BYO successfully designed and produced innovative, unique HP-Batt with 10 000 cycles, specific power of 5 kW/kg (up to 20C), and energy density of 90 Wh/kg. More than 1000 HP-Batt cells were produced at BYO’s facilities in Norway and delivered to EK for HP-Batt module production and for cell testing by IFE, AAU and EK. BYO also developed and documented HP-Batt pre-lithiated cells with >10 000 cycles. BYO has developed and gained significant knowledge within battery technology development and manufacturing that has been a core for commercializing Beyonder’s first product, BePowered, spring 2024.
IFE and AAU completed cell characterization (capacity, cycle life, thermal and electrochemical properties). IFE also developed and delivered Si-material for development of some pre-lithiated HP-Batt that were produced by BYO. AAU developed SoX algorithms for the BMS for the HP-Batt modules.
EK designed and produced 17 HP-Batt modules of 2 kWh each for the demonstrator. The design process included cell testing, and need for compression pads and cooling system. Final HP-Batt module design was without housing that made some challenges with respect to safety. The issue was solved by a new site for the demonstrator provided by FHG and giving all installation and commissioning responsibility to FHG that could install the HP-Batt modules in a safe environment. LBA developed the BMS for the HP-batt modules in close cooperation with AAU, and delivered two high energy battery racks (LIB).
SIEMENS performed the system integration and developed the isolated DC/DC converter and the EMS. Siemens received all components from partners and tested each component individually before the whole system was tested at TRL5. Test results confirmed i) a possible maximum power of the system of 220 kW, ii) demonstrated a safe and reliable operation of the HEROES system and iii) the demonstration that the EMS automatically controlled the power flow, monitored the safety status of all components and guaranteed the communication between the system components.
FHG prepared the site for the demonstrator, and designed, installed, and commissioned the demonstrator at site. To evaluate the performance of the HEROES demonstrator, several extended charging procedures (approx. 20...80 % SOC) were carried out with different vehicles. Various cars were charged demonstrating fast charging of EV’s with 400 and 800 V platform. During the tests regarding the size of the energy storage units, a usable energy quantity of 105.6 kWh was determined for the high energy battery and 19.6 kWh for the HP-Batt (specifications: High Energy Battery 140 kWh, HP-Batt 26 kWh). The lower values compared to the design were because for safety reasons, both battery storage systems were operated within stricter voltage limits than it would have been technically possible.
INNOVA performed exploitation strategy and market assessment identifying the Key Exploitable Results that HEROES partners aimed to achieve through technical development. Results have also been added to the Horizon Result Booster. EASE has ensured communication and dissemination of the project and its results in different media and at different events. ENSO performed a LCA and LCC analysis by comping HEROES to two existing commercial charging solutions. The cycle cost for HEROES with power output of 300 kW and system lifetime of 12 years estimated to 0.037 €/kWh/cycle.
