Greencars 2012: Bussiness, Challenges and Global Oportunities

Bussiness Challenges and Global Oportunities

WELCOME LETTERS .............................................................. 3

GREEN CARS: BUSSINESS CHALLENGES AND
GLOBAL OPORTUNITIES.
SPANISH NATIONAL CONFERENCE 2012 .............. 7
• PROGRAMME ....................................................................... 8
• ORAL COMMUNICATIONS .............................................. 10

DIRECTORY OF
PRODUCTS/TECHNOLOGIES ........................................ 23
• Energy storage technologies, ancillaries and
management systems ............................................. 24
• Power electronics and ancillaries .................... 37
• Powertrain: advanced ICEs, e-motors ........... 44
• Other vehicle systems: safety,
communications, comfort ..................................... 51
• Electric vehicles .......................................................... 58
• Materials, production systems, ecodesign,
recycling ........................................................................... 67
• Charging infrastructure ......................................... 73
• Testing infrastructure ............................................ 83
• Others: Simulation, Transport system
integration, Business models ............................. 89

-2-


WELCOME LETTERS

Bernabé Unda
Viceconsejero de Industria y Energía.
Gobierno Vasco

Since several years ago the society in which we live is changing a number
of pillars that until now had become the basic fundamentals. However,
the same social evolution, their internal interactions, shows that the
construction of the future is doing day to day, without dogmas, with
respect, with imagination and above all, with work.
Is this the current situation in the automotive industry and
transportation in general. Just ten years ago, few people could suspect
that the essential oil and its derivatives could have a serious rival as an
engine of humanity. In recent years, what began as a bold proposal of
some visionaries who retrieved the concepts of the origin of electric cars,
has become a global movement, aided by the geopolitical, emerging
needs and technological development.
So today we stand in the midst of social change-up, compared to an
open future in the field of mobility, where there is room for new ideas,
proposals and initiatives. In short, we can stop being spectators and
become actors, and why not, the protagonists of this change. This
requires to be very clear about the challenges and provide for research
and technological development the importance it deserves.
It is in this situation, providing opportunities and opening doors, for
example through the Green Cars Initiative, as we move forward and
introducing fruit market performance of daily work and team oriented.
The Basque Government is convinced of this road and it has sought for
years a firm commitment entrenched in the Plans for Science,
Technology and Innovation, the latter of which has been presented
recently. The clear and unreserved support to the actions of Research &
Development (R&D) has enabled it to present our companies and
technology centers in European Programmes (FP 7), in a market growing
Green Cars, and addressing all the facets that open: vehicles, electronics,
components, communications ... in summary mobility. This is the path
that will allow us to be agents of change that is occurring.
Let me take this moment to encourage companies from the sectors
involved in the movement "Green Cars" to be active investors in R&D,
and seize the opportunities available to everyone from governments,
Basque, Central and Europe.
As Minister of Industry, Trade and Tourism of the Basque Government, is
pleased to present this document which sets out the technology and
content result of the day Green Cars 2012.

-4-

Jesus Monclus
Spanish Representative in the FP7 Transport Programme Committee,
CDTI Member of the CAPIRE Advisory Board

Dear colleague, and technology centers, public administrations and
It is a great pleasure to address you on the occasion of research centres… A true team work, in other words. Also,
this new edition of the national event Green Cars 2012 a work sustained in time: as a saying from my homeland
“Business challenges and global opportunities”. Among says, “let the full rush, that the giants march slowly”. I
many other reasons, because along the current situation would also like to acknowledge, because it is fair to do it,
of uncertainty and difficulties, this gathering should be the efforts of many persons and entities that lit the flame
considered “a door toward hope” (if you allow me to of this events and have kept it alive until now: Serafín
bring here the title of the Vallejo Nájera's book that I read Olcoz and Tecnoebro (they were the promoters of the first
many times ago) and a living proof of our future event in Zaragoza in 2009), SERNAUTO (Maria Luisa and
potential. I would like to thank all the organizers of this Cecilia: I am proud to be your fans), ANFAC (Fernando
week's events and, in particular, the Basque Government, and Arancha, who have been caring of Green Cars in spite
the City Government of Vitoria, TECNALIA and SPRI, as of the many other pressing issues they have dealt with
well as all the rest of partners in the organizing team. during these rough seas), Iberdrola (Jesús and Ana),
Thank YOU all too for participating. And, of course, I TECNALIA (Manu and Dioni, among many others), the
want to express my gratitude to the European regional governments and bodies in Aragón, Valencia,
Commission for its seamless support to all our initiatives Castilla y Leon and, this year, the Basque Country, where
in this and other uncountable matters. all the events have landed.
During these last few years, and above all because of It might be just the awakening of a dormant potential,
your involvement, we have succeeded in putting the since we enjoy an automotive sector that really excels
spotlight on the European Green Cars Initiative and worldwide and, at least so far and I hope it will continue
presenting it as an example, mainly for us, of what the this way, with an astonishing resilience. Nothing more,
European R&D must be: an initiative in support of a key and nothing less, that “to improve to become what we
European economic and social sector (this being are”, recalling that quote from the classic greed poet
especially true in our country), launched in the perfect Pindar.
moment (just-in-time) and with an agile and light (lean) But all this has just begun. In front of us, we are already
structure… Many of these terms, closed attached to the facing the new challenges, even if we have not finished
automotive manufacturing industry. And, what is yet solving the old ones. And not only business
probably more important in the long term, an initiative challenges, as the title of this conference reads, but also
where Spain has been able to deploy a large part of our challenges linked to research and innovation: green
potential. Whereas before Green Cars the Spanish vehicles will continue to play a protagonist role in the
participation in European projects related to automotive coming Horizon2020 programme, which is just around
matters seem to have a glass ceiling of around 5%, the corner. Europe is already setting the grounds for it
nowadays and after three years of call, we can be proud and, as the small print of the bank agreements claim,
to say that we have managed to double that percentage. “past earning do not guarantee future rates”.
Another extremely relevant indicator: Spain ranks now Competence is not meant to diminish, but the contrary,
the position that it deserves in the raking of countries, and for this reason we cannot be complacent and relax
holding the fourth place behind Germany, Italia and back. We have no other option that to reinvent ourselves
France, and ahead of other countries such as United (another book title, this time of a work of contemporary
Kingdom or Sweden (these two last countries, for several writer Mario Alongo Puig) in these times of changes and
reasons, are normally situated before Spain in the overall tribulations.
ranking of FP7-Transport calls). One additional comment: Let us move forward and, if you allow me a last smile, let
the Spanish entities are leading a total of 12 projects, us substitute the “who switched off the light at the end of
which is to say that almost one out of six European Green the tunnel” with a clear and loud “let us hit the gas and
Cars projects is coordinated by a Spanish entity. get out this tunnel as soon as possible”.
Success is not random, at least for many of us. An this I wish you a very successful and useful conference in
success has been an achievement of many: industries Vitoria, and congratulations to all of you that have taken
(close to a 50% of the Spanish participation in the part in the European Green Cars Initiative,
European Green Cars Initiative projects should be
credited to companies) the industrial actors), innovation

-5-

András Siegler
Director Transport Research
DG Research and Innovation - European Commission

