Lithium-Ion Battery for Audi A6 PHEV -...

Steve Lehnert, AUDI AG

Lithium-Ion Battery for Audi A6 PHEV

2

› Overview of the battery system

› Mechanical Overview

› Advantages/disadvantages of common battery package

› Architecture

› Modular set part concept

› Advantages of set part concept

› Cooling system

Contents

AUDI AG I/EE-832 Lithium-Ion Battery for Audi A6 PHEV 02.02.2017

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Audi A6 PHEV 2,0l TFSI


› Drive Train

Performance Data

System power: 180 kW

System torque: 500 Nm

Electrical speed: 135 km/h

Electrical range: 50 km

HV Battery System

Onboard Charger

Charging Point

HV wiring harness

Power Electronics

Engine 2,0l TFSI

Electric Machine

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Audi A6 PHEV 2,0l TFSI


› Location of the Lithium-Ion Battery

Cell box inside luggage compartment

Reduced environmental influences

Fits under the rear luggage cover

Crash protected

Interfaces in the outside

No HV-connections and no coolant tubes inside

luggage compartment Challenge to match inside/outside requirements

Inside

Outside

HV Battery system

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› Structure

Battery Junction Box

Cover

Coolant Distributor

Battery Housing

Cell Module

Cooling Plate

High-Voltage Connection

Low-Voltage Harness

Battery

Management Controller

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› Mechanical Structure

Low weight

High stiffness, supporting stiffness of the car body

Good crash performance Challenge of tight welding seams

Aluminum 2-Layer Cover

Aluminum extruded profiles

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› Common battery package

Advantages / Disadvantages

Reuse of whole cell box

Adaption of fixation to car body

Limited flexibility regarding project

specific requirements

A6 Battery Common Cellbox

Adaption for new vehicle

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› Technical Data Battery system

Battery system

Cell 37 Ah (Pouch)

Cell Module 8x 13 cells (13s1p)

Topology 104s1p

Energy 14,1 kWh (BOL)

Peak Power 110 kW (25 °C, 18 s, BOL, 50% SOC)

Voltage 382 V (nom.)

Peak Current -335 A (18 s)

Operating Temperature

-28 °C – 60 °C

Cooling Fluid cooling

Protection Class IP6K4K (Inside)

IP6K6K, IPx7, IPx9K (Outside)

Weight 140 kg

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› Technical Data Battery system

-25°C

-10°C

0°C 10°C

25°C 40°C

60°C 0W

20000W

40000W

60000W

80000W

100000W

120000W

140000W

95% 80%

65% 50%

35%

15%

5%

SOC Temperature

Pe

ak

Po

we

r

-25°C

-10°C

0°C 10°C

25°C 40°C

60°C 0W

20000W

40000W

60000W

80000W

100000W

120000W

140000W

5% 15%

35% 50%

65% 80%

95%

Temperature SOC

Pe

ak

Po

we

r

Discharge Power Charge Power

Wide temperature- & SOC-range with high Discharge Power

Colt cranking capability until -28 °C

Wide range for onboard charging up to 7,2 kW

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› Technical Data: set parts Battery Junction Box

› HV-sensor system & safety box

› Separate housing

› HV-interface to the vehicle

› Direct contacting system between Battery Junction

Box and Battery Housing

Battery Management Controller

› Battery intelligence

› Separate housing inside luggage compartment

› LV-interface to the vehicle

Service friendly

Challenge outside requirements

Service friendly

Only 12V



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› Technical Data: set parts Cell Module

Topology 13s1p

Cell Module Controller Integrated

Dimensions 387 x 151 x 108,5 mm

Weight 12,3 kg

Cooling Indirect

Cell

Technology Li-Ion Pouch

Capacity 37 Ah

Chemistry Li NMC / Graphite

Dimensions 327,5 x 102,2 x 10,6 mm

Weight 0,70 kg

Energy density 386 Wh/l 195 Wh/kg

Cell

Single cell Cell Module

Controller

Cell Module

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› Set part concept

Cell Module


Modular concept

Service friendly

Reuse of components in different projects


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› Cooling system

Coolant Distributor

Cell Module

Cooling Plate

Coolant Connector

Coolant Inlet / Outlet

Thermal Pad

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› Conclusio

Perfect integrated without loss in luggage space

Robust mechanical Design

High Power

Common Cellbox Design

Efