MAGNA STEYR Template - Letter (New Template) - ARPA-E

14 Pages·2012·0.9 MB·English

Magna Steyr Discussion on
xEV Battery Pack Designs
November 12, 2012
Agenda
• Magna Steyr Fuel and Battery System Introduction
• Four main areas of xEV Li-ion Battery design consideration:
– Li-ion Cell
– Mechanical/structural
– Electrical
– Thermal
• RESS Safety – A Systems Perspective
11/16/2012 Disclosure or duplication without consent is prohibited 2
Worldwide Presence MAGNA Int.
(Status Q3 2012)
Westeurop 81
a 34
32.325
Canada 46 Austria
Belgium
19,075 10 England Osteuropa 32
Aurora France 10.450 3
(Headquarters) 59 USA Germany Czech Republic
16 19.450 Irland Hungary 33 Asia
Poland
Italy Russlia 22 9,050
Mexico 29 Schweden China
Slowak Republic
20,000 1 Spain Turkey Korea
Japan
India
Thailand
South America 14
4,975 2
Brazil
Argentina Africa
2
100
South Africa
~ 115,000 employees | 26 countries
296 manufacturing operations | 88 product development / engineering / sales centers

$28.7 billions (Sales 2011)
Fuel & Battery Systems – Worldwide Presence
(Status Q3 2012)
Germany Austria
Grevenbroich Graz
Neumarkt Sinabelkirchen
North
Potsdam Weiz
America
Schwäb. Gmünd
Auburn Hills
China
Changchun
Filler Pipes (plastic and
Battery Systems steel)
1.500 employees | 7 locations in Europe
Plastic Fuel Tanks Fuel and Oil Caps
1 location in Asia
Steel Fuel Tanks Water-Carrying Components
1 location in North America
Aluminum Fuel Tanks Steel Compressed-Air
Tanks
We offer …
Engineering services including
Engineering
complete vehicle engineering
Vehicle Contract Flexible solutions from niche to volume
Manufacturing production
Fuel & Battery
Innovative fuel & battery systems
Systems

Roof Systems Entire range of roof systems
Innovative Battery Systems
• Battery pack development & production
based on state-of-the-art lithium-ion cell
technology
• Cell, module and battery pack testing
• Material testing − Excellence in automotive engineering and production
• Truck/Bus HEV Battery Packs − Deep knowledge of international safety standards
• HEV Battery Packs − Integrated thermal and electronic management
− Customizable solutions due to modular design
• PHEV / REX Battery Packs
− Leading Li-ion battery provider for commercial vehicle
• EV Battery Packs
segment
Battery Pack Portfolio

s
t
c
u
d
o
r
P

e
r
u
t Truck/Bus HEV EV PHEV / REX HEV Battery Pack
u
Battery Pack Battery Pack Battery Pack
F

& Energy Content: 2 - 18 kWh Energy Content EV: up to 36 kWh Energy Content PHEV: 6- Energy Content: 0,2 -3 kWh
Power: up to 180kW Power: up to 200 kW 16 kWh Power: 15 -60 kW

t Nom. Voltage: 360V / 650V Battery Weight: <10 kg/kWh Power: 50-120 kW Battery Weight: 10 -40 kg
n
e Battery Weight: 60 to 150 kg Cooling: air / liquid Battery Weight: < 10 kg/kWh Cooling: air / liquid
r Cooling: air or liquid SOP: Q4/2010 Cooling: air / liquid SOP: 2014 (2nd Gen.)
r
SOP: 2009 Flexible Modular Concept SOP PHEV: 2013
u
C Next Generation: 2011 Passenger Car & Commercial
Applications
Battery Development Timeline
2006 2007 2008 2009 2010 2011 2012 2013 2014
1st Generation 2nd Serial Serial Serial . Serial Serial
Li-Ion Battery Generation Production Production Production Production Production
Systems Li-Ion Battery Truck/Bus EV Battery Truck/Bus PHEV Battery HEV Battery
Systems HEV Systems HEV Systems Systems
Gen 1 Gen 2
xEV Battery Design Considerations
Li-ion Cell
• Cell type
– Cylindrical
– Prismatic
– Pouch (Laminate)
• Chemistry
– LFP, NMC, NCA
• Safety Features
– Vents
– Current Interrupt Devices
– Safety Separator

11/16/2012 Disclosure or duplication without consent is prohibited 9
Mechanical / Structural
• Single or multiple packs
• Pack mounting location
– Inside vehicle cabin
– Exterior to cabin
• Permanent or Removable
– Battery Swapping
• Module type and concept
– Different module types for different cells
11/16/2012 Disclosure or duplication without consent is prohibited 10