Dear Green Cars colleague:
I am really happy to welcome you to this 2012 edition of the National
Green Cars Conference.
I would also like to thank the Basque Government, CDTI, the City of
Vitoria, Tecnalia, ANFAC, SERNAUTO, SPRI and Iberdrola for their
continuous commitment towards the organization of this event and, in
general, the dissemination of Green Cars information in the Basque
Country and Spain. I am fully aware of the tight restrictions that we are
all experiencing and for this reason your efforts are particularly
commendable.
During the four rounds of calls of Green Cars, I am proud to say that
hundreds of entities from all around Europe and beyond are taking part
in the activities. A considerable part of them are Spanish and Basque
partners, and let me know that you are making a substantial
contribution towards this important Europea initiative. Ongoing projects
cover a myriad of matters related to electric vehicles, efficiency of heavy
vehicles, logistics, comodality, ITS… And they range from further
looking research to activities that are much closer to the market that one
could think, giving the fast pace of innovation in the road vehicle sector:
I am sure that we will see “Green Cars” innovation on our roads in the
next few years.
If this context, the title of the conference, showing your wishes to push
European research results towards the real and global markets, has been
particularly well chosen. Europe really needs to deploy its full potential
at this time, but the potential grows out of research and innovative
efforts and cooperation. So the role of research is more important than
ever.
As we are entering into the next steps for shaping the future Horizon2020
programme that will start on January 1st 2014, and where clean and
competitive mobility will play a central role, you should be sharpening
your assets in order to strengthen your contribution to the European
research and innovation activities. During the next months there will be
numerous opportunities for interaction and networking in connection
with the preparation of Horizon2020. In this context, I am extremely
happy that the European car industry is proposing to launch a „European
Green Vehicles Initiative” under H2020 as a contractual public-private
partnership following the success of the European Green Cars Initiative
(EGCI). I urge you to be an active player in this preparatory (and
exciting) phase.
I also hope you will all be responding to the last round of FP7 Green Cars
calls currently open and am really looking forward to seeing you in
Horizon2020 too.
Sincerely,

-6-


GREEN CARS: BUSSINESS CHALLENGES
AND GLOBAL OPORTUNITIES.
SPANISH NATIONAL CONFERENCE 2012


1: PROGRAMME

Green Cars: Bussiness Challenges
And Global Oportunities.
SPANISH NATIONAL CONFERENCE 2012

08:30 - 09:00 RECEPTION OF PARTICIPANTS AND 13:25 - 14:55 Lunch / exhibition / Posters / Best Posters
DOCUMENTATION Vote

09:00 - 09:35 WELCOME 14:55 - 15:55 MODULE 3 ► Greencars: programmes and
Joseba Jaureguizar / General Director of Global Perspectives
TECNALIA Moderator: Mario Armero / Executive
Opening of the conference Vicepresident/ ANFAC
Bernabé Unda / Minister of Industry, Trade and Greencars CASE 1: LNG Blue Corridors Spain
Tourism / BASQUE GOVERNMENT pioneer of the greater European project of
Juan Carlos Cortés Pulido / Director of global alternative fuels for transport - Manuel Lage /
innovative markets / CDTI NGVA Europe; Xavier Ribas / IDIADA; José Luis
Pérez Souto / IVECO
09:35 - 11:00 MODULE 1► Initiatives and Positioning Greencars CASE 2: Nissan
Moderator: Maria Luisa Soria / General Secretary
/ SERNAUTO 15:55 - 17:40 MODULE 4 ►Round Table: Future Perspectives
EUROPA: Horizon 2020 - Emilio Dávila / DG Moderator: Luciano María Azpiazu / President of
CONNECT / COMISIÓN EUROPEA the Editorial Board of DYNA, (official organ of
Positioning Greencars Europe - Jesús García / the Federation Associations of Engineers
Bussines Manager – Brussels office / IBERDROLA Industrial from Spain)
National support programmes - Raúl Garcia / Francisco Aparicio / INSIA
NCP Greencars / CDTI Javier Coleto / Development Business Area of
Euskadi y Greencars. Proyects and transport / TECNALIA
Inniciatives - Xabier Garmendia / Deputy Iván Gallego / MONDRAGÓN University
Minister of industry and energy / BASQUE Jesús Goiri / ENERGIGUNE
GOVERNMENT Francisco Trinidad / EXIDE
The winning poster Awards
11:00 - 11:45 Coffe / Exhibition / Posters / Best Posters Vote Evaluation of the first four years of the
Greencars inicitive and future prospects /
Jesús Monclús / Transport / CDTI
11:45 - 13:25 MODULE 2 ► Technologies and products
selected by the Scientific Committee
Moderator: Javier Coleto / Development 17:40 - 17:55 Closure of the day GREENCARS 2012
Business Area of transport / TECNALIA José Ignacio Hormaeche / General Director of
“Advanced Battery for Electric Vehicles in EVE- Ente Vasco de la Energía
CEGASA” Igor Cantero / CEGASA
“RANGE EXTENDER: A bridge towards the pure
EV” Miguel A. Mateo / Fagor Ederlan S.Coop
“AERC: All Electric Race Cars development”
Miquel Mateu / ALTRAN
“INNELBUS: Innovative technologies for the
electric urban buses development” Carrocera
Castrosua; insia-upm; avia ingeniería
“Initiative for the integral development of the
Electric Vehicle recharge infrastructure in the
Basque Country” MUGIELEC

-9-


2: ORAL COMMUNICATIONS

The European Green Cars Initiative evolving towards Horizon 2020
European Commission, DG CONNECT Unit H.5. - Smart Cities and Sustainability

Emilio DAVILA GONZALEZ

Aiming at economic recovery and the fight against climate The Commission earmarked 500 million Euros within the 7th
change, the European Commission in response to the financial Framework Program to fund research and technological
crisis of 2008 launched as one of the three Public Private development projects in the different areas covered by the
Partnerships (PPP) within the European Economic Recovery Plan Green Cars Initiative, (which addresses not only cars, but all
announced by the President of the European Commission on kind of vehicles), with a major focus on electromobility and
the 26th of November 2008. road transport, but covering also research topics on trucks,
internal combustion engines, bio-methane use, and logistics.
The European Green Cars Initiative, a Public-Private Partnership
for research and development on zero emission, safe and
efficient road vehicles and transportation. A total of 1 billion Considering the positive experience of the EGCI as a fast, lean
Euro was announced to be made available jointly by the and efficient PPP during FP7, the needed added value of an
European Union and the industry and Member States for integrated R & D & Innovation & Demonstration programme at
collaborative research projects mainly in the field of European level and the commitment and the shared vision of
electrification but also for developing novel solutions in long the sector, which has set objectives critical to the EU industrial
distance freight and logistics, complemented by loans from the competitiveness and taken also into account the importance of
European Investment Bank. this sector in Europe, now, the EGCI must evolve towards
Horizon 2020, the next Framework Programme for Research
At the side of the European Commission, the PPP European and Innovation.
Green Cars Initiative has been implemented by the involved
units of the Directorates General for Research; Information The presentation will summarise the main achievements of the
Society and Media (now Directorate General for EGCI since its creation, including more than 50 research
Communications Networks, Content and Technology); Mobility; projects started since the first call of proposals was launched in
Environment as well as Enterprise and Industry. The industry July 2009, present the main lines and structure of the Horizon
has been included via three European Technology Platforms, 2020, the ideas proposed by the Advisory Group and the
namely the European Road Transport Research Advisory Council stakeholders consultation, and the initial reflections of the
(ERTRAC), the European Technology Platform on Smart Systems Commission for the future European Green Vehicles Initiative
Integration (EPoSS), and the SmartGrids Platform. within Horizon 2020.

The members of these platforms formed an Industrial Advisory
Group and edited a roadmap, at first on electrification, and
later complemented by the other two technology fields, long
distance freight and logistics. Moreover, a multi-annual plan
prioritizing the topics for implementation in calls for proposals
for the 7th Framework Programme was presented.


