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BMS PLATFORM
20
Flexible BMS software platform enables continuous improvement of
degradation diagnostic and suppression techniques of in-the-field batteries
Kept current with technological advances
CPU
SSD
Increased sensing
OTA updates of calibration
and functionality (without
compromising security/safety
of base code)
Futureproof
processing power
Battery Fingerprint
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MODULE MECHANICAL DESIGN
21
Module mechanical components to
serve dual purpose:
Thermal Management:
Cooling components to form
mechanical ‘base’
Composite housing to contribute
‘useful’ thermal mass
Cell Compression:
Composite exoskeleton joined with
elastomer for tuneable constant
pressure solution
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INTEGRATED COMPOSITE CASE
22
Stressed composite case for reduced
mass whilst maintaining structural
performance
Built in thermal event suppression &
protection
Built in EMC protectionConfidential Material
Confidential Material
Confidential Material
Confidential Material Confidential Material
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INTEGRATED COMPOSITE CASE
23
Stressed composite case for reduced
mass whilst maintaining structural
performance
Built in thermal event suppression &
protection
Built in EMC protectionConfidential Material
Confidential Material
Confidential Material
Confidential Material Confidential Material
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CONCLUSIONS
24
Motorsport is an
excellent platform for
innovation and rapid
development
Significant scope to
transfer learning from
motorsport battery
development to
automotive batteries
Advanced BMS
computing enabling
‘smart’, adaptive and
more capable packs
Rapid cell-to-pack
engineering development
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