Periodic Reporting for period 1 - HELIOS (High-pErformance moduLar battery packs for sustaInable urban electrOmobility Services)
Período documentado: 2021-01-01 hasta 2022-06-30
The transition from the internal combustion engines (ICE) age to a fully electric mobility scenario is one of the main challenges to be overcome, to reduce the impact of climate change. The roadmaps and targets for the optimisation of Li-ion technologies and for the development of new chemistries, such as Li-S, Li-air, or solid-state batteries, are then defined in the Integrated SET-Plan (Action 7).
HELIOS addresses the need for increasing the density of battery packs in terms of weight and package space to improve the performance and range of EVs fleets utilised in growing urban electromobility models. A hybrid approach combining different Li-ion modules within the battery pack is developed to maximise energy and power capabilities depending on the application while optimising dimensioning. This hybrid configuration of the battery pack influences the electrical and thermal behaviour of the system. It also affects the design of the thermal management system, as well as the overall configuration of the different components and sub-systems within the battery pack. The proposed battery pack design makes use of advanced materials in the structural components, such as polymers and composites, to enhance mechanical resistance and lightweight, as well as in the thermal management system. Optimised designs for the electric and thermal management systems, casing and insulation, wiring, and other structural components, are reduced within the battery packs.
In HELIOS, the architecture of the different Li-ion modules, the electrical connections, current collectors, and wiring are optimised to ensure high efficiency, cost, and compact design. Advanced concepts of BMS relating to hardware and software enabling cell/module/pack communication need to be developed. IoT technologies connected to the BMS reduce the computational resources significantly, save space and time for data storage, and improves security. Finally, manufacturing processes of modules and their easy and efficient integration into packs need to consider the choice of materials and requirements related to safety, quality, and fast and cost-efficient fabrication.
HELIOS addresses the need for increasing the density of battery packs in terms of weight and package space to improve the performance and range of EVs fleets utilised in growing urban electromobility models. A hybrid approach combining different Li-ion modules within the battery pack is developed to maximise energy and power capabilities depending on the application while optimising dimensioning. This hybrid configuration of the battery pack influences the electrical and thermal behaviour of the system. It also affects the design of the thermal management system, as well as the overall configuration of the different components and sub-systems within the battery pack. The proposed battery pack design makes use of advanced materials in the structural components, such as polymers and composites, to enhance mechanical resistance and lightweight, as well as in the thermal management system. Optimised designs for the electric and thermal management systems, casing and insulation, wiring, and other structural components, are reduced within the battery packs.
In HELIOS, the architecture of the different Li-ion modules, the electrical connections, current collectors, and wiring are optimised to ensure high efficiency, cost, and compact design. Advanced concepts of BMS relating to hardware and software enabling cell/module/pack communication need to be developed. IoT technologies connected to the BMS reduce the computational resources significantly, save space and time for data storage, and improves security. Finally, manufacturing processes of modules and their easy and efficient integration into packs need to consider the choice of materials and requirements related to safety, quality, and fast and cost-efficient fabrication.
• Definition of the base requirements of the system, and components. Overall description of the system, and the functions of the components. An architecture model was established, which can be used in the following development phase.
• Cell testing scenarios and procedures for electrochemical & thermal testing, safety testing, and ageing studies defined.
• Check-up procedures, EoL criteria, and data acquisition rates for ageing tests defined and finalized
• A detailed material list with required material properties was provided for the thermal management system.
• Guidelines to improve the recyclability of modular and scalable battery packs
• Design and documentation for prototyping of two battery packages – for M-size EV and e-bus
• Various thermal management system (TMS) strategies were surveyed and discussed. A design decision matrix has been made for the final design selection.
• Different pack designs of commercial EVs were evaluated to determine the design criteria.
• Initial experimental studies for design alteration and thermal requirements of the pack.
• Basic simulations were performed to evaluate proposed TMS designs. Control algorithms were proposed and discussed.
• Early results from battery testing have been delivered from WP4 and implemented into the thermal design.
• Decision about High Energy and High Power cells has been made.
• Data warehouse platform has been provided and improved by DTI.
• Cyclic and calendric ageing tests have been started, and the first tests completed.
• Dynamic performance test (compressed real-driving-emissions cycle test) has been initiated to accelerate the SOX algorithm development.
• Roadmaps for State-of-Charge (SOC) and State-of Health (SOH) modelling have been established. A detailed review of the state-of-the-art on battery modelling approaches has been performed.
• Decision about the suitable Equivalent Circuit Models (ECM) and Electrochemical Models (EM) has been made
• Software requirements specifications (SRS) of the models have been elaborated, including the scope, functional requirements, internal and external interfaces, and design constraints such as memory and CPU requirements.
• BMS functionalities were defined in three level states
• DC-DC converter topologies analysis and preselection, according to HELIOS specifications. A multilevel topology for scalable design was defined, studied, and developed.
• Website online. Social media account on Twitter (https://twitter.com/helios_h2020) Social media account on Linkedin (https://www.linkedin.com/company/helios-h2020/)
• Communication Plan and Report and Project Press kit
• The Helios IAB (Industrial Advisory Board) has been constituted and accounts now in M18 of nine experts from academia and across the entire battery value chain
• “Collabat,” a Cluster of the four projects (Albatross, Helios, Liberty, and Marbel) awarded under the LC-Bat-10 call, has been constituted, and four expert “sub-cluster” groups launched for internal exchange and discussion
• Cell testing scenarios and procedures for electrochemical & thermal testing, safety testing, and ageing studies defined.
• Check-up procedures, EoL criteria, and data acquisition rates for ageing tests defined and finalized
• A detailed material list with required material properties was provided for the thermal management system.