- 11 -

The European Green Cars Initiative.The next step.
IBERDROLA

Jesús García Martín

The European Green Cars Initiative is one of the three Public The activities of the PPP European Green Cars Initiative are
Private Partnerships (PPP) of the European Economic Recovery supported by the EU-funded Coordination Actions “PPP
Plan announced by the President of the European Commission Implementation for Road Transport Electrification” (CAPIRE)
on the 26th of November 2008. The objective of the initiative is and “Information and Communication Technologies for the
to support R&D on technologies and infrastructures that are Fully Electric Vehicle” (ICT4FEV).
essential for achieving breakthroughs in the use of renewable Now the initiative will follow the approach of HORIZON 2020, in
and non-polluting energy sources, safety and traffic fluidity. this way the instrument considered the most suitable is the
Despite its name the Green Cars Initiative is not only for contractual Public Private Partnership as described in article 19
passenger cars. Under the Green Cars Initiative, the topics of the HORIZON 2020 proposal, in which both the public and
include research on trucks, internal combustion engines, bio- private sides express their commitment to support the
methane use, and logistics. However a main focus is on the development and implementation of a research and innovation
electrification of mobility and road transport. Beyond activity of strategic importance to the EU competitiveness and
providing loans through the European Investment Bank, the industrial leadership, and to address specific societal
PPP European Green Cars Initiative is making available a total of challenges. A legal entity will be created to represent the
one billion EUR for R&D through joint funding programmes of private part of the PPP, in the format of a nonprofit association,
the European Commission, the industry and the member states. to formalize the principles of work and get the commitment of
These financial support measures will be supplemented by the interested members to the objectives of the Initiative.
demand-side measures, involving regulatory action by The objective of the PPP European Green Vehicles Initiative
Member States and the EU. (EGVI) in HORIZON 2020 will be Energy Efficiency and
For a rapid implementation of the PPP European Green Cars Alternative Powertrains. The total estimated budget for the
Initiative, the instruments of the 7th Framework Programme period 2014-2020 will be of 3Bn € to represent critical mass and
were chosen, and an Industrial Advisory Group was established allow to reach tangible results.
as a high-level forum for a strategic dialogue between the
The Multi-Annual Implementation Plan of the PPP EGVI will be
European Commission and the involved industrial sectors. Due
based on the relevant research and innovation roadmaps
to the horizontal character of the topic, various services of the
developed by the different European Technology Platforms
European Commission work tightly together in this PPP: DG
involve in the initiative ( ERTRAC, EPoSS and SmartGrid).The
Research and Innovation, DG Information Society and Media,
EGVI topics will include activities offering significant
DG Mobility and Transport, DG Energy, DG EnvironmentandDG
opportunities but with high level of risk. Consequently it
Enterprise and Industry. The industry is represented by
cannot be expected that all results will be achieved exactly as
industrial members the European Technology Platforms
planned. However, without public financial support for these
European Road Transport Research Advisory Council (ERTRAC),
projects, it is likely that there would be much less or no
European Technology Platform on Smart Systems Integration
opportunity at all to address these challenges.
(EPoSS), SmartGrids and other stakeholders. They have made
recommendations for the annual FP7 Calls for Proposals of the The annual recommendations for funding topics will be made
European Green Cars Initiative since 2009. Their advice is based on this basis by the new PPP organization, with priorities
on a continuous process of strategic stakeholder consultations, selected by industrial delegates. The annual selection is
consisting of workshops and multiannual implementation therefore a matter for the future prioritization exercise, which
plans which rest upon the long-term roadmaps and strategic should be open and flexible, and allow adapting it according
research agendas of the European Technology Platforms. The to technology and market evolutions towards 2020.
Industrial Advisory Group is chaired by Prof. Dr. Wolfgang The activities of the PPP EGVI will be regularly evaluated in
Steiger from Volkswagen. order to monitor and assess their performance.The findings will
Three rounds of annual calls for proposals have been launched be published in a generalized manner as an annual progress
within the PPP European Green Cars Initiative since July 2009, report which may also give advice to the European Commission
and more than 50 collaborative research projectshave been and the ETPs.
started.


- 12 -

EUSKADI & GREENCARS: Projects and Activities
Industry and Energy Viceminister. Basque Goverment

Xabier Garmendia

Efforts and contribution of people to common society are even early stages of use, when technology risks of new
more valuable when global situation becomes harder and developments must be carefully controlled.
implies strong changes for everybody. From the Basque
Country, this contribution to common development and to the From industrial community, new business models are being
future of transport and mobility is clear and all implied people tested and developed as an answer to open needs. Our
are doing this huge joint effort. entrepreneur community is taking decisions in all aspects of
the new society, from new featured parts to final products as
The Basque Country is geographically a small community with electric Mercedes Vito, produced in Vitoria, without forgetting
2.1 M inhabitants. Industrial activity is highly developed and new companies that promotes the use of electric vehicles and
the social and economic structure lets us to push strategies in infrastructure development.
coordination with European and Spanish policy in a quick way
and with a high capacity of sensibility and motivation. To be success in this new age of activity, Basque Government,
has fixed policies that help projects and activities which deals
At this point, there are in the Basque Country four main actors: with technologic and non technologic challenges. There are
ŸFour Universities highly developed for the education of skilled already results of some of these projects, and in others we can
professionals. foresee results that place their responsible in leading positions
considering future opportunities.
ŸFirst level applied R+D technology centres.
ŸWorld class companies, leaders in their sectors. Historically, hard times have offered big opportunities to
societies which have learnt how to manage them in a decided
ŸA responsible and R+D concerned public administration.
and sure way. In our case, sustainable future transport offers
us a big opportunity to set our development as society.
In this scenario, our contribution to the development of new
sustainable transport systems faces all conditions to lead the Therefore, according to our Energy Strategy 3E2020 and
new social revolution. considering our Plan de CIencia, Tecnología e Innovación 2015
(Science, Technology and Innovation 2015 Plan) the priority is
Our university community offers new training and education stablished in Energy as a key specialization area,
grades which let youngsters dealing with new aims through electromobility and smart grids, subjects all of them which will
giving society generations of professionals able to contribute fuel the market for our industrial development.
with their efforts to society. Knowledge and experience of R+D
centres eases general access to new technologies from the very


- 13 -

EUSKADI & GREENCARS: Projects and Activities
Industry and Energy Viceminister. Basque Goverment

Xabier Garmendia

This strategy must drive us to win the implicit challenges: ŸAdaptation of the regulatory framework: electricity sector,
electricity grid, municipal legislation, connection
standards...
EV TECHNOLOGICAL CHALLENGES
ŸNew and imaginative funding solutions to drive market
ŸOptimisation of current batteries: penetration of the electric vehicle. PPP
§Increase in energy density to extend the autonomy of EV ŸPromote a sufficient “critical mass” to stimulate subsequent
§Price reduction growth
§Extended lifespan ŸRaise social awareness of sustainable mobility and
knowledge and confidence in the electric vehicle
§Reduction in charging times
ŸBroader supply of EV models
The Basque Government, through policies mainly driven by
EnergiBasque aims to win every challenge of energy storage,
EV NON TECHNOLOGICAL CHALLENGES and therefore contributing with responsibility in energy model
transformation, side by side global leaders.
ŸAvailability of an advanced network of charging stations


- 14 -

NATIONAL SUPPORT PROGRAMS
Pedro Prado Ministry of Economy and Competitiveness

Raúl García CDTI

1. NATIONAL SUPPORT PROGRAMS: MINECO
Presentation of the instruments available from MINECO
supporting activities of R & D and innovation on the subject of
Green Cars: INNPACTO results for 2010 and 2011 calls, as well as
an advance for the current year call. Additional information
concerning the National Technological Platforms program
(INNFLUYE Call) will be presented

2. NATIONAL SUPPORT PROGRAMS: CDTI
The presentation will focus on the main instruments of CDTI in
order to support R&D projects, with special emphasis on the
results obtained on Green Cars activities, with special mention
to major R&D programs as CENIT, INNPRONTA, and
INNTERCONECTA. Besides, the return of Spanish entities in the
PPP Green Cars will be presented.
http://www.mineco.gob.es/portal/site/mineco/idi
http://www.cdti.es/


