Technical Design of a Plug-in Hybrid Electric Vehicle

With an average daily mileage of 35 km and a maximum mileage of 400 km with an electric motor
power of 70 kW

28.05.2024
Yunze Li, Melek Albayrak, Sivakumar Ravichandran, Hiba Youssfi

Chair for Electrochemical Energy Conversion

1
and Storage Systems
Outline

1 Introduction and motivation

2 Choice and sizing of energy storage system

3 Design of battery pack (Topology, Cells, BMS)

4 Charging

5 Economic analysis

6 Summary and outlook

2 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Climate Change and Fleet CO2 Emissions

Fleet CO2 95 g/km

Emissions 117 g/km
121 g/km (until 2021)
(until 2020):

Climate change and strict CO 2 emissions ask for the electrification of individual transport
Source: VDA

3 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Our Task

Requirements
o Average daily mileage: 35 km
o Maximum range: 400 km
o Electric motor: 70 kW

Application
o City car in day-to-day life
o Commuting, shopping etc.
can be done “electric”

Source: VW

4 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
The principle of a hybrid plug-in vehicle

Electric
Battery Converter Advantages:
motor
1. Shorter Charging time compared with full-electric
vehicles.
2. Higher energy conversion efficiency than
Fuel Tank Engine conventional hybrids.
3. Save around 60% or 40% in energy costs,
compared with conventional gasoline vehicles and
A plug-in hybrid electric vehicle (PHEV) is a hybrid
electric vehicle whose battery can be recharged by HEVs.
plugging it into an external source of electric power, as 4. Lower emission of CO2 and harmful gases
well as by its on-board engine and generator. (from
Wikipedia) compared with conventional gasoline vehicles.

5 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Battery sizing

■ Desired fully electric Range: 35 km

■ WLTP consumption of fully electric vehicles:
Car Renault Zoe VW E-Golf Opel Ampera
Engine power 68 kW 100 kW 150 kW
Consumption per 100 km 16.9 kWh 15.8 kWh 16.5 kWh

■ Consumption of fully electric vehicle: 17

□ 6 kWh Capacity 1.5 kWh
■ 80 % Depth of Discharge (DoD) to prevent deep discharge 1.5 kWh
□ Additional 1.5 kWh 9 kWh
■ Prevention of aging and temperature-related capacity fade 6 kWh
□ Additional 1.5 kWh

6 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Lithium-Ion-Battery

Power Density Security

+-
Energy Density Cycle Lifetime

Costs Calendric Lifetime

Technology Lead Acid NiMH Lithium-Ion SuperCaps

Costs [€/kWh] 50 – 300 2000 200 – 1800 300 – 4000
Lifecycle [Cycles] 200 – 1500 500 – 2000 300 – 3000 500.000 – 1 Mio.

Efficiency [%] 70 – 85 70 – 80 90 – 95 95 – 100

Lithium-Ion-Batteries fulfill the requirements of our application the best

Source: Tschöke et al. (2012)

7 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Battery Cell Chemistries

Material Energy density Power density Safety Costs

NCA very good good very bad cheap
(Nickel Cobalt Aluminium)

NMC good bad bad cheap

(Nickel Manganese Cobalt)

LCO good good very bad very expensive

(Lithium Cobalt Oxide)

LMO very bad good good cheap

(Lithium Manganese Oxide)

LFP very bad good very good very cheap

(Lithium Iron Phosphate)

Lead-acid very bad very bad very good very cheap

LFP-Chemistry shows the best specific characteristics for our use-case

Source: Tschöke et al. (2012)

8 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Energy storage system design based on VW Golf GTE
Comparable model: VW Golf GTE
Battery Capacity 8,7 kWh
Electric range Max. 50 km
Consumption Combined:
3,3l/100km gasoline
+ 7kWh/100km
Combustion engine
Petrol engine 110 kW

Electric motor
75 kW
Source: Cars and Specs
■ Vehicle specifications satisfy
■ 35km electric range
■ Electric motor power of 70 kW

Can be used as a baseline for our application and battery storage system

9 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems
Battery pack design - Cell type

Pouch Cylindrical Prismatic

• High packing density

• Good safety features integrated
• Easily cooled due to large surface
• Inexpensive • Mechanically strong
area and thin packaging
• High production volumes • Easily packaged and connected
• High power density
• “Future proof” • Good energy and power density
• High energy density
• Flexible packaging

 Mechanically weak  Uncertain long-term support

 Cooling less efficient
 Expensive  Cooling suffers due to housing
 Energy and power density lower
 Uncertain long-term support  Expensive

10 28.05.2024 | Sivakumar Ravichandran

Chair for Electrochemical Energy Conversion and Storage Systems