INCOBAT - Innovative Cost Efficient Management System for Next Generation High Voltage Batteries

INCOBAT - Innovative Cost Efficient Management System for Next Generation High Voltage Batteries

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Description: The aim of INCOBAT is to provide innovative and cost efficient battery management systems for next generation HV-batteries. To that end, INCOBAT will propose a platform concept in order to achieve cost reduction, reduced complexity, increased reliability as well as flexibility and higher energy efficiency. The main outcomes of the project will be: Very tight control of the cell function leading to an increase of the driving range of the FEV for current chemistry and by enabling the use of new cell chemistries such as LiS or even Li-air, Radical cost reduction of battery management system, Development of modular concepts for system architecture and partitioning, safety, security, reliability as well as verification and validation, thus enabling efficient integration into different vehicle platforms, INCOBAT is in the position to provide a 100% European value chain for the development of next generation HV battery management systems.

 
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Domain:  Green Tech Category: Battery & Fuel Cell 
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Contents:
INCOBAT - Innovative Cost Efficient
Management System for Next Generation
High Voltage Batteries
Joint EC & EGVIA workshop for advanced
automotive batteries research
Brussels, October 12th, 2016
The research leading to these results has received funding from the European Union’s Seventh Framework Programme
(FP7/2007-2013) under grant agreement n° 608988
Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

1

Agenda

 INCOBAT project in a nutshell

 Project results
 4th EV cluster

 Future challenges and research potential

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

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2

INCOBAT – key facts

Project Name: INCOBAT - INnovative
COst efficient management system for
next generation high voltage BATteries

Project Duration: 39 months

Funding: European research project
ICT STREP (FP7)

Budget: 5.8M€

Duration: Oct. 2013 – Dec. 2016

Participant organization name
AVL List GmbH
Ideas&Motion
Fraunhofer Institute ENAS (Chemnitz)
Infineon Technologies Austria AG
Infineon Technologies AG
Impact Clean Power Technology S.A.
Kemet Electronics Italia SRL
Chemnitzer Werkstoffmechanik GmbH

Country Status
AT
LE
IT
SME
DE
RE
AT
LE
DE
LE
PL
SME
IT
LE
DE
SME

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

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3

INCOBAT – abstract

The aim of INCOBAT is to provide innovative and cost efficient battery
management systems for next generation HV-batteries. To that end, INCOBAT
will propose a platform concept in order to achieve cost reduction, reduced
complexity, increased reliability as well as flexibility and higher energy efficiency.

The main outcomes of the project will be:
• Very tight control of the cell function leading to an increase of the driving range
of the FEV for current chemistry and by enabling the use of new cell chemistries
such as LiS or even Li-air
• Radical cost reduction of battery management system
• Development of modular concepts for system architecture and partitioning,
safety, security, reliability as well as verification and validation, thus enabling
efficient integration into different vehicle platforms.
• INCOBAT is in the position to provide a 100% European value chain for the
development of next generation HV battery management systems.

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

Public

4
4

INCOBAT – innovation topics
Customer needs and integration aspect

1

Ensure validity of the
technology for integration
in vehicle platform

12
Car demonstrator / vehicle
validation

Mission profiles

Transversal innovation: consistent concept and specification
act [Activ ity] 00_Recuperation [AC_Recuperation_Prov ide_Neg_Torque]

bdd [SysML Block Definition] 00_Pow ertrain_Env ironment [BDD_Pow ertrain_Env ironment]
«block»
Vehicle

Prov ide negativ e recuperation torque
«Operational Actor» HV Battery

«Operational Actor» IPU_D

«Operational Actor» HCU

«operational_activ ity»

«block»
Ignition

«block»
Steering

«block»
Brake

«block»
Body

«block»
Vehicle CAN

«block»
Plug

«operational_activ ity»

Determination of max.
av ailable TM torque

«operational_activ ity»

Determination of max.
av ailable TM torque

«continuous»

«operational_activ ity»
Determination of max.
av ailable HV battery
discharge pow er

«block»
Hybrid Pow ertrain

«block»
Accelerator Pedal

3

Get Recuperation torque
form CRBS

«continuous»