- 15 -

Advanced Battery for Electric Vehicles in CEGASA

Dr. Igor Cantero, CEGASA

1. Description of CEGASA´s technology 3. Expected Impact
The technological proposal of CEGASA in the area of electrical CEGASA considers that there is a clear market opportunity
energy storage is described as follows: related to lithium-ion technology, specifically in regard to its
ŸDevelopment and manufacturing of cells and battery packs application in electric vehicles (EV). The actions that CEGASA is
based on lithium ion technology of internal development carrying on are focused in the objective of positioning the
together with IK4-CIDETEC. company as one of the few European manufacturers of lithium-
ŸDevelopment of Green Pouch type Cells based on aqueous ion batteries. The experience and the industrialization skills of
processing for electrodes which involve the removal of highly CEGASA together with the development and the technological
harmful organic solvents. innovation proposals will allow CEGASA the access to a major
market share in a strategic sector of electric energy storage
ŸModular system design for battery packs allowing quick and
easy integration into a wide variety of applications in terms
of required power.
The technological innovation that CEGASA offers in relation with
the state of the art is based principally in the development of
electrodes by an aqueous procedure and in the modular design
of the battery pack. Both developments allow CEGASA to satisfy
on the one hand environmental requirements and for the other
one to access by means of the modular design to different
applications and therefore to different markets.
CEGASA takes part in the whole chain of value in the
development of technology of lithium–ion batteries, from the
development of electrodes, cells and modules at laboratory
level (in collaboration with IK4-CIDETEC) to the production in
pilot plant, including manufacturing of cells and modules up
to the stage of large-scale production in Spanish facilities.
2. Applications
The applications that CEGASA contemplates for the products in
development are the following ones:
ŸTransportation: Electrical vehicle and forklifts are CEGASA's Fig. 1. CEGASA´s pilot plant for electrodes manufacturing
target applications. The electrical vehicles turn out to be
increasingly attractive for automotive industry due to its
potential to reduce the greenhouse gases and to diminish the
dependence of the oil. In 2009, the world market of batteries
HEV and PHEV was estimated in 1000 M€. In 2020, the world
market of advanced batteries for electrical vehicles is
expected to reach 20000 M€ being approximately three times
the size of the global market of lithium-ion batteries for
consumer electronics.
ŸThe investment and innovation carried out in lithium-ion
batteries for the automotive sector impacts beneficially on
the integration of such technology in stationary applications
such as fast recharge points for EVs or the management and
regulation of the electrical grids, increasing the distributed
generation and with utilization and optimization of
renewable energies. Several studies predict that the
worldwide incomes derived from the installation of energy
storage systems in the electrical grid will increase from 1100 M
€ in 2010 to 27000 M € in 2020. Fig. 2. Chain of value of the manufacturing of lithium-ion batteries.
In red the scope of CEGASA's activities is shown.


- 16 -

RANGE EXTENDER: A BRIDGE TOWARDS THE PURE EV

Miguel A. Mateo, Fagor Ederlan S.Coop

1. Why a bridge to EV is needed 4. Options for Range Extender: markets & products
The future in passenger-cars is electrical. No doubt. When and how Fleets & promotion
pure EV's will reach a critical mass is a problem whose solution will The promotion of the Range Extender technology could be a tool for
take longer than expected. Some factors are: a)Battery technology public administrations to manage the cultural change needed to reach
readiness and at affordable price level; b) Existence of enough the final target through the use of pure EVs.
recharging infrastructure; c) End-users acceptance of the EV
technology and its features. If we agree on the final target -reduction Government fleets –cars and vans- with Range Extenders, for those
of CO2 emissions-, why don't we agree on reducing the gap by partly cases in which range is important, sharing market space with other
overcoming those disadvantages, that is, by using a bridge? A Range pure EVs, could be a starting point so that end-users could feel and
Extender is a bridge towards the pure EV: a) Its use implies the need of touch this technology.
a lower capacity battery, and it also has a lower price than batteries; Distributors' fleets containing Range Extenders: for those who need to
b) the hybrid EV with Range Extender wouldn't depend on recharging be green, but also need range: i.e. vans distributing goods in city
infrastructure; c)It is a well-known technology, thus minimizing the centers, where access of non-green vehicles is more and more
risk of end-users' reluctance to use the new technologies; and also its restricted.
use avoids the “range anxiety” problem of pure EV's.
As example: China is promoting the use of hybrid and pure EV with
2. Fagor Ederlan-Lotus Range Extender subsidies of around 20.000€ per vehicle. France has recently changed
Following its strategic planning, Mondragon Automotive Division its subsidies to 7.000€ for fully electric and 4.000€ for hybrid.
started three years ago the development of strategies within electric EV/PHEV sales currently clearly depend on incentives given by
vehicle segment, process which led us to a partnership with Lotus governments, as read in a recent study. But, still, end-user has to feel
Engineering. its needs are going to be properly fulfilled; they need to touch and try
Based on an original Lotus design, both Fagor Ederlan and Lotus the product: therefore demo-vehicles are a must.
Engineering have developed together a family of Range Extenders. New Products
This device generates energy to recharge, while running, the The currently mentioned products are the beginning of a strategic
view that may continue with the design of an electric powertrain,
batteries of an electric powered vehicle. It was created from a blank
which has similar technologies to the ones developed for the generator
sheet for that specific function and it combines an internal- and inverter of the Range Extender.
combustion- engine (ICE), a generator and a inverter. Functional But, even other option with potential is a Range Extender combining
prototypes of 50kW version have been manufactured and are already gas (CNG/LPG) with electric. Based on the current Range Extender
in demo-vehicles. design, minor changes would be needed. Brasil with ethanol, China
Fagor Ederlan, a well-known supplier in automotive chassis and and USA with gas, Europe with LPG for substituting diesel, are real
powertrain industry intends to become a Tier 1 supplier for Range opportunities for the Range Extender.
Extenders. This business has now become a new company within Fagor New markets
Ederlan Group, called Fagor Edermotion. it is also involved Fagor
The potential to service to other sectors is also a market demand which
Automation –a specialist in electronics within Mondragon Corporation
is under analysis: marine, truck, bus and other sectors have put their
and developer of both the generator and the inverter-. We also count
eye on this technology.
with the support of the Basque Regional Government.
As shown, there are many reasons why a Range Extender is the bridge
3. Fagor Ederlan value proposal
towards a pure EV. But, that bridge may become a very promising
The content of our value proposal is the following: road.
Value for the customer: around 60% of Bill of Materials costs are www.fagorederlan.es
–directly or indirectly- under our control, which will allow us to
supply a cost-efficient solution. It will also mean value for our region
in terms of employment creation.
Versatility: this product family is designed with package optimization
in mind: it is possible vertical, horizontal installations or any angle in-
between.
Product range: With versions in 3 and 2 cylinders and electric power of
50, 35 and 20kW, it covers the needs of the different automotive
segments.
Multifuel: designed for alternative fuel compatibility (i.e. ethanol,
methanol, GLP, CNG)
Emissions compliance: engineered to meet Euro 6 and SULEV emissions
regulations.


