Periodic Reporting for period 2 - MARBEL (MANUFACTURING AND ASSEMBLY OF MODULAR AND REUSABLE EV BATTERY FOR ENVIRONMENT-FRIENDLY AND LIGHTWEIGHT MOBILITY)
Período documentado: 2022-07-01 hasta 2023-12-31
A key component in the endeavour to reduce carbon dioxide (CO2) emissions from transport, power and industry sectors, is the ultra-high-performance battery with capabilities beyond the ones that nowadays are able to produce 50 % less CO2 emissions over its lifetime than an average EU oil or diesel vehicle. To achieve these capabilities, energy and power performance approaching theoretical limits, as well as outstanding lifetime and reliability, and enhanced safety and environmental sustainability must be addressed.
Furthermore, to be commercially successful, these batteries must support scalability that enable cost-effective large-scale production thus definitely playing a major role for the ongoing digital and transport transformation of our future societies.
MARBEL main goal is to design and develop versatile solutions for modular and lightweight Battery Packs (BP), easy to disassemble, with the aim to facilitate the recycling of its components and/or reconditioning for second life applications, composed by plug & play modules with a housing made from recycled Al alloys, along with weldless electrical connections between cells and ultra-fast charge control based on set and controlled battery temperature. Advanced BMS will also be developed including intelligent functions that will extend battery life and predictability by making use of built-in sensors that will allow the battery cells to self-manage with the aid of AI providing real time overview of the battery, parameters control and efficiency check as well as high voltage systems. Innovative and efficient performance and safety related test procedures in real world conditions will be released and could set new basis for battery validations and laboratory procedures without the need of the actual vehicle.
Furthermore, to be commercially successful, these batteries must support scalability that enable cost-effective large-scale production thus definitely playing a major role for the ongoing digital and transport transformation of our future societies.
MARBEL main goal is to design and develop versatile solutions for modular and lightweight Battery Packs (BP), easy to disassemble, with the aim to facilitate the recycling of its components and/or reconditioning for second life applications, composed by plug & play modules with a housing made from recycled Al alloys, along with weldless electrical connections between cells and ultra-fast charge control based on set and controlled battery temperature. Advanced BMS will also be developed including intelligent functions that will extend battery life and predictability by making use of built-in sensors that will allow the battery cells to self-manage with the aid of AI providing real time overview of the battery, parameters control and efficiency check as well as high voltage systems. Innovative and efficient performance and safety related test procedures in real world conditions will be released and could set new basis for battery validations and laboratory procedures without the need of the actual vehicle.
Description of the concept of the module design has been carried on. Investigations had been done regarding the thermal characteristics of the cells. The results were fed into thermal modelling. Cell electrochemical and thermal model were developed, and simulation framework was set up. A concept cooling test setup has been then designed to test and ensure the hypotheses and assumptions taken during the module design. From this test, thermocouple readings were provided to extract accordingly the thermal contact resistances component-wise required to validate the virtual models.
Cooling system was designed to provide evenly distributed cooling to minimize the temperature spread within the cells. The manufacturability, assembling and disassembling of the system has been considered and assessed during the design. The final result of this part is that a new thermal management system for MARBEL battery pack was developed to guarantee moderate temperature gradients on the cell, module and pack level and therefore increase battery lifespan.
Intergated Smart Cell Manager (iSCM) has been developed and first functional prototypes have been released. First tests with wireless communications have been performed in a laboratory.
Cloud connectivity of BMS has been achieved via gateway for interoperability of the systems. BMS models have been developed and are deployed and functional. Cybersecutrity has been applied and validated in cloud-gateway connection, validated and tested under controlled environment.
Module design including weldless solution for smart cell to cell connection enabling easy dismantling of modules at cell level has been completed. Module design improves repairability and accessibility to cells, facilitating refurbishment and 2nd life transition. First module prototypes have already been assembled.
The development of optimized recycled aluminium alloys has been completed achieving a 60 % of recycled scrap material in the housing extruded profiles.
The design of the extruded profiles and the dies to manufacture the aluminium profiles for it, have been completed. Different samples were produced and mechanically tested. Different profile joining techniques to manufacture considering mechanical integrity and sealing aspects for safety have been explored. A final welding procedure has been determined and tested experimentally with real extruded profiles.
The final design of the 800V and 400V battery packs and related technical documentation for manufacturing. The structure of assembly flow chart and assembly area has been adapted to the battery pack design.
Collection of data for the LCA and LCC analyses is being carried out from all the partners developing and designing battery pack components. Follow up of the different eco-design actions identified at the beginning of the project is assessed.
Dissemination efforts have been effective with partners participating in over 21 events to raise awareness and visibility of the project to foster collaborations within the scientific and industrial community.
Cooling system was designed to provide evenly distributed cooling to minimize the temperature spread within the cells. The manufacturability, assembling and disassembling of the system has been considered and assessed during the design. The final result of this part is that a new thermal management system for MARBEL battery pack was developed to guarantee moderate temperature gradients on the cell, module and pack level and therefore increase battery lifespan.
Intergated Smart Cell Manager (iSCM) has been developed and first functional prototypes have been released. First tests with wireless communications have been performed in a laboratory.
Cloud connectivity of BMS has been achieved via gateway for interoperability of the systems. BMS models have been developed and are deployed and functional. Cybersecutrity has been applied and validated in cloud-gateway connection, validated and tested under controlled environment.
Module design including weldless solution for smart cell to cell connection enabling easy dismantling of modules at cell level has been completed. Module design improves repairability and accessibility to cells, facilitating refurbishment and 2nd life transition. First module prototypes have already been assembled.
The development of optimized recycled aluminium alloys has been completed achieving a 60 % of recycled scrap material in the housing extruded profiles.
The design of the extruded profiles and the dies to manufacture the aluminium profiles for it, have been completed. Different samples were produced and mechanically tested. Different profile joining techniques to manufacture considering mechanical integrity and sealing aspects for safety have been explored. A final welding procedure has been determined and tested experimentally with real extruded profiles.
The final design of the 800V and 400V battery packs and related technical documentation for manufacturing. The structure of assembly flow chart and assembly area has been adapted to the battery pack design.
Collection of data for the LCA and LCC analyses is being carried out from all the partners developing and designing battery pack components. Follow up of the different eco-design actions identified at the beginning of the project is assessed.
Dissemination efforts have been effective with partners participating in over 21 events to raise awareness and visibility of the project to foster collaborations within the scientific and industrial community.
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.
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.