• Guidelines to improve the recyclability of modular and scalable battery packs
• Design and documentation for prototyping of two battery packages – for M-size EV and e-bus
• Various thermal management system (TMS) strategies were surveyed and discussed. A design decision matrix has been made for the final design selection.
• Different pack designs of commercial EVs were evaluated to determine the design criteria.
• Initial experimental studies for design alteration and thermal requirements of the pack.
• Basic simulations were performed to evaluate proposed TMS designs. Control algorithms were proposed and discussed.
• Early results from battery testing have been delivered from WP4 and implemented into the thermal design.
• Decision about High Energy and High Power cells has been made.
• Data warehouse platform has been provided and improved by DTI.
• Cyclic and calendric ageing tests have been started, and the first tests completed.
• Dynamic performance test (compressed real-driving-emissions cycle test) has been initiated to accelerate the SOX algorithm development.
• Roadmaps for State-of-Charge (SOC) and State-of Health (SOH) modelling have been established. A detailed review of the state-of-the-art on battery modelling approaches has been performed.
• Decision about the suitable Equivalent Circuit Models (ECM) and Electrochemical Models (EM) has been made
• Software requirements specifications (SRS) of the models have been elaborated, including the scope, functional requirements, internal and external interfaces, and design constraints such as memory and CPU requirements.
• BMS functionalities were defined in three level states
• DC-DC converter topologies analysis and preselection, according to HELIOS specifications. A multilevel topology for scalable design was defined, studied, and developed.
• Website online. Social media account on Twitter (https://twitter.com/helios_h2020) Social media account on Linkedin (https://www.linkedin.com/company/helios-h2020/)
• Communication Plan and Report and Project Press kit
• The Helios IAB (Industrial Advisory Board) has been constituted and accounts now in M18 of nine experts from academia and across the entire battery value chain
• “Collabat,” a Cluster of the four projects (Albatross, Helios, Liberty, and Marbel) awarded under the LC-Bat-10 call, has been constituted, and four expert “sub-cluster” groups launched for internal exchange and discussion
Progress beyond state of the art:
• Hybrid module configuration battery packs, integrating LFP and NMC cells
• Advanced polymers and composite material for structural components, housing and insulation
• Hybrid thermal management system integrating tab and surface cooling with PCMs
• Multilevel converters for the efficient management of energy and power
• Multilevel converters for modularity, scalability and adaptability to the powertrain
• In-vehicle AC-DC converters for ultra-fast charge
• Improved charging protocols and communications
• Improved state estimation methodologies, SOC and SOH
• Improved control and health management strategies
• Development of BMS with enhanced functionalities for state estimation and connectivity
• DC-DC converter for cell balancing
• AI algorithms for improved PHM embedded in the datAssistTM IoT software platform
• Digital twins for performance and process circularity optimisation
• LCCA tool for circular economy of Li-ion battery packs
• V2G communication protocols for 1st and 2nd life battery pack utilisation
• Big data analysis and IoTs applied to the management of performance and carbon footprint of EV fleets
• Multisensing units integrated in the BMS for measurement of multiple parameters
• Gas sensors for early detection of CO, VOCs, etc
IMPACT-1: Considerably improved performance of the EV through reduced battery system weight by 20% at constant electric vehicle range for mid-size battery electric car
IMPACT-2: Overcome the uncertainty of range by achieving 25% shorter recharging time with a 150kW charger compared to best in class electric car available on the market in 2018. The demonstrator must have the same battery capacity as the reference car and meet the useful battery life mentioned below
IMPACT-3: Improved attractiveness of the EV through achieving extended useful battery life to 300 000 km in real driving[1] referring to a mid size passenger car using improved battery management, balancing and thermal management during high-power charging/discharging
IMPACT-4: Contribution to Circular Economy goals through a minimum 20% Life Cycle Analysis improvement compared to existing products.
IMPACT-5: Considerably improved knowledge on module and pack sensorisation and thermal management
• Hybrid module configuration battery packs, integrating LFP and NMC cells
• Advanced polymers and composite material for structural components, housing and insulation
• Hybrid thermal management system integrating tab and surface cooling with PCMs
• Multilevel converters for the efficient management of energy and power
• Multilevel converters for modularity, scalability and adaptability to the powertrain
• In-vehicle AC-DC converters for ultra-fast charge
• Improved charging protocols and communications
• Improved state estimation methodologies, SOC and SOH
• Improved control and health management strategies
• Development of BMS with enhanced functionalities for state estimation and connectivity
• DC-DC converter for cell balancing
• AI algorithms for improved PHM embedded in the datAssistTM IoT software platform
• Digital twins for performance and process circularity optimisation
• LCCA tool for circular economy of Li-ion battery packs
• V2G communication protocols for 1st and 2nd life battery pack utilisation
• Big data analysis and IoTs applied to the management of performance and carbon footprint of EV fleets
• Multisensing units integrated in the BMS for measurement of multiple parameters
• Gas sensors for early detection of CO, VOCs, etc
IMPACT-1: Considerably improved performance of the EV through reduced battery system weight by 20% at constant electric vehicle range for mid-size battery electric car
IMPACT-2: Overcome the uncertainty of range by achieving 25% shorter recharging time with a 150kW charger compared to best in class electric car available on the market in 2018. The demonstrator must have the same battery capacity as the reference car and meet the useful battery life mentioned below
IMPACT-3: Improved attractiveness of the EV through achieving extended useful battery life to 300 000 km in real driving[1] referring to a mid size passenger car using improved battery management, balancing and thermal management during high-power charging/discharging
IMPACT-4: Contribution to Circular Economy goals through a minimum 20% Life Cycle Analysis improvement compared to existing products.
IMPACT-5: Considerably improved knowledge on module and pack sensorisation and thermal management