- 17 -

AERC: All Electric Race Cars development

Miquel Mateu (ALTRAN)

1. The project energy density of batteries, comparing with fuel, does not
The AERC (All Electric Race Cars) is a project leaded by the allow the vehicles to run longtime without recharging.
Quimera Company with Altran as Global Technical Partner. It In the project different cell technologies were used, from
deals with the development of 100% electric competition cars in Lithium polymer cells (AEGT, for instance) to LiFePO4 (AEDC).
different platform or categories, with two main goals: Both technologies allow energy storage with a density ranging
To create a motorsport competition based on sustainable between 120-170 Wh/kg. With space and weight limitation on
technologies, with similar performances than combustion the vehicle, this low energy density involves a short vehicle
equivalent vehicles. range, between 15-30 min, depending on the power and
performances developed in the car. With this energy barrier,
To use these vehicles as living labs for the technical battery swapping development is mandatory for competition,
development and testing of new technologies to be applied on to increase race time. We consider “fast battery swapping” a
passenger cars. better solution for competition than fast charging, considering
These vehicles must consequently be the platform for new the too high electrical power which would be involved to reach
technology development such as new cells, composite short recharge times.
materials, embedded energy generation systems, etc. The cells packaging, insulation and protection, as well as the
The companies collaborating in this project, with Quimera and thermal management, are key parameters for the good
Altran, are Sunred and Evelio, as well as other behavior of the battery pack.
partners/suppliers of technology and components. Concerning the powertrain, current electric motor technologies
2. The vehicles are quite competitive, compared with internal combustion
engines. Using Permanent Magnet Synchronous Motors, each
The main vehicles in development or already developed in the unit can develop up to 150 kW power, being more compact and
context of this project are the following ones: lighter than equivalent ICE. The system for coupling motors, to
AEGT (All Electric GT): it is a pure electric GT1 class car. It is reach higher power values, and the transmission system are
powered by 3 electric motors with a total power of 500 kW and also important technical issues.
top speed of 300 km/h. The design and assembly of the first Another key point in the vehicle is the global electrical
prototype has been leaded by Sunred, with Quimera and Altran architecture and safety systems. On one hand, the integration
as technical supervisor. The vehicle is already in test and of different insulation levels, between the cells, the conductive
optimization phase, while an improved second version (AEGT components and even the battery box acting as insulation, as
Evo2) is currently being developed, with Altran as technical passive safety systems. On the other hand, the cells monitoring
leader. system (through the BMS) and the contactors driving to
Electric X-Bow: this is a pure electric version of the GT4 class manage the high voltage in the vehicle (between 350V and
KTM X-Bow. The project, with Altran as technical leader, is in 700V, depending on the application) in stop or running mode,
the end of engineering process. The power of this electric as active safety systems.
version will be 300kW. The development and integration of the 4. Next steps
battery pack has been a critical issue, considering the limited
space available in the vehicle. A part of the remaining engineering and assembly activities of
the prototypes. the project is ongoing in different ways.
AEGF (All Electric Grand Formula): it is a Grand Formula car
designed to meet with FIA Formula-e standards. It is a very Quimera is looking for investment to build short series of these
light vehicle with high performances, similar to the current vehicles and to organize a pure electric competition based on
Formula 1 performances, with the electric powertrain system them.
and aerodynamics as main issues. The engineering phase is In parallel, the developed vehicles must be used as living
ongoing with Altran as technical leader. laboratories for new technologies. They are platforms for the
AEDC (All Electric Drift Car): this is a pure electric race car based integration and evaluation of the performances of new
on a Formula Drifting platform. The vehicle was developed by technologies such as high energy density cells, light
Evelio, with 200kW of power and it is already in test phase. The composites and high recycling materials, allowing to improve
AEDC was officially unveiled in the Goodwood 2012 speed vehicle performances and environmental impact or even
festival. embedded energy generation technologies.
3. Technology and barriers On another side, we are starting the process for using the
expertise and know-how acquired in this project, as well as the
The main limitation of electric race cars, in direct comparison technological solutions developed, on electric passenger cars,
with the equivalent combustion cars, is the range. The low for urban use or others.


- 18 -

INNELBUS: Innovative technologies for the electric
urban buses development
CARROCERA CASTROSUA; INSIA-UPM; AVIA INGENIERÍA

Background Optimized structure to meet strength, lightness and space
Due to the experience obtained in several collaborative projects requirements for that kind of vehicle.
regarding to hybrid and electric vehicles powetrain, the All optional equipment is available like in any other modern
partners involved in the Project INNELBUS have been set a sort urban bus, including conditioned air.
of Activities leading to obtain an innovative high dimension A product according with best service and accessibility
pure electric urban bus. standards at most European public transport companies, such
Due to a market research, the project has focused its effort to as communication services, low floor, 2 and 3 doors, etc.
meet customers needs to get a potential market position, Map of participants
getting a vehicle capable of drive in eco-friendly cities, with
zero emissions, very low noise but with the current quality and Leader: CARROCERA CASTROSUA
service standards. Participants: INSIA-UPM; AVIA INGENIERÍA
All the members of the Consortium has got the experience and Type of funding
technology needed in their own fields to achieve successful
results. Carrocera Castrosua is one of the leaders in urban buses Shared cost funding between ERDF and Framework of the
market, and contribute with technology and the knowledge of National R&D&I Plan through INNPACTO 2010 Subprogram.
the own market. INSIA-UPM has been at the forefront of buses Project Total Budget: 827k€
and coaches development for more than fifteen years and in
Contact
the last six has started its research line in electric and hybrid
powertrain integration. AVIA INGENIERÍA has the experience of Ph. D. José María López Martínez
a company that has been making heavy duty vehicles for more mailto: josemaria.lopez@upm.es
than twenty years.
INSIA-UPM University Institute for Automobile Research
All these ingredients form a Consortium capable of getting a
product that belongs to the future, and meets with final users Campus SUR UPM
needs and environmental requirements of the cities of Crtra Valencia km7
tomorrow, providing technological solutions.
28031 Madrid
Main characteristics
Tel. +34913365300
Up to 5 hours in pure electric mode, due to its Rechargeable Fax.+34913365302
Energy Storage Systems (RESS) based on one of the most safety
and reliable lithium-ion batteries technology. http://www.insia-upm.es/
Up to 140kW power. http://www.insia-upm.es/ingles/innelbus-project--17-fi.asp
9, 11 and 12 meters option.


- 19 -

Initiative for the integral development of the Electric Vehicle
recharge infrastructure in the Basque Country
MUGIELEC Project

