Introduction to Hybrid and Electric Vehicle Battery Systems

I.D. #

C0626

Duration

2 Days

Driven by the need for lower emissions, better fuel economy and higher efficiency, hybrid vehicles are appearing in many different configurations on today's roadways. While the powertrain components such as the drive motor, motor controller and cooling system are somewhat familiar to the automotive industry, the battery systems are a relatively unfamiliar aspect. This seminar will introduce participants to the concepts of hybrid vehicles, their missions and the role of batteries in fulfilling those requirements. Battery topics including limitations, trends in hybrid development, customer wants and needs, battery system development timelines, comparison of electrochemistries and safety will be examined. Current offerings, cost factors, pack design considerations and testing will also be reviewed.

Students will have an opportunity to perform a battery pack analysis exercise using a real world application and are requested to bring a calculator to class.

Learning Objectives

By attending this seminar, you will be able to:

Capture customer wants and expectations of the battery system
Identify factors that drive power and energy requirements
Determine test program structure
Compare and contrast the newest relevant battery technologies
Calculate estimates of electric range and quantify the assumptions
Critically assess media claims of new battery discoveries

Who Should Attend

This seminar is primarily intended for vehicle systems engineers, battery system integration engineers, testing engineers, electrical engineers and thermal management engineers recently assigned to their roles or returning to hybrid or electric vehicle programs. It will also be beneficial to those involved in the specification, design, development, testing and planning of hybrid vehicle programs. Product planners and program managers will find the overview aspects helpful.

Prerequisites

Material presented will be practical in nature with basic mathematics used to describe quantitative measures. An undergraduate degree in electrical or electromechanical engineering will assist in gaining maximum benefit from the material presented. Experience or training in battery electrochemistry is helpful, but not essential.

Seminar Content

DAY ONE

Terminology, Definitions and Conventions
Brief Review of the Hybrid Market
- Market drivers and expectations
- Market influences
- Competing technologies
- Customer expectations
Review of Common Vehicle Product Offerings (battery descriptions, power, technology, size, architecture)
Fundamentals
- Fossil fuel vs. hybrid vs. electric
- Source ragone plot
- Efficiencies, weights
- Cost of fuel (fossil vs. electrons)
Role of Battery
- ICE vs. electric systems
- Energy vs. power
- Expectations over vehicle lifetime
Product Liability / FMEA
Battery Development Cycle
- You don't know what you don't know!
- Why does it take so long and cost so much?
Cost Factors
- Scope of product: system vs. cells vs. sticks
- $/kW vs. $kWh
System Considerations
Electrochemistry Selection
Safety
- Advance planning for safety tests
- Thermal runaway
- String configuration (series, parallel)
Range Estimation (hybrid vs. electric)

DAY TWO

Real-life Battery Analysis Exercise (using a contemporary vehicle as an example)
Battery Pack Design Considerations
Failure Modes
- Wear-out
- Power and energy degradation
- High resistance / open circuit
- Controller / signal malfunction
Vehicle Trends
- Plug-in hybrid
- Battery electric
- Demanding applications
- Fuel cell hybrids
Battery Trends
Battery Warranty
Battery Recycling

Instructor(s):

Erik Spek

Mr. Spek is Chief Engineer for TÜV SÜD Canada, a member of the global TÜV SÜD third party testing services organization for cell and battery manufacturers, vehicle OEMs and utility grid users of energy storage systems. He is also a consultant in the field of energy storage systems focusing on applications, verification testing, cell and battery production facilities safety and sodium ion battery development. Mr. Spek is co-holder of a patent for next generation sodium metal chloride architecture for low cost and very high energy density. He has authored articles on Weibull statistics for battery life and BEV range modeling and has been active in the battery industry since 1984. Mr. Spek is a member of SAE International and is a Certified Manufacturing Engineer with SME. He received an M.A.Sc. from the University of Waterloo and is a registered Professional Engineer in Ontario, Canada.

Fees:

$1305

SAE Members*:

$1045 - $1175

* The appropriate SAE Member discount will be applied through the Registration process. Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%

CEU

1.3