powertrain strategies for the 21st century: next generation electric

Powertrain Strategies for the 21st

Century: Next Generation

Electric Vehicle Strategies

Li-ion Batteries for

Electrified Mobility

Ann Arbor, MI | 20.07.2016

Jacob Bemrich, PE

Systems Engineering Manager

Robert Bosch Battery Systems LLC

Robert Bosch Battery Systems LLC | BBSN/ENA1 | 7/20/2016

© 2016 Robert Bosch LLC and affiliates. All rights reserved.2

Bosch Powertrain Electrification – future mobilityWorldwide Footprint

Stuttgart (Region)

Headquarter EM, LE, BATResearch & Development

EM: E-Motor

PE: Power Electronics

BAT: Battery Pack

CELL: Battery Cell

Detroit (Region)

Farmington Hills,

local office

PE Dev & Plant

Reutlingen

EM Plant

Hildesheim

Tokyo (Region)

Yokohama, local office

Shanghai UAES

Development & Plant

PE Dev. & Plant

Budapest &Hatvan

BAT Plant

Suzhou

BAT Plant

Bamberg

BAT Development

Orion

BAT Plant

Springboro

Cell Development

Stuttgart

Cell Dev. & Plant

Kyoto & Ritto

PE SW/HW Develop.

Coimbatore, Bangalore

Cell Development

Hayward

~ 1800 employees working on power train electrification within Bosch group

R&D and Production



Global Locations – North America

Springboro, Ohio Production plant, (50,000+

vehicle packs built since 2006, Li-Ion SOP

Nov 2012)

Technical and Product Services in place for

Aftermarket to support complete Product Life Cycle

Approx. 150 employees

Orion, Michigan Engineering facility (several

OEM projects since 2005)

Experienced xEV battery pack mechanical, HW-, SW- and

systems-engineering

On-site development labs, test labs, and validation

facilities for Li-ion

Approx. 100 employees

Mission:

Produce and Deliver ‘Zero Defect’

Battery Packs ‘On-time’ for Production

and Service Customers.

170,000 ft2 (16,000 m2)

Expandable to 213,000 ft2

R&D and Production



Influence variables on eMobility

• Applications

• Market volume

• Customer expectations

• Requirements

Technology

Web 3.0EV-train

KPIs

Infrastructure

Megatrends

electrified, automated, connected

Business models

Legislation

User experience UX



Content

Market requirements for batteries 2020ff – the Bosch view

Applications

Market volume

Customer expectations

Battery requirements

KPIs

Technologies to reach the targets

Battery cell technologies – until 2020 LIT

From 2020: PLIT

Summary and prospect

Bosch 48V Mild HEV



Applications

HEV PHEV EV BRS

Generation 1 (series)

Generation 2 (in development)

Electrical range

Electrical power

Challenges • High power

• Low cost

Technology Li-ion

(available)

HEV PHEV EV BRS



Electrical range

Electrical power


• Low cost

• High performance

• Cycle life

• Cost down

Technology Li-ion

(available)

Li-ion

(improved)

HEV PHEV EV BRS



Electrical range

Electrical power


• Low cost


• Cycle life

• Cost down

• High energy

density

• Cost down

Technology Li-ion

(available)

Li-ion

(improved)

Li-ion

(improved)

Post Li-ion

Applications

HEV PHEV EV BRS



Electrical range

Electrical power


• Low cost


• Cycle life

• Cost down

• High energy

density

• Cost down

• High power

• Low cost

Technology Li-ion

(available)

Li-ion

(improved)

Li-ion

(improved)

Post Li-ion

Li-ion

(available)

HEV PHEV EV BRS


HEV PHEV EV BRS



BBSD/ENA | 7/20/2016


Market volume

1.5

6 5.30.1

4.58.3

0.2

2.5

8

0

5

10

15

20

25

2014 2020 2025

Un

its [m

io. ve

hic

les]

Vehicle sales PC incl. LCV<6t: Estimation Bosch

HEV Hybrid Electric Vehicle PHEV Plug-in Hybrid Electric Vehicle EV Electric Vehicle

