version 1.2 benchmarking overview ©ricardo 2015 · ©ricardo plc 2015 1 benchmarking overview...

1© Ricardo plc 2015

Benchmarking Overview

2014MY BMW i3 w/ REX

Version 1.2©Ricardo 2015

2014 BMW I3 W/ REX – 22 KWH BATTERY WWW.RICARDO.COM © RICARDO 2015 2

Disclaimer

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Ricardo Inc. has taken all reasonable care in compiling the analyses and recommendations provided in this report. Information contained in this report is based on limited data available to Ricardo believed correct

on the date of publication. Ricardo does not assume any liability, nor provide any warranty to activities based on the contents of this report.

This report is restricted and may not be distributed, re-published, sold or exchanged outside use by purchased companies.

INTRODUCTION


Executive Summary

Ricardo and partner A2Mac1 conducted a benchmarking teardown and analysis review of a 2014MY BMW i3 with range extender vehicle. This report provides an overview of:

– Selected vehicle features

– High voltage battery pack design

• Enclosures

• Thermal system

• Battery module

• Battery cell

• Battery management system

– Traction motor and eMachine electronics (inverter/ DC‐DC converter)

– Charging system

– Range extender system

Most imagery is courtesy of A2Mac1 and Ricardo, and is available through A2Mac1.com subscription services and may be purchased by contacting A2Mac1.com or [email protected]. This report provides a review of selected vehicle and component features, suppliers and patents.

Additional information is provided in the Appendix of this document including public domain resources and patent files.

INTRODUCTION


1. Vehicle……………………………………………………….……………..4

2. Battery Pack…………………………………………………………….11

3. Battery Module………..……………………………………………..20

4. Battery Management System…………………………………..34

5. Traction Motor………………..………..…………………………….40

6. Gearbox…………………..…………………..………………………….52

7. eMachine Electronics……………………………………............54

8. On‐Board Charger………………………………..…………………..60

9. Charging Station……………………………………………..………..65

10. Range Extender System………………………….......………..…68

a. Generator eMachine……………………………….…………..71

b. REX eMachine Electronics…………………………….……..76

c. Combustion Engine……………………………………….…….82

d. REX Engine ECU……………………………………………..…….85

11. Appendix……………………………………………...…………….……88

Table of Contents


Vehicle Model Year 2014 Vehicle Market (as purch.) USA

Vehicle Price as Purchased $47,025 Vehicle Mass (as weighed) 1,404 kg

Powertrain ArchitectureBattery electric vehicle with range extender

Fuel Tank Capacity1 1.9 gallons

All Electric Range (label) 72 milesGasoline Only Range (label)

78 miles

Battery Location Under vehicle floor Battery Cooling Refrigerant (R134a)

Battery Pack Capacity (stated)

22 kWhBattery, Number of Modules

8

Battery Configuration XXX Battery, Number of Cells XX (1X per module)

Battery Voltage (label) 3XXVDCBattery Pack Capacity (label)

XXAh

Battery Cell Type Rigid Prismatic Battery Cathode Chemistry NMC

Motor Architecture 3- phase, AC hybrid sync. Motor Max Speed XX,X00

Motor Peak Torque 2XX Nm Gearbox Single-speed fixed gear

Motor Peak Power XX5 kW Final Drive Ratio X.X:1

Engine Configuration (REX) 4-stroke, Inline 2 cylinder Engine Displacement (REX) 647 cc

Engine Power (REX) XX kW @ XX00 RPM Engine Torque (REX) XX Nm @ 4300 RPM

AC Charging Capacity XX kWDC Charging*(Not included in purchased vehicle)

XXkW

1775mm 3999mm

1578mm

Source: http://www.bmwusa.com/Standard/Content/Vehicles/2014/i3/BMWi3RangeExtender/

Benchmarked Vehicle Overview

VEHICLE


2014MY BMW i3 Battery PackBattery Pack – Parameter Summary

BATTERY PACK


2014MY BMW i3 Battery ModuleBattery Module Overview

BATTERY MODULE


Battery Module Sense Controller Circuit Board Major Components (Bottom)

BATTERY MODULE


1-spd Gearbox – Internal Assembly

GEARBOX


REX eMachine Electronics (REME) Interfaces

11 9a

12

9b

12

11

9a 9b

Connection: XXXManufacturer: XXXMaterial: XXX

Connection: XXXMaterial: XXX

Connection: XXXManufacturer: XXX

5a

5a

Connection: XXX

15

15Connection: XXXManufacturer: XXX

REX EMACHINE ELECTRONICS


Contact Information

Ricardo Strategic Consulting (RSC) is the global management consulting subsidiary of RicardoPLC and is a natural extension of Ricardo's high value‐added engineering services. We serve abroad range of clients in both the Automotive & Transportation sectors.

Coupling Ricardo’s significant work in the xEV sector product development and strategyconsulting with A2Mac1, the industry’s most recognized provider of web‐accessible automotivebenchmarking services, provides a unique toolset that supports companies efforts to deliverinnovative, high‐value services to their global automotive clients.

The following vehicles have been benchmarked:

Hands‐on workshops, interactive benchmarking tools, and battery CAD models are available forpurchase.

[email protected]

+01‐734‐394‐3939

http://estore.ricardo.com/

Ricardo Benchmarking

CONTACT US TO LEARN MORE ABOUT OUR xEV BENCHMARKING ACTIVITES

Workshops CAD ModelsEV/Hybrid Analysis

• 2015 VW e‐Golf• 2014 BMW i3 w/ Range Extender• 2014 VW Jetta Hybrid• 2014 Chevrolet Spark EV• 2013 Tesla Model S 60• 2013 Ford Fusion Hybrid

• 2013 Ford C‐Max Energi• 2013 Chevrolet Malibu Eco• 2012 Toyota Prius Plug‐in Hybrid• 2011 Chevrolet Volt• 2011 Nissan LEAF• 2011 Mitsubishi i‐MiEV

APPENDIX

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