«operational_activ ity»

«block»
Pow ertrain CAN

Current HV battery
charge / discharge
pow er

«actuator»
ICE

«block»
LV Battery

ECU

«block»
Electrical Generator

«block»
ACDC Conv erter

No

«operational_activ ity»

4

uc [Use Case] 00_Recuperation [UC_Recuperation_Scenario_Start]

steering : Steering

body : Body

To Vehicle CAN

Connection is
TBD

Name:
UC_Recuperation_Scenario_Start
Package: 00_Recuperation
Version: 1.0
Author: krallinm

Brake
From Brake

Reduce torque request

Provide negative
recuperation torque

Vehicle

brake : Brake

Yes
«operational_activ ity»
Send torque request and
slew rate

«block»
HV Battery

ibd [SysML Internal Block] 00_Pow ertrain_Env ironment [IBD_Pow ertrain_Env ironment]

To Vehicle CAN

Able to charge all
recuperation energy into
battery?

«continuous»

«operational_activ ity»
Control traction motor
according to the demand

«block»
HCU

«block»
Transmission

«block»
Gearbox

2

«block»
TCU

«block»
DCDC Conv erter

«operational_activ ity»
Charge Battery

«block»
DCAC Conv erter

«actuator»
Electrical Traction Motor

Hybrid Powertrain

From Steering

«operational_capability»
Prov ide negativ e torque

vehicle bus : Vehicle CAN

«operational_activ ity»
Press Brake Pedal

From Powertrain
To Vehicle CAN

Ignition Signal

hybrid powertrain :
Hybrid Powertrain

Normal
Charging
Cable

Normal
Charging
Cable

Fast
Charging
Cable

Fast
Charging
Cable

«include»

«include»

extension points
behavior

«operational_scenario»
Brake Recuperation

plug : Plug

ignition : Ignition
Ignition Signal

accelerator pedal :
Accelerator Pedal

Accelerator Pedal Position
Pedal Position

Driv er

The powetrain is in the
correct state:
- Vehicle Speed is above
minimum speed threshold
- Gear lever is in position D
or R

«include»

«operational_capability»
Charge HV battery

extension points
behavior

System architecture – efficient
partitioning of the functionalities

Model-based systems engineering

Integration of multiples functionalities
(such as charging and billing)

Provides more consistent system
definition and enables global
optimization (instead of local)

Technology innovation: E/E control system
5

...

6
TriCore AURIX platform for
additional computing resources

7

Smart and integrated
module management unit

8
Modular SW platform

Improved BMS control
algorithms

Provides innovation for the E/E
control system based on multicore
technology and smart sensors

Transversal innovation: improving system maturity
9

10
11

Definition and integration of safety
and security concepts

Design and validation plan including
reliability consideration

Reliability and robustness
assessment

Ensure the maturity and readiness
for industrialization of the
proposed technology

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

Public

5
5

Smart satellite: TLE8001QK – Infineon BMS Chipset



Support of Active and Passive Balancing
– 1Ω internal pass device (up to 200mA balancing)
– 5A Active balancing with external components

– Accurate Cell Voltage Measurement

– 12 cell voltages in parallel (13bit / ±1.75 mV / ±3LSB)
– Secondary Voltage Meas. path (10 bit muxed)
– Block Voltage Measurement (12 x cells) time of ~3.4ms



Accurate Temperature Measurement



2 Wire Bus for Chip to Chip Communication

– 5 Temperature Sensor Inputs
– Adjustable to a wide range of NTC’s

– Capacitive isolation
– Redundant Network Architecture compatible
– 1 Mbit/s, 6bit CRC

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

Confidential

6
6

INCOBAT iBMS-CCU Prototype

 Lowest cost BMS system solution by fully integrating all main BMS functions into one
ECU
 Close-to-production platform supporting the exploitation of advanced BMS
approaches

 Reduced system installation space, high level of integration and of functional density
 Comprehensive hardware safety measures by Infineon AURIX™ and Safety Power
Supply ASIC
Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

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7
7

INCOBAT SW development environment

 Low cost development environment
solution with capabilities to be deployed
by each partner while minimizing the
licensing costs
 Constructive integration by flexible
configuration of source files and
capability of updating a core
independently from each other
 IPR protection and linking of external
pre-compiled objects / libraries to the
main binary of each core

 Tool flexibility: Adaptations to other
compilers and integration of additional
tools shall be possible with minimal
effort.

