The “Eco-design” principle is a key element throughout the entire project. In this sense, versatility at MARBEL means taking a key step towards new materials (recycled and recyclable), new optimized designs and processes. With the aim of reducing weight without losing sight of the circular economy objectives, MARBEL is addressing the development of new recycled Al alloys and optimized extruded profiles design. For this, mechanical simulations have been carried out to evaluate what is the effect of impurities present in the scrap on its mechanical properties and extrudability, and thus on the battery housing performance and safety.
MARBEL treats the versatility and safety from the design for disassembly point of view by means of a modular battery pack design. This implies the study and implementation of weldless cell connections using a new solution, which allows the automation of the assembly and disassembly, thus improving its safer repairability and its second application lifetime. Modular also means that MARBEL Project batteries are easy to scale, being the solutions developed including the housing from a module scale and valid also to scale up to light and heavy-duty vehicles.
Versatility and safety is a concern of MARBEL also. To improve the efficiency of the battery, and therefore extend its useful life, a new BMS is including innovative features that will facilitate the implementation of the technology developed in other applications. The technical developments, which include layers of cybersecurity, provide flexibility and modularity with the idea that the management system is independent of the type of cells and vehicle as well as adaptable, through updates, to other applications beyond the electric vehicle in a second life application. For this purpose, algorithms and models based on artificial intelligence are being carried out with the aim of providing correct estimation of the cells performance, as well as offering remote diagnostics for fault detection and continuous improvement. Other concepts being implemented in the BMS are Functional Safety considerations according to the automotive ISO 26262 standard, as well as communications and sensors. Smart cell manager has been developed to oversee monitoring signals such as cell voltage or temperature while sending them wirelessly to the BMS. This safety layer allows for a remote configuration, maintenance, and assistance. On the other hand, cybersecurity issues are being considered as well as its Human-Machine interface.
