•Investigation into suitable cell technologies according to the corresponding applications (FIAT 500X P-HEV, IVECO BEV Bus) and usage profiles (driving range, operation time, charging time): Li-Ion cells (Toshiba Lithium Titanium Oxide 23 Ah) were selected.
•Analysis of the most appropriate BS architecture focusing on the modularity, functionality, safety, costs, volume and weight requirements.
•Address the use of novel compound sandwich material for the housing and structure to reduce the weight and volume overhead.
•Investigation into innovative cooling solutions.
•Development of the electrical design matching the modular requirement while providing flexibility with respect to the corresponding applications (FIAT 500X P-HEV, IVECO BEV Bus); integration of reversible cell-to-cell connections with voltage, temperature and current measurement into the novel Power PCBs, monitored by the UCSB (BMS).
•Investigations into a new cell temperature monitoring system based on electrochemical impedance spectroscopy (EIS) measurements; Definition of a measurement plan using the PCB demonstrator and preparation of related the lab. equipment.
•Development and execution of a test methodology for characterization and ageing of batteries to assess the LTO-based cell electrical, thermal and lifetime behaviour; definition of the cells parameters for the modelling requirements; definition of standardized test protocols and models for the next generation of cell technologies such as Li-S; development of a 1D-electro-thermal and a 3D thermal model for the LTO cell at different operating temperatures (0°C to 45°C);
•Development of a multi-concern safety methodology to support the holistic safety analysis of the BS with reference to standards (e.g. ISO 26262) and based on the Failure Mode & Effect Analysis method;
•Definition and application of a test strategy to enable the validation of system safety under laboratory conditions emulating real operational conditions, reflecting the identified critical failures and operational scenarios, application to the 2nd life application);
•Evaluation of the 2nd life aspects of Li-Ion batteries through specific use case scenarios and system specifications with respect to the 1st life (remaining capacity, 1st life history, etc.);
•Generation of fundamental design requirements and execution into the BS design to reduce the cost of dismantling and for EoL operations.
•Development of a comprehensive re-qualification test program; Evaluation of testing and assembling cost towards reuse and 2nd life evaluation.
•Design of a novel scaled-down laboratory level Dual Li-Ion and Li-S demonstrator system. Design and development of a test bench to test the selected semiconductors and to define final requirements of the DC/DC converter.
•Execution and evaluation of 2nd life testing of aged LTO cells tested against photovoltaic (PV) profile for energy storage.
•Evaluation of safety, technical, economic, social, and environmental impacts of reuse and repurpose of the GHOST Basic Unit.
•Validation of the GHOST BS at lab level: mechanical pre-tests with two non-functional BS (Dummy System), several tests under mechanical, thermal, and electrical load at the MAST (Fraunhofer Lbf).
MAIN RESULTS:
GHOST Basic Unit Demonstrator in Public Event.
•Final Event held in December 2021.
•Demo vehicles: a 400V P-HEV vehicle (Fiat 500X), tested on private track and dyno (WLTP and RDE), a 800V BEV with ultra-fast charge, tested at test bench level.
•All BSs were assembled, enabling Labs testing in Fraunhofer and demo vehicles integration (PHEV and BEV) and testing.
•Development of a robust lifetime model based on a semi empirical methodology, based on 2-year long test lifetime testing started in March 2019, to predicts the SOH and remaining useful life of the BS.
•The prototyping and assessment of the dual Li-ion and Li-S battery module system were completed while using EIS to estimate cell temperature.
•Business model analysis for reuse and recycling in Europe.
•Results can be exploited by vehicle manufacturers (specific application for clean and sustainable mobility, manufacturing cost reduction), suppliers and services providers (know-how to improve the product portfolio), industry and research organization (expertise to improve end-of-life knowledge and design capability), academic partners (scientific exploitation of GHOST results).
•Exploitation and dissemination activities: participation in 35+ events and lectures, 14 technical publications, 1 public workshop, 1 final event, 6 newsletters, 1 patent registered proceeding from GHOST’s research and innovation.