Total vehicle market: 12511285

21,6

13

1,8

PHEV and EV with strong growth

HEV volume declining



Consequences on production capacity

3 12 111

68166

4 150

600

400

100

200

300

400

500

600

700

800

900

2014 2020 2025

Pro

du

ctio

n c

ap

acity [G

Wh

/ye

ar]

HEV Hybrid Electric Vehicle PHEV Plug-in Hybrid Electric Vehicle EV Electric Vehicle

Required battery production capacity

777

230

8

Li-ion Consumer 2014



Customer expectations towards an EV

Driving range ≥ 350 km

Good performance

Fast charging

No battery exchange

during vehicle life

Reasonable safety

Affordable

Customer expectations Battery requirements

≥ 50kWh

200Wh/kg…400Wh/kg

150kW…250kW

P/E ratio 3…5

250km

with 15min charge time

80% capacity &

performance @ 300Tkm,

> 10years

Safety level equal or higher

than in vehicle with ICE

Market price target battery:

6,600USD



KPIs: status 2015, market targets 2020 - 2025

Energy Density

Cost

Lifetime

Quality

Safety

Energy Density

Cost

Performance




Cost

0

100

200

300

400

500

2015 2020 2025

Cell Pack

Co

st

[EU

R/k

Wh

]

~ F

acto

r1

/4

~ F

acto

r1

/3

0

100

200

300

400

500

2015 2020 2025

Cell Pack

En

erg

y d

en

sit

y [

Wh

/kg

]

Energy Density

~ x

2~ F

acto

r3

EV




Cost

0

100

200

300

400

500

2015 2020 2025

Cell Pack

Co

st

[EU

R/k

Wh

]

~ F

acto

r1

/4

~ F

acto

r1

/3

EV



Content


Applications

Market volume



KPIs



From 2020: PLIT


Bosch 48V Mild HEV



Battery cell technologies

LIT: Li-ion Technology PLIT: Post Li-ion Technology

Conversion

cathode

>2025

Li-S

>2025

EV with solid state

electrolyte, SOP > 2020

Gravimetric energy density cell [Wh/kg]

Vo

lum

etr

ic e

ne

rgy

de

ns

ity

[W

h/l

]

1500

1000

500

800400 600200

LIT Maximum

EV 2020

~ 800Wh/l

PHEV 2020:

~400Wh/l

• Market until 2020 dominated by Li-ion Technology (LIT)

• Energy density in 2020 already close to the technical limit of LIT

• Post Li-ion Technologies (PLIT) with potential for higher gravimetric and volumetric energy densities in combination with improved safety

• EVs w/ SOP > 2020: PLIT with solid state electrolyte very promising



PLIT cell technologies

Terminology

Li-ion Technology (LIT)

Lithium in both electrodes

mainly intercalated

Structure of electrodes hardly

changed due to intercalation

Li-ions migrate free

via (liquid) electrolyte

Post Li-ion Technology (PLIT)

At least one electrode not intercalating lithium

Acronym PLIT often used as synonym for Li-Sulfur and Li-Air technologies

Cells with metallic Lithium anode are counted among PLIT

Anode Separator Electrolyte Cathode

Charging

Discharging

Li+

Li+

Graphite Lithium-metal-oxide

Li



PLIT cell technologies, examples

Solid State Cells

Anode Separator Cathode

Charging

Discharging

Li+

Li+

Metallic

lithium

Solid state electrolyte

with active material

Polymer

Active

material

Li-Sulfur Technology


Charging

Discharging

Li+

Li+

Metallic

lithium

Mixture of sulfur and carbon

particles with binder

S8

BinderLi2S

C

Li-Air Technology

Anode Separator/Electrolyte Cathode

Charging

Discharging

Li+

Li+

Metallic

lithium

Mesoporous

carbon

Solid state

electrolyte

Li2O2

Charging

Discharging

O2

O2

Cells with conversion cathode


Charging

Discharging

Li+

Li+

Metallic

lithium

Metal fluoride

FeF2



Solid state cells, status Bosch

Bosch acquired Californian battery technology company Seeo

Engineering prototype cells available

Seeo DryLyteTM Technology

Dry Solid

Anode Lithium Foil

Separator

CathodeDry Solid

Polymer

Composite

Dry Solid

Electrolyte

Technology very promising: Lifetime > 1000 cycles reached with LFP cathode,

operating temperature 80..100°C



Solid state cells, Safety

Safety test results (LFP cathode, Li metal anode)