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

Public

8
8

Electrochemical Impedance Spectroscopy

 Downscaling of existing EIS technology to fit on automotive embedded
computing platform, execution in real time
 EIS currently available as discrete solution (prototyping platform); integration
in standard smart sensors already evaluated
 Preliminary evaluation performed on industrial cells (normal, abused)
10

9
8
7
6
New

5

Abused

4
3
2
1
0
0,01

0,1

1

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

10

100

1000

Public

10

Battery state estimation at cell level

 Validation of the migration performed by regression test (MIL vs SIL) based
on real driving cycles (SoC and SoH difference below 0.05%)
 Computation of the battery state estimation at cell level provide more
accurate estimation, therefore having a positive impact on battery range

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

Public

11
11

Combined reliability testing
Thermal-mechanical behavior of the measurement chip (BMS
satellite board) during operation:

 Target of combined reliability testing
o Ensuring functionality of the modules
during lifetime due to the definition of
design rules
o More relevant environmental tests by
considering different load cases
(temperature, vibration and humidity)
Experimental verification of numerical simulation:

 INCOBAT advance: method for analyzing
combined thermo-mechanical stress within the
package
 Method applied for BMS satellite board to
assess the dependences on:
o location of the balancing resistors,
o balancing power losses,
o number of cells,
o and intrinsic power losses of the
measurement chip.
Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

Public

12
12

Vehicle demonstrator

 Basis vehicle: Renault Twingo 2004 , modified
as eVehicle running with battery pack
 Two battery packs at front and rear of the
vehicle

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

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13

Clustering Concept



Vision and mission of the project cluster as a collaboration platform



Vision Statement


Foster information exchange for the alignment of R&D activities to achieve optimal resource
utilization and gain synergistic technical understanding for future EVs



Coordinate joint dissemination/ marketing events to achieve higher visibility and thus higher
(market) impact for each single project



Mission Statement


Provide the European Commission and relevant industrial initiatives insight into some major
challenges faced by future EVs as basis for strategic decisions



Performance potential of vehicle electrification





Comprehensive energy management
Central computing platform

Contribute to the evolution of existing standards for standardization bodies, as well as
preparation and proposing new solutions/ technologies for standardization

Armengaud, Watzenig, John, Brandstaetter, Villareal, 03-11-2015

14

Graphics based on graphic from ARTEMIS POLLUX project

Project Cluster – „4th Generation EV“

Armengaud, Watzenig, John, Brandstaetter, Villareal, 03-11-2015

15

Clustering WGs
Initiative
Contributing
Partners

Working Groups
• OEM & Tier 1
• Research

Working Group

Working Group

Further projects
Further projects
Further projects
Project …

Comprehensive Energy Management

Central Computing Platform

• Tier 1 & 2
• Research

Working Group

Potential of Electrification

• All partners

Project Cluster

Armengaud, Watzenig, John, Brandstaetter, Villareal, 03-11-2015

16

Future challenges and research potential

 Battery technologies for higher performances and tailored to customer needs
 New chemistries, hybrid batteries, more accurate battery state estimation for better
usage of energy available over the lifetime (incl. 2nd life)
 Covering full range of road transport applications

 Efficient integration in comprehensive energy management concept
(both at electrified drivetrain and entire vehicle level)
 Improved energy efficiency of electrical drive-train, energy harvesting,
comprehensive thermal energy management

 Increasing maturity of the technology over the entire lifecycle
(including 2nd life and recycling)
 Dependability including safety, reliability and robustness, health-monitoring of critical
components, virtual prototyping (DfR, DfT, DfM) and improved stress testing
methods

 Convergence e-mobility and autonomous driving functions
 Predictive energy management taking into account road profile, environment, traffic
situation

Armengaud on behalf of the INCOBAT consortium, Join EC & EGVIA workshop, October 2016, Brussels

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