ir ing Tim de Langeir ing Tim de Lange

�� System IntegrationSystem Integration

�� Power electronics, storage, controls and Power electronics, storage, controls and

transmissionstransmissions

�� www.innosysdelft.comwww.innosysdelft.com

Goals Innosys Delft BVGoals Innosys Delft BV

�� System integration:System integration:

�� Delivery of systems with battery packs, power Delivery of systems with battery packs, power

electronics, motors, chargers and controlselectronics, motors, chargers and controls

�� Engineering, simulations and design of drive systemsEngineering, simulations and design of drive systems

�� Production and onProduction and on--site installing drive systemssite installing drive systems

�� Sustainable Entrepeneurship:Sustainable Entrepeneurship:

�� Charging facilities all over the worldCharging facilities all over the world

�� Cooperation with utility companiesCooperation with utility companies

�� Establishement of Establishement of ‘‘All Electric SocietyAll Electric Society’’

Projects: Nuna 1Projects: Nuna 1

Projects: Formula Zero H2 KartProjects: Formula Zero H2 Kart

Projects: InnoCarProjects: InnoCar

Projects (April 2010: 70.000km)Projects (April 2010: 70.000km)

Projects: InnoCarProjects: InnoCar

Projects: InnoCarProjects: InnoCar

Projects: Lotus Electric 200BHPProjects: Lotus Electric 200BHP

Projects: Volkswagen GOLF Projects: Volkswagen GOLF

100BHP100BHP

City CarCity Car

Current activityCurrent activity

�� Development of 100hp budget drive trainDevelopment of 100hp budget drive train

�� 2011: Electric broad cast vehicle olympic 2011: Electric broad cast vehicle olympic

gamesgames

�� October 2010: Smart Grid charger for low October 2010: Smart Grid charger for low

voltage EVvoltage EV’’s and high voltage EVs and high voltage EV’’s, 5s, 5--

10kW, 1&3 phase (auto detection)10kW, 1&3 phase (auto detection)

�� EV to DC sustainable network EV to DC sustainable network

compatibility: all DC networkscompatibility: all DC networks

Conversion ChallengesConversion Challenges�� SpaceSpace

��Weight distributionWeight distribution

�� Dynamic behaviorDynamic behavior

��WaterproofWaterproof

�� Battery temperature managementBattery temperature management

��Modularity and serviceabilityModularity and serviceability

��Wire harness productionWire harness production

�� SafetySafety

�� Compatibility electric grid (cos phi, EMI)Compatibility electric grid (cos phi, EMI)

SpaceSpace

Weight DistributionWeight Distribution

Dynamic behaviorDynamic behavior

WaterproofWaterproof

Batt. temperature managementBatt. temperature management

�� Temperature distribution across packTemperature distribution across pack

�� Use in winterUse in winter

�� Use in summerUse in summer

�� Charging vs Lithium platingCharging vs Lithium plating

�� Regenerative brakingRegenerative braking

�� Drive control as function of battery statusDrive control as function of battery status

Modularity and serviceabilityModularity and serviceability

�� Different battery packs all over the car?!Different battery packs all over the car?!

��Motor overhaul?Motor overhaul?

�� External people working on carExternal people working on car

�� Component replacementComponent replacement

�� Price reduction for broken partsPrice reduction for broken parts

�� Safely working on live partsSafely working on live parts

Wire Harness ProductionWire Harness Production

�� About 500 connections in the Drive train About 500 connections in the Drive train

wire harness only (!)wire harness only (!)

�� Around 70 sub harnesses (!)Around 70 sub harnesses (!)

�� Not only 12V but also HVDC!Not only 12V but also HVDC!

��Waterproof connectorsWaterproof connectors

�� Cable quality: status after 5Cable quality: status after 5--10 years?10 years?

�� Handling of extension wireHandling of extension wire

�� Small series production: hand labour!Small series production: hand labour!

�� Voltage ratings / Color codesVoltage ratings / Color codes

SafetySafety

SafetySafety

SafetySafety

�� Battery position in chassisBattery position in chassis

�� Ventilation toxic gassesVentilation toxic gasses

�� Flame retardant materialsFlame retardant materials

�� Compare with fuel tank bay, but only 10 Compare with fuel tank bay, but only 10

times less contained energy!times less contained energy!

�� Switch gear strategy when crashing: Switch gear strategy when crashing:

safety contactorssafety contactors

SafetySafety

�� Original ABS functionality (inertias drive Original ABS functionality (inertias drive

train might change)train might change)

��Mechanical safety between motor and Mechanical safety between motor and

transmisiontransmision

Compatibility electric gridCompatibility electric grid

Compatibility electric gridCompatibility electric grid

Compatibility electric gridCompatibility electric grid

�� All electric society vs good old ac networksAll electric society vs good old ac networks

�� DC advantages: DC advantages:

-- Always power factor 1Always power factor 1

-- No reactive power billingNo reactive power billing

-- No distortionNo distortion

-- Higher efficiency due to solid state Higher efficiency due to solid state

electronicselectronics

-- Smaller equipmentSmaller equipment

-- Easier network management: EV is bufferEasier network management: EV is buffer

ICTICT�� AC: AC:

-- Monitoring reactive & active powerMonitoring reactive & active power

-- FrequencyFrequency

-- DistortionDistortion

-- Power balancePower balance

DC: DC:

-- Monitoring active power onlyMonitoring active power only

-- Power balancePower balance

-- Different vision peak shaving due to bufferDifferent vision peak shaving due to buffer

ICTICT�� AC: AC:

-- Intens!Intens!

-- System is subject to collapse!System is subject to collapse!

DC: DC:

-- ICT can focus on relevant challenge: ICT can focus on relevant challenge:

sustainable power implementation!sustainable power implementation!

-- InnoSys: ICT controlled chargingInnoSys: ICT controlled charging

ConsiderationsConsiderations��Make EVMake EV’’s more automotive; compact, etcs more automotive; compact, etc

�� EVEV’’s use energy but 100% compatible with s use energy but 100% compatible with

sustainable energy sourcessustainable energy sources

�� Is AC the future? DC is more likely!Is AC the future? DC is more likely!

��Managing the AC/DC networks is definitely Managing the AC/DC networks is definitely

optimized with ICT.optimized with ICT.

Questions?Questions?

�� Site: Site: www.innosysdelft.comwww.innosysdelft.com

�� EE--mail: mail: delange@innosysdelft.comdelange@innosysdelft.com