new concepts for system integration in smart battery ... · pdf file06.10.2011 ·...

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Business Unit Transmission

New Concepts for System Integration in Smart Battery

Management Systems and Transmission Control Units

Martin Steinau, Bernhard Schuch, Dr. Matthias Wieczorek

Division Powertrain – BU Transmission

EPoSS Annual Forum "Towards Smart Systems Products"

Barcelona - October 6TH 2011

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Development of Electric Vehicles (EV)

11-10-06 2 M. Steinau, © Continental AG

Market share of EV is estimated to increase

within the next 10 years to ~3%

Development of EV is relatively at the

beginning and technology is still expensive

Biggest drawback

High weight and low live time of batteries

Energy- and CO2 balance are similar to

those of cars with combustion engine

New developments for conventional cars still

necessary

Two-Tier Development

Higher fuel efficiency of conventional cars

Higher reliability and cost-efficiency of EV

Integration of Smart Systems as approach for both technologies!

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System Integration in Transmission Control Units

System Integration of Smart Battery Management Systems (Smart LIC)

Summary

System Integration by Transfer Moulding

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Project Partners


France - Germany - Italy

“Smart and Compact BMS Module for Integration into

Lithium‐Ion Cell for FEV” – (Smart LIC)

http://www.enas.fraunhofer.de/

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Set-Up of Battery Packs


Typical Cathode

Materials:

Li(NiCoMn)O2

Li4Ti5O12

LiFePO4

Cathode

Coating

Cathode

CoatingTab Cu-Anode

Seperator

Film (20µm)

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State of the Art Battery Pack


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Smart BMS on Cell Level as proposed in Smart-LIC


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Reduced cost of ownership for the end user due to significant increase in battery lifetime

Reduced maintenance by the monitoring on cell level (individual cells can be switched off

from the rest of the pack)

Increased flexibility of the overall energy-power routing by assuring all cells perform at their

maximum rating

Detailed monitoring of the electrochemical mechanisms in the cell like charge transfer

reaction and diffusion by electrical impedance spectroscopy

Lower system complexity by a radical reduction of wiring and connectors by wireless

communication

BMS module as a System-in-Package (SiP) directly integrated into the lithium-ion cell using

moulding technologies

Goals of the Smart-LIC Project


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System integration of Smart Battery Management Systems (Smart LIC)

Summary


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New Packaging Approach – Moulding instead of Housing


PA-Housing

Silicon-Gel

PI-Flexfoil

Al-Housing

ECU on PCB or

Ceramic Substrate

Al-Bonds

Au-Bonds Top-Cover

Novel Approach

Moulded ECU with leadframe

contacts

Current Approach

Complex housing with various materials and

complex assembly

Gasket or

Laserwelding-Seam

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Technology – Transfer Moulding


Novel, innovative concept for media-tight encapsulation of electronics

Encapsulation by temperature resistant and thermal conductive epoxy compounds

Advantage: replacement of housing, gaskets and silicon gel

Challenge: asymmetric moulding for better heat transfer, combination of several materials

Technology offers many advantages for system integration of BMS but is also for TCUs

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System Integration of Smart Battery Management Systems (Smart LIC)

Summary


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Automatic Transmission


Automatic Transmissions contribute to reduce fuel consumption and CO2 emission

The market share of automatic transmissions worldwide increases every year

At the same time the range of automatic transmission types and their variants are increasing

AT DCT CVT

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Different Levels of System Integration


For each housing technology, different environmental requirements have to be fulfilled

Integrated TCU Standalone TCU Attached-to TCU

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DCT for Rear Wheel Drive with Controls


Transmission

Integrated TCU

Hydraulic

Cover

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Advantages of an Integrated Mechatronic Control Module


No additional connectors due to integration of sensors

No separate sensor housings necessary

Reduced wiring due to direct connection of

electromagnetic actuators

Only one central connector to interface between

ECU and vehicle electrical/electronic system

Autonomous calibration of electronics and

sensors, of the electro hydraulic control unit

and the entire transmission

=> Reduced costs and improved quality in the system approach

Conventional Mechatronics

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Advantages of an Integrated Mechatronic Control Module


Overmoulding of electronics for improved

tightness and reliability

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System integration of Smart Battery Management Systems (Smart LIC)

Summary


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Despite high efforts in development of EV’s, still big need for innovations in vehicles with

combustion engines

Increased reliability and efficiency necessary for both electric and conventional vehicles

System Integration as important approach to improve competitiveness of EV

Smart Battery Management System on cell level for increased lifetime and reduced cost

Mechatronic Transmission Control Units (MTCUs) with highly integrated electronic,

mechanic and hydraulic components will be the next step in the technology evolution

Necessity of integration concepts with better thermal and chemical resistance due to

demand for higher efficiency (=> Overmoulding of electronics)

Summary


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Many

Thanks

for Your

Attention!

new concepts for system integration in smart battery ... · pdf file06.10.2011 ·...

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