Modern Battery Systems ¿ the eMobility Enabler Virtual Pre-Conference Certification
I.D. # C2017 Duration 3 Days

eMobility presents enormous challenges to engineers who have been engaged primarily in non- electrical sectors of vehicle engineering. Yet, eMobility also presents exciting opportunities to those who are ready to understand how high voltage batteries contribute to the success of eMobility. This seminar will bring together all the materials in an easy to follow format geared to a wide range of participants from engineers to technicians to sales staff to executives.

To grasp the opportunities, we need to understand a small number of topics that describe how a battery system contributes to eMobility applications. However, that is only one aspect of how to develop a successful product. As the history of automotive engineering has demonstrated in the marketplace time after time, if the customer is not satisfied with the product, success will be elusive. This seminar will take us, in a team-based problem-solving session, through what we think the customer needs and wants are. As importantly, we¿ll look at who the customers are and how that influences their wants and needs.

Once these requirements are established, we can cover how cells behave, what materials are used in them and how they need to be handled. All of these are then important factors in cell design and battery design to support the expected levels of performance in energy and power. A lithium ion battery¿s sensitivity to its environment and how to manage that sensitivity will also be explored. We will also look at the need to keep all cells performing together rather than as individuals.

Another team-based exercise will examine one of the key concerns for consumers ¿ range anxiety. We will explore how range can be estimated and what sensitivities drive this calculation. If range anxiety is a key issue still today, when will it not be so. We¿ll look at what can be expected in battery performance beyond today in areas such as solid state, lithium sulfur and others.

As important as skillful battery design is, it is just as important to verify that the battery will indeed, perform as promised in the specifications. Verification comes through a through a thorough testing program structured as part of the APQP (Advanced Product Quality Planning) disciplines. We will look at what is contained in such a test program and the regulations and standards that drive the tests. We¿ll look at what makes up the safety and abuse test program of lithium ion batteries. We will look at media reports of electric vehicle fires in context of expectations of lithium ion batteries as a part of electric vehicle safety.

The hazards that can be expected when working with high voltage lithium ion batteries will be examined and related to the management of the associated risks. The hazards will be related to the sensitivities of lithium ion cells and what can cause these hazards in a team-based session. We will look at common practices to measure and manage the risks in the various environments such as manufacturing, assembly, installation, R&D, testing fault detection, repair, disassembly and undefined states.

No battery will be commercially successful if it is not cost competitive. On this subject we will examine product cost and its constituents such as material costs, overhead costs, labour costs and legacy costs.

The three-day session will include short quizzes at key points as well as a post seminar short question set. In addition, early registrants are invited to submit battery technology related problems which will be used to pose a team-based challenge to be solved on the afternoon of the last day of the seminar.

Learning Objectives
By attending this seminar, you will be able to:

  • Identify the handling risks of the battery system
  • Respect the risks and work with them
  • Develop a safety program to manage the risks
  • 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 course is appropriate for individuals who are new to both eMobility and modern high voltage battery systems. Those individuals engaged in eMobility engineering and who require a deeper understanding of modern high voltage batteries may also be interested in this course. Lastly, those individuals who need to understand how to work safely around modern high voltage batteries would be also be a good fit.
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
  • High Voltage Batteries

    • Electrochemical energy
    • Construction aspects and controls
    • DC vs AC
    • Lithium Ion aspects

  • Risks of HV Batteries

    • Team exercise: identifying the risks
    • Risk drivers
    • Hazards classifications
    • Cell vs pack level

  • Risk Management

    • Abuse prevention
    • Best practices, design measures, error proofing
    • Prevention & warnings
    • Claims vs. test data
    • Housekeeping
    • Containment

  • High Voltage Issues in Engineering and Manufacturing Environments

    • Avoidance of internal dangers from handling
    • What can go wrong in different environments
    • MSDS
    • Special tools
    • Handling of 'failed' batteries or cells
    • Dealing with an incident - team exercise

  • 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)
  • 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 J. Spek or Kevin Konecky

    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.

    Mr. Kevin Konecky recently joined Byton Automotive as Director of Powertrain; responsible for all development and design activities for the high-voltage powertrain. Byton is a newer global company developing an innovative and connected long-range electric vehicle. Recently, as an Energy Storage Systems consultant for Total Battery Consulting, where he¿s worked with a number of companies in the field of Energy Storage Systems (ESS) for automotive, stationary and consumer applications. Mr. Konecky has been a career-long proponent of strong product development and validation plans that ensures a robust product for production. Mr. Konecky has worked in the advanced vehicle and battery industry for 20 years at Fisker Automotive, General Motors, EnerDel, Cobasys and Lockheed Martin. Mr. Konecky has a BS in Electrical Engineering from Clarkson University (Potsdam, NY) and a MS in Electrical Engineering from Purdue (IUPUI-Indianapolis, IN).

    Fees: $1899 SAE Members: $1899


    CEU 2