Abstract optimize the overall structure and management according to a
This paper introduces MUGIELEC's approach and objectives and master-slave concept, using PLC (PowerLine Communications) for
presents its last results for a proposal for the exploitation of the local communication and diverse media, such as 3G M2M, to
infrastructure for charging Electric Vehicles. The main goal of the provide WAN connectivity towards the service provider or to ease
initiative is to position the Basque industry in a leadership position the integration in the electricity grid management systems.
in this field, paving the way for the deployment of this new form of V2G concept has been also developed, following a vehicle to EVSP
mobility and its integration in the electricity distribution grid. approach, and is being validated through 2012.
MUGIELEC is a publicly funded R&D project in the Basque Country, In order to implement communications between the electric vehicle
in the north of Spain, contributed by many important players in and the EVSE, two protocols have been implemented based on the
the energy sector in order to collaborate on EV (Electric Vehicle) most widely accepted standards during the project lifecycle:
related technology and applications, with a strong focus in the ISO/IEC 15118 and CHAdeMO for AC and DC respectively.
infrastructure side. The project comprises a complete system-level Intelligent secondary substations are also a part of the project. This
approach, covering from grid operation, to the infrastructure-to- is a critical point to integrate intelligence into the distribution grid
vehicle communication, including critical subsystems such as MUGIELEC has taken advantage of the need of a smart EV
recharge infrastructure scenarios, impact on the grid, V2G management in order to propose innovative concepts and tackle
technical feasibility, or customer behaviour analysis. their implementation. As a result of this, a secondary substation
MUGIELEC is led by ZIV, and TECNALIA is its technical coordinator. with integrated storage has been developed, whose capacity can
AEG, CEMENTOS LEMONA, FAGOR, GAMESA, IBERDROLA, INCOESA, be optimally managed taking also into account the EV loads
INDRA, INGETEAM, ORMAZABAL and SEMANTIC SYSTEMS are the rest connected to it, but also dynamic energy prices, or requisites of
of the partners. It will be running from September 2010 until the the distribution system operator.
end of 2012. Information management system, aimed at provisioning services
MUGIELEC aims at enabling a seamless integration of EVs and to the different players in the EV charging scenario and its
charging infrastructure. In this sense, a current or future EVSE (EV associated information processes. This information management
Supply Equipment, which is a Charging Point or a group of system can make possible new value-added services for any or the
Charging Points) of different manufacturers may be integrated players. For this reason, MUGIELEC has chosen to separate
with the management system of the EVSP (EV Service Provider, or information and knowledge into different specific formats and
eMobility Operator) using a normalized interface, as it can also protocols, creating an integral modelization layer, independent of
find a simple interface connection of the EV management system the proprietary systems that may exist below it. Semantic
with other open systems. technologies which ease rich XML model definition have been used.
One of the main outcomes of the project is the integral These are flexible and will be able to cope with the adaptation that
management of the information and knowledge in interoperable the evolution of the EV charging market may require.
formats, which will enable advanced value added service At the end of 2012, as the activity of the Project reach its end, a
provision, and will pave the way to the appearance of new, demo will take place. EVSE coming from different manufacturers,
innovative business models in this area. representing domestic systems, parking systems and fast charging
During the technology development phase in MUGIELEC, the stations, are going to be controlled from a central operation
communication protocols and technologies have been developed dispatch belonging to a service provider, communicating with the
and implemented, as well as the interaction among the different infrastructure and effectively managing it.
players and systems: electric vehicle, charging infrastructure, The demo will test the open platform for the integration of multiple
service provider and distribution system operator. During two and EVSE systems, making it possible to assess the technical and
a half years the project partners have developed different economic feasibility of each of the solutions. This platform and
products, in line with an integrated and replicable concept. concept has been also used as a documentation source for some
Electric vehicle recharge stations, trying to deliver the service in a standardization activities that are taking place now at the
friendly environment for the user. AC and DC recharge stations European level.
have been developed, with power values of 22kW and 50kW As a conclusion, MUGIELEC system provides an integral coverage of
respectively. the EV charging infrastructure and the electric vehicle, both as it is
Regarding parking Systems, individual (per parking place) now and as its potential evolution. Additionally, due to the
charging points of 3,7kW and semi-fast AC charging points of up modular and open approach of the concept, new features and
to 43KW have been developed. In residential applications, an functionalities can be added to the system at any time, making it
environment that is probably the first to be deployed in the future, able to sync with future evolutions of the electric vehicle as it is
a modular system has been defined, where the chargers can now an infant stage.


- 20 -

LNG-BC: Liquefied Natural Gas - The Blue Corridors

IVECO

While the use of natural gas for short distances is well known in Ÿ Range of LNG is higher when compared to CNG, about 3 times
Europe for passenger cars, the use in heavy duty applications for higher for LNG
medium and/or long distance is still very limited. Passenger cars,
Ÿ Cost of LNG is lower when compared to Diesel, providing an
taking advantage of CNG (Compressed Natural Gas) high pressure
advantage to retail operative costs
storage systems (200 bar) provide the necessary range for a daily
use in those cities and towns where fuel stations are available. This The main lacks for commercial development of LNG in Europe is:
CNG solution is much used in some countries in Europe, as in Italy.
Ÿ Lack of common European standards that regulate the use of
Urban use of Natural Gas engines is available in bus fleets, LNG
especially in public transport, as well as for garbage collection.
Ÿ Lack of OEM trucks for the European Market
This fleets are always using common fuel stations in a well know
location of the city/town and their routes are always the same in Ÿ Lack of a European network of LNG stations
order the range is granted.
Ÿ Lack of information which provides a real study of the LNG use
The use of Natural Gas for long distance transport is not feasible for long distances across Europe
via the CNG solution, which provides a low autonomy as requested.
With the increase of the GHG (Green House Gases) emissions the CO2
In order to make the Natural Gas fuel a real alternative for the fleet
balance has become a real interest for Governments and local
operators using heavy duty trucks for long distances, the only
authorities.
alternative is the LNG (Liquified Natural Gas) storage systems.
The LNG allows the use of BioMethane, which is the best fuel in
LNG technology is not well known in Europe, however it is in USA
terms of sustainability (highest efficiency per hectare of land)
and Australia. China has a running park of heavy LNG trucks of
when compared to any other biofuel, including bioethanol.
more than 4000 units already.
The European Commission White Paper on transport published on
Main limitations in Europe are due to the fact it is not available any
28th March 2011 aims at dramatically reducing Europe's
regulation which provides the necessary tools to provide European
dependence on imported oil and cut carbon emissions in transport
approvals to vehicles and component suppliers to sell, install, use
by 60% by 2050. Methane (NG/Biomethane) is mentioned as one of
and control technologies as LNG (Liquified Natural Gas) for the
the alternatives.
automotive applications. Currently the only way to use LNG in
trucks is via a National Certification approval, which depends on It is necessary that the infrastructure build up to cover the growth
local governments and their designated Technical Services. of NG vehicles in the coming years, and specially for the medium
and long distance transport, is based on best practices and real
The Iberian Peninsula receive more than the 70% of gas used in
needs to facilitate the market take-up of vehicles.
Spain and Portugal comes via ships already in LNG form.
Ÿ In cities: CNG methane is already use and will increase in
Development of LNG markets for heavy trucks is developed firstly in
coming years
this countries were in others receiving mainly pipeline from Russia,
LNG is not yet developed. Holland is also a LNG country. Europe Ÿ Medium/Ling distances: Methane as LNG is the only alternative
and normally owned by private fleet operators who use LNG trucks to Diesel's. LNG refuelling at least every 400 km is expected
due to the good cost efficient solution. This allows them to reduce
Ÿ Alongside Motorways (LDV): Methane refueling stations each
their operative expenses.
150 km for light duty vehicles
There are only two OEM's who sell trucks with LNG tanks, however
LNG stations need a constant demand in order to prevent the
any CNG truck can be converted to LNG with the proper system.
emission of Methane to the atmosphere (boil-off). Technical
Additional concerns about LNG use in Europe, mainly due to the solutions to avoid this emissions will be also of interest.
lack of regulations, is the lack of standardization of the filling
A short term solution which will be explored is the use of L-CNG
hoses. This makes no possible that all the LNG trucks could actually
stations instead of LNG only. This will allow CNG cars/buses/trucks
refuel in any LNG station.
working at low distances as well as to the LNG trucks to refuel in the
Some projects have been performed locally at different European same stations, providing both advantages to the fleet
countries with good results. However it is necessary to combine this operators/drivers as well as being more cost efficient for the fuel
experiences for the proper development of the LNG trucks. station operators.
The main advantages of LNG use for long distance are described as The concept of Blue Corridors is to have 3 main LNG available
follows: corridors in Europe, with strategically placed LNG filing stations,
that would allow Euro VI heavy duty trucks running on Methane for
LNG is mainly based on methane (CH4), which is the lowest Carbon
medium and long distance transport.
based fuel. This allows a close to zero emission of particles in its
combustion, therefore there is no need for advanced after- The main blue corridors need to cover routes as:
treatment systems for particle reduction as it is in Diesel engines.
Ÿ Portugal – Spain – France, Netherlands, Belgium, UK