Z-Axis

X-Axis

Y-Axis

Test Result

Crush No smoke or flames

Penetration test No smoke or flames

Short circuit test No smoke or flames

Thermal shock No smoke or flames

Over-discharge No smoke or flames

Overcharge No smoke or flames

Thermal stability Stable up to 180°C

Intrinsic safety of Seeo technology is a big advantage

Crush test




Li-ion technology will dominate the market until 2020

Li-ion technology technical feasible for EV and PHEV

Technical limit of automotive Li-ion

expected @ ~350..400Wh/kg

Post Li-ion with potential to further

increase energy density and to reduce cost

Solid state cells for EV expected

to be ready for series past 2020

PLIT with high chance

for game changer



Content


Applications

Market volume



KPIs



From 2020: PLIT


Bosch 48V Mild HEV

Bosch 48V Mild HEV



Evolution of Electrification

AStart

Stop2

46

x 1000 / min

40

80

160

200km/h

120

0

Coasting

Inn

ov

ati

on

lin

e

AStart

Stop2

46

x 1000 / min

40

80 120

160

200km/h0 20

A

Start

Stop2

46

40

80-

sHEV

Start/StopCoasting

AdvancedStart/Stop

24

6

x 1000 / min040

80 120

160

200km/h0

AStart

Stop

Baseline:Start/Stop

x 1000 / min

200km/h0

Recuperation

Boost

e-drive

Coasting

AStart

Stop2

46

x 1000 / min

40

80

160

200km/h

-

0

PHEV

160

Recuperation

Boost

e-drive

Coasting-

AStart

Stop2

46

x 1000 / min

40

80

160

200km/h0

48V Systems

Recuperation

Coasting

Boost

e-drive entry

Further improvement of cost-benefit

ratio plus feeling of electric driving

CO2 potential

ICE Dominant HEV Dominant

sHEV: ‘Strong Hybrid Electric Vehicle’; electric motor operation independent of engine state; typically operating at VDC>120

BBSN/ENA1 | 7/20/2016


Powertrain Scenarios – 48VBRS 48V shows considerable market growth

0

2

4

6

8

10

12

2020

3.1

2014

0.0

Un

its [m

io. ve

hic

les]

2025

11.3

Vehicle sales PC incl. LCV<6t1)

1) Estimation Bosch

total market 125 mio.112 mio.85 mio.

BRS 48V

BRS 48V Boost Recuperation System

Bosch 48V HEV

Robert Bosch Battery Systems | BBSN/ENA1 | 7/20/2016


Increasing Total System Power Required to Achieve Operation

Inc

rea

sin

g P

ow

er

Ne

ed

s f

or

Ind

ivid

ual C

om

po

nen

ts

Limited Change wrt.

TodayBrake Actuation

Electrical Power

Increased

EPS Power

Increased in coord.

w/ Brakes

Time to Stop

Further EPS Power

Increase

Longer Duration

Duration after

system electrical

failure

Power-Net Redundancy – Autonomous Functions

Bosch 48V HEV



Summary

48V seen as a bridge to a higher voltage future

‒ Main focus is on easy to integrate belt-machines

‒ Other topologies considered, but with a later implementation (post 2021)

‒ Cost effective CO2 reduction the main driver

Power-net requirements may drive manufacturers towards 48V solutions

‒ Highly Automated Driving will require redundant and powerful actuation systems

pushing charging systems to their limit

New concepts may change the landscape

‒ SSC could be one path where a non-traditional strategy that delivers real-world

fuel savings may also drive the need for redundant power-net capability

THANK YOU

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