Periodic Reporting for period 1 - MARBEL (MANUFACTURING AND ASSEMBLY OF MODULAR AND REUSABLE EV BATTERY FOR ENVIRONMENT-FRIENDLY AND LIGHTWEIGHT MOBILITY)
Okres sprawozdawczy: 2021-01-01 do 2022-06-30
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 of a new aluminium alloy including large amount of recycled material and optimised topology, 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 of a new aluminium alloy including large amount of recycled material and optimised topology, 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.
Functional Requirements, KPIs and different BP guidelines (safety, modularity, dismantling, second use and eco-deisng) have been delivered in the form of WP2 deliverables.
Description of the Ultra-fast Charge strategy, algorithm and selected current profile has been completed.
Description of the concept of the module design (cells configuration, housing design, heating/cooling integration and electrical connections) has been carried on.
Cell electrochemical and thermal model are currently under development at the end of the first reporting period. The simulation framework is already set up and the first batch of simulations are being run.
Cell Characterisation is in progress. Test started and cell characterization is expected to be completed by end of 2022.
The design of the mini housing and the dies to manufacture the aluminium profiles for it, has been completed.
Module design and battery pack ecodesign are in a final step.
Design and production of visual identity, creation of the project website, opening social media accounts, creation and promotion of a community of interest and production of promotional materials have been accomplished during the first three months of project.
Description of the Ultra-fast Charge strategy, algorithm and selected current profile has been completed.
Description of the concept of the module design (cells configuration, housing design, heating/cooling integration and electrical connections) has been carried on.
Cell electrochemical and thermal model are currently under development at the end of the first reporting period. The simulation framework is already set up and the first batch of simulations are being run.
Cell Characterisation is in progress. Test started and cell characterization is expected to be completed by end of 2022.
The design of the mini housing and the dies to manufacture the aluminium profiles for it, has been completed.
Module design and battery pack ecodesign are in a final step.
Design and production of visual identity, creation of the project website, opening social media accounts, creation and promotion of a community of interest and production of promotional materials have been accomplished during the first three months of project.
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, and after establishing requirements and guidelines within the first six months of the project, MARBEL is addressing housing research and development considering recycled materials and topologically optimized profile design. For this,mechanical simulations has 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. The design of an optimized extruded profile of battery pack housing is being carried out by means of topological optimization methods.
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 from a module scale and valid also to scale up to light and heavy-duty vehicles. Furthermore, the housing is being designed as a modular combination of extruded recycled aluminum profiles.
Versatility and safety is a concern of MARBEL also. Flexible and advanced BMS that is being developed in the project . To improve the efficiency of the battery, and therefore extend its useful life, this new BMS is including innovative features that will facilitate the implementation of the technology developed in many 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.
The detailed evaluations of environmental and economic costs, through LCA-LCC methodologies are being performed in MARBEL, having dual approaches throughout the project.
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 from a module scale and valid also to scale up to light and heavy-duty vehicles. Furthermore, the housing is being designed as a modular combination of extruded recycled aluminum profiles.
Versatility and safety is a concern of MARBEL also. Flexible and advanced BMS that is being developed in the project . To improve the efficiency of the battery, and therefore extend its useful life, this new BMS is including innovative features that will facilitate the implementation of the technology developed in many 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.
The detailed evaluations of environmental and economic costs, through LCA-LCC methodologies are being performed in MARBEL, having dual approaches throughout the project.