- 21 -

LNG-BC: Liquefied Natural Gas - The Blue Corridors

IVECO

Ÿ Portugal – Spain – France – Germany - Denmark – Sweden The routes object of study will be those related to the
Demonstration part of the project in the “pre-Blue Corridors
Ÿ Spain – France – Italy – Slovenia (Mediterranean arch)
definition”.
The main trucks running on LNG will be:
However, the information of their fleets running on daily basis will
Ÿ Natural gas dedicated: 100% NG – Euro V and Euro VI be also of interest.
Ÿ Diesel Dual Fuel: NG as main fuel but injection of Diesel- Euro V Applications as medium and long distance buses running on LNG
and Euro VI are also of interest to provide information regarding the logistics
and special requirements of those vehicles/applications related to
Project Scope
the transport of people instead of goods
Ÿ To demonstrate the LNG is the alternative fuel to Diesel in the
The main actors (fuel suppliers, fuel distributors, fleet operators,
long distance heavy duty trucks for trans-European transport
OEM's and technical entities) will collaborate across the different
Ÿ To study the current state of the art in Europe for LNG WP's, based on the following scenario:
regulations, technologies for both trucks, fuel systems and
Study of the available technologies for vehicles, fuel stations, fuel
refueling stations, taking advantage also of previous projects
logistics, fuel tanks and its interface with the fuel station.
experience
engines dedicated and dual injection systems, aftertreatment.
Ÿ To study the current availability of LNG and BioMethane as well
Definition of an open issues list.
as to understand the future scenarios at 5 to 10 years.
Identification of each market needs (Portugal, Spain, France,
Ÿ In order to have the best possible experiences, real use of LNG
Germany, BeNeLux, Italy and UK) as well as their cross-sectional
trucks will be performed in a sort of pilot fuel stations, some
interactions.
already existing and some new, that will permit the
demonstration of long distance transport trucks running on Study of the regulations available in each country and definition
LNG during the demonstration part of the project. It will be of harmonized standards to allow the operation between different
necessary to define a sort of tests, measurement procedures countries. Study also of the open issues critical for the
and validation activities for each participant of the demonstration (parking, tunnels, etc).
demonstration part.
Definition and build-up of a set of demonstrator vehicles and its
With the demonstration part with real trucks, which will combine related technology which is suitable for the demonstration part:
LNG fuel tanks with the available refueling hoses, as well as
Ÿ OEM's and suppliers will define the needs of Euro VI vehicles
different engine technologies – dedicated and Dual fuel -, as well
for the demonstration project. In order to allow
as OEM and retrofit solutions, it is expected to collect the core data
necessary to understand and define the sort of regulations fleet operators to define the best practices and demonstrate in real
necessary to ensure the correct launch to the market, in terms of conditions the use of LNG technology with their current fleets
standardization and safety, of the vehicles and the fuel stations. running on LNG (Euro V) or new trucks where critical for the
project, will be used.
Ÿ To define a sort of tests to measure and collect data related to
the fuel consumption and emissions of the NG engines when Ÿ OEM's will develop their Euro VI trucks by their own and fleet
fuelled with LNG coming from well or from liquified operators will test in real service in order to provide operating
BioMethane (LBM), and to confirm the compliance with the results.
regulation Euro VI
Ÿ A common measurement system will be defined for truck
Ÿ To disseminate the results in a common Webpage of the tracking during the demonstration
project, where all the relevant information and results of the
Definition of a set of fuel stations, located in fix or movable
project will be published, as well as to a certain number of
positions, to allow the demonstration part of the project
publications and conferences.
Ÿ All the stations will be available for project partner trucks
Project Development
Ÿ All new fuelling stations critical for the project will be L-CNG,
OEM's and suppliers of NG systems (both dedicated and DDF) will
allowing in parallel the supply of CNG for other users
provide one of their demonstration truck/engine to measure its
fuel consumption and emissions according to Euro VI as well as for
comparatives against Diesel's.


- 22 -


DIRECTORY OF
PRODUCTS/TECHNOLOGIES


1: Energy storage technologies,
ancillaries and management
systems

Directory of products/technologies

ASCAMM
EV ENERGY MANAGEMENT SYSTEM
Contact Information:
Rafael Rubio Bonilla
e-mail: rrubio@ascamm.com
Webpage: www.ascamm.com

■ Technological description
Energy storage system for electric vehicles –especially lightweight– based on a rack that can integrate
different modules, dimensions, geometry and standard connection system, regardless of the principle of
energy storage.
The system has a management subsystem (Rack Management System) that identifies the type and number of
modules and automatically adjusts the power electronics and vehicle settings to that particular integrated
module configuration. It is a system that allows "plug and play" for any storage module that meets minimum
functional requirements based on a standard. In addition to the inherent requirements of industrial design
(geometry, structure ...) the modules must have an electronic record with information on their technical
characteristics and the historical original of usability.

■ Status
The technology is still pending to be validated in a 'proof of concept' prototype.

■ Applications
EV Energy Management.

■ Potential cooperation partners / Customers
ŸEV Fleet Managers
ŸEV Manufacturers
ŸEV End users

- 25 -


CEGASA
Advanced Battery for Electric Vehicles in CEGASA
Dr. Igor Cantero
e-mail: icantero@grupocegasa.com
Webpage: www.cegasagroup.com

ŸDevelopment and manufacturing of lithium ion cell and battery packs
ŸDevelopment of Green Cell Pouch type cells based on aqueous processing for electrodes (No use of NMP)
ŸModular system design for battery packs allowing quick and easy integration into a wide variety of
applications

■ Status
Products in development: Cells and modules of lithium-ion for transportation

■ Applications
ŸTransportation: Electric Vehicles, Handling vehicles, etc
ŸStationary Applications

IK4-CIDETEC / SEAT

- 26 -


CEIT-IK4
High power and energy density supercapacitor
standard modules
Leyre Suárez
e-mail: lsuarez@ceit.es
Webpage: www.ceit.es

The standard module developed by CEIT has been optimized in terms of stored energy and power density
taking into account also the cost of the auxiliary components in order to keep the final cost to a minimum. It's
main characteristics are the following:
ŸHigh power and energy density: provided by the use of the best supercapacitors available in the market in
terms of capacitance and life cycle
ŸRe-configurable: Each standard module is equipped with its own intelligence, so it can cope autonomously
with the overvoltage protection, voltage balancing, and the management of warnings from the temperature
and gas sensors
ŸEfficient: All the auxiliary components have been designed in order to reduce as much as possible energy
losses during its normal operation. For example, the active voltage balancing circuit as been specially
designed in order to be able to transfer up to 15 amperes between individual supercapacitors with an
efficiency bigger than 98%
ŸSafe: Predictive maintenance strategies have been implemented to predict possible substitutions of
supercapacitor stacks or auxiliary components before their malfunctioning affects the entire system

■ Status
Several prototypes have been developed and validated in the frame of R&D projects. Some of them will be
industrialised in 2013.
In parallel with this technological development, CEIT in collaboration with other European partners is
coordinating a European Initiative (FP7 HESCAP project) oriented to the development of a new supercapacitor
technology capable of storing ten times more energy than the reported State of the Art devices, while keeping
the high power density, long life cycle and production cost of currently available supercapacitor systems.
HESCAP project will end in 2013.

■ Applications
This technology is directly addressed to, among others, the following applications:
ŸHybrid and full-electric vehicles and their charging networks
ŸVoltage stabilization support to the electric smart grid

OEMs, Electric traction system suppliers, energy storage system suppliers.

- 27 -


CEIT-IK4
Battery Modules and Packs for Traction
Applications
Oscar Miguel
e-mail: omiguel@cidetec.es
Webpage: www.cidetec.es

CIDETEC has developed a lithium ion battery module technology capable of extracting the maximum power
and energy from the cells, while preserving their lifetime by means of an efficient equalization and thermal
management strategy.
The main functions developed and implemented in the Battery Management System (BMS) are:
ŸAlgorithms for state of charge –SOC- and state of health –SOH- estimation based in Kalman filter
calculations.
ŸCell equalization –passive; active under development
ŸCommunications, protections, safety
ŸPassive and active –liquid- cooling
As an improvement over other state of the art BMS's, the algorithms implemented are obtained from a
detailed program of optimized, accelerated testing of the actual cell type to be used in the module. This
testing program includes charging and discharging at selected rates and temperatures, including accelerated
cycling. With this strategy, the BMS is capable of estimating the SOC with actual precision under 1%. A master
controller at the battery pack level has also been developed.
CIDETEC cooperates closely with its customer and partner CEGASA regarding all battery technologies under
development.

