EGVIA - ERTRAC 1st European Conference Results from Road Transport Research in H2020 projects 29 November 2017 to 30 November 2017 Brussels

1. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 723970
Reiner John
Less emissions, and congestion more comfort and safety

2. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
OSEM-EV is taking a leap
towards 3rd and 4th Generation
Intelligent Electric Vehicle with
a value-based functional
integration of electro-thermal
energies

3. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
EGVI GV2-Call 2014
Optimised and systematic energy management in electric vehicles”
Concerns and objectives
§ “Range limitation, due to the limited storage capacity of electric batteries
[…]”
§ “In extreme conditions up to 50% of the batteries' capacity is absorbed by
[auxiliary equipment]“
Improvements
1. Comprehensive thermal management system
2. Battery life duration enhancement (as a side effect of thermal management)
3. Energy efficiency of electrified accessories
4. Energy harvesting functions and automated and eco-driving strategies

4. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
Predictable
mileage

5. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
Team and
target

6. 1 Predictable mileage Systematic control of electro-thermal energy flows
2 Driving range increase
Intrinsic higher battery performance and capacity, higher
powertrain efficiency, energy density at same cost
3 Battery thermal endurance Optimal operating conditions and intersystem operability
4 Battery lifetime prolongation
Peak and pulse performances in driving, charging and
recuperation phases
5 Affordable battery capacity Downsizing
6 Thermal preconditioning
Powertrain and compartment heating/cooling to optimal
operation range
7 Thermal insulation materials Reduced thermal energy demand
8 Functional thermal network Integration of subsystems for reduced size, weight and cost
9 Coupled electro-thermal architecture Systematic subsystem electro-thermal management
10 Electro-thermal energy management
Control algorithms and computing platform for energy storage,
reuse, substitution and harvesting

7. This is property of Osem-EV

8. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
OSEM.EV models virtual vehicle of all categories
and demonstrates two real vehicles

9. OSEM-EV-SC2Feb 8th, 2017 9
Direct with dual heat sources
Heating mode
Waste heat Ambient
heat

10. OSEM-EV-SC2Feb 8th, 2017 10
Indirect with dual heat sources
Heating mode
Waste
heat Ambient
heat
Integrated heat
pump
Secondary cabin
heating/cooling loop

11. OSEM-EV-SC2Feb 8th, 2017 11
Different solutions were proposed and analyzed:
ØAlternative thermal management architectures with heat pump
ØInfluence of thermal mass (direct copper cooling)
ØInfluence of coolant management
§ Maximum coolant flowrate
§ Reduced flowrate
Ø Effect of machine and inverter cooling by AC system in hot weather conditions
(on-going)
Ø Influence of new cooling methods on lifetime of components (e.g. oil cooling)
Thermal management systems for powertrain
Q: How can the powertrain help to improve the overall energy
management of the EV?

12. OSEM-EV-SC2Feb 8th, 2017 12
Schematization of the Powertrain
TE-MCU
VE-MCU
Adding computation power to the powertrain for thermal management.
Thermal management CPU interfaces with e-motor control
Heat pump
Battery

13. Battery System Overview
System Architecture
n System power and energy
n 96 Cells à 94Ah (Geometry: Prismatic BEV4, Chemistry: NMC/Graphite)
n Total energy content: 33kWh
n Max. continuous power: 120kW
2016-02-08 13OSEM-EV
n Battery system thermally insulated for all-time
controlled energy exchange with the other
components of the car
n Battery pack and battery system electronics can
be installed separately and connected afterwards
leading to a flexible installation of the battery
system

14. Design of the Battery Module
14OSEM-EV
Battery module without top frame
Fraunhofer IISB
Assembled battery module 12s1p battery module without cover lid
2016-02-08
Module overhead:
n Weight 5kg / 20%
n Volume 3L / 25%

15. WP 5
WP 3
WP 1
Supply Chain 3 – Tasks
15OSEM-EV
WP 3
Requirements
• Mechanical requirements and
specifications
- installing space
- vertical and lateral coil offset
- structural part requirements
• Electrical requirements and
specifications
- voltage levels
- interfaces
- switching frequency
• EMF
• Functionality
• Temperatures
• Communication protocol
System Setup
• Magnetic field simulations
• Coil parameter
- windings
- diameter
- litz wire
• Thermal & Electric Design
- currents, losses
Mechanical Design
• Mechanical design
• Embedding process
• Materials
• Thermal design
Electrical Design
• Driver stage
• Connectors
• Circuit
Simulation
• Control logic and algorithms
• Communication interfaces
HIL – test bench
• HIL test bench with battery as source and sink for
application
related testing
• Efficiency and loss
analysis
• EMV tests

16. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
Qualified and quantified targets
Competitive
Advantage of
European
automotive
industry
Increased electro-thermal
performance and reduced costs
of automotive subsystems and
the overall EVs produced in
Europe
Cost -20%
Productivity +5%
Value proposition and
customer satisfaction drives
increased production numbers
of European EVs
Production
volume per year
ahead of current
track
+0.5%
Improved usability by range
increase and predictable
mileage
Range +10%
Pred. mileage +20%
Significant improvement on
safety and comfort
+ 60 %
Sustainability Improved total energy
efficiency of the EV
+ 30 %

17. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
OSEM.EV is focused on 2 real car demonstrators
LEV for food delivery
Daimler B-class

18. This project has received funding from the [European
Union’s Horizon 2020 research and innovation
programme under grant agreement No 723970
Thank you
Enjoy Life with fresh food
with less emissions
through electrified mobility
Acknowledgment: This project has received funding from the
European Union's Horizon 2020 Programme under Grant
Agreement No. 653514