■ Status
Li-ion modules are available at the prototype stage. Industrial pre-series will be available in 2013.

■ Applications
Lithium ion technology is well known as the technology of reference for all kinds of electric and hybrid
vehicles. Also, li ion batteries are suitable for energy storage at recharge points to handle transitory power
surges.


CIDETEC already cooperates with several partners to develop these technologies, and more specifically in the
context of European projects. CIDETEC coordinates GREENLION, a Green Cars project for the development of
environmentally friendly li-ion batteries.
CIDETEC is willing to cooperate with other RTD or industrial partners for further development, either in the
context of European projects or other instruments.

- 28 -


CEIT-IK4
New Battery Technologies for Electrochemical
Energy Storage
Oscar Miguel
e-mail: omiguel@cidetec.es
Webpage: www.cidetec.es

At IK4-CIDETEC several battery technologies are under development pointing to the electric car. Taking
advantage from its extensive expertise in electrochemistry, industrial processes and product development,
this development is focused into two main technologies: lithium ion for the short to medium term, and
metal/air for the long term.
CIDETEC is working on lithium ion technology from the starting raw materials up to the cell, covering:
Ÿmaterials selection (active, inactive and structural)
Ÿelectrode formulation and coating at the pilot plant level (organic solvent free process)
Ÿpouch type cells from 1 to 30 Ah (also mAh size button cells for materials testing)
Ÿprocedures for electrolyte filling, formation, and cell degassing steps
The current particular technology of choice is based in graphite/LFP chemistry, including proprietary
additives for improved cyclability and power density. The knowledge developed allows to taylor the electrode
and cell characteristics to favor energy density over power density or the other way round.
Metal/air technologies are seen as the next step in battery development. They offer the promise of an energy
density several times higher than li ion batteries. However much development is needed before these new
technologies reach commercialization.
CIDETEC is working in Zn/air and Li/air secondary –rechargable-technologies, taking advantage of the
knowledge accumulated in the primary Zn/air chemistry, electrocatalysis and fuel cell gas diffusion
electrodes.
CIDETEC cooperates closely with its customer and partner CEGASA regarding all battery technologies under
development.

■ Status
Lithium ion technology is available at the prototype level. Industrial pre-series will be available in 2013.
Metal/air is at the laboratory stage, with lab test cells already demonstrated.

■ Applications
Lithium ion technology is well known as the technology of reference for all kinds of electric and hybrid
vehicles. Also, li ion batteries are suitable for energy storage at recharge points to handle transitory power
surges.

CIDETEC already cooperates with several partners to develop these technologies, and more specifically in the
context of European projects. CIDETEC coordinates GREENLION, a Green Cars project for the development of
environmentally friendly li ion batteries.
CIDETEC is willing to cooperate with other RTD or industrial partners for further development, either in the
context of European projects or other instruments.

- 29 -


EXIDE Technologies
Advanced AGM Lead-Acid batteries (spiral shape)
for Mild-HEV market
Cristobal Gimeno
e-mail: cristobal.gimeno@eu.exide.com
Webpage: www.exide.com

Advanced Lead-Acid batteries with spiral cells (that allows thinner electrodes and higher compression
assembly) have been developed with some additives into their Active materials and design features that
improve existing performances in the following aspects:
ŸPower peak performances ÒHigher Specific Power rate ÒBoosting events
ŸCharge acceptance ÒHigher Specific Charge Acceptance rate ÒRegenerative Braking
ŸCycle life under Partial State-of-Charge (PSoC) ÒEUCAR HEV driving profile ÒCycle life under HEV
applications (Micro- & Mild- Hybrid)

■ Status
12V Battery (series product) assembled into a Demo Car (VW Passat 1,4l TSI “retro-fitted”). Next step is a 48V
system (under development) with 8 x 6V modular assembly.

■ Applications
Combined with electric Super-Charger and ISG technologies
can bridge the gap between micro- and mild-hybrid with a
cost effective alternative to high-voltage solutions (made of
more expensive battery chemistries). Whole system is capable
to near-term down-sizing and down speeding the existing
engine families, delivering proven CO2 reduction and fuel
economy without the usual dynamic compromises.

PARTNERS: VALEO, CPT, MUBEA, AVL SCHRICK, PROVECTOR
CUSTOMERS: All electrical suppliers interested in cost-effective hybridisation projects

- 30 -


FICOSA
BMS: Battery Management System
Jaume Prat
e-mail: jprat@ficosa.com
Webpage: www.ficosa.com

Battery Management System includes all the hardware PCB's and software algorithms that ensures the
following functions in a Battery Pack System:
ŸTo monitor up to 1680 Lithium-Ion cells
ŸTo balance the cells charge (passive energy balance)
ŸTo control the charge and discharge rates
ŸTo improve the battery pack autonomy
ŸTo keep the system under safe conditions (ASIL D compliant product)
ŸTo include thermal management algorithms which are able to maintain the cells into an optimized
temperature range
ŸTo predict the State of Charge (SOC) and State of Health (SOH) with <2% error

■ Status
Pre-series.
Start of production: 2013.

■ Applications
EV / PHEV

- 31 -


FICOSA
BPS: Battery Pack System
Jaume Prat
e-mail: jprat@ficosa.com
Webpage: www.ficosa.com

The Battery Pack is a system able to store energy to propel Electric / Hybrid vehicles, as cars, buses or
motorbikes using modern Lithium-Ion cells which provide enough energy density to allow short and medium
drive autonomy.
The battery Pack system design can be customized to different requirements. First prototype sample provides
12kWh with an output voltage of 270 – 320 Vdc by using Li-ion NMC pouch cells.
The Battery Pack includes a Battery Management System (BMS) that is able to control the charge and
discharge rates, the energy balancing in order to improve the autonomy and to keep the system under a
high-safe conditions. BMS also controls the power distribution box (TNV) that provides all protections for the
own battery pack integrity and for the users safety.
BPS also includes a Thermal System (air cooling or liquid cooling) which is able to handle 1000W and thermal
management algorithms which are able to maintain the cells into an optimized temperature range (from 0ºC
up to 50ºC), to maximize their lifetime.
Automotive grade product with mechanical housing ensuring IP65 protection.

■ Status
Prototype.

■ Applications
Designed for EV / PHEV / Hybrid cars, buses applications.

- 32 -


IK4-IKERLAN
Electrical Energy Storage
Fran Blanco
e-mail: fjblanco@ikerlan.es
Webpage: www.ikerlan.es

Component development (HW/SW) for electrical energy storage
ŸBattery technology analysis and selection
ŸBattery module and pack Topology and Control Development
ŸBattery Module Thermal Design and Control
ŸBattery Management Systems (BMS) development

■ Status
These technologies are currently in use in other transport sectors (rail, light rail, vertical transport, ...) or in
stationary applications (domestic, industrial).

■ Applications
Full electric and hybrid electric vehicle energy storage applications.

Vehicle manufacturers (OEMs), EV electrical energy storage manufacturers, vehicle design houses.

- 33 -

Greencars 2012: Bussiness, Challenges and Global Oportunities

Greencars 2012: Bussiness, Challenges and Global Oportunities

Recomendados

Recomendados

Mais conteúdo relacionado

Semelhante a Greencars 2012: Bussiness, Challenges and Global Oportunities

Semelhante a Greencars 2012: Bussiness, Challenges and Global Oportunities (20)

Mais de TECNALIA Research & Innovation

Mais de TECNALIA Research & Innovation (20)

Greencars 2012: Bussiness, Challenges and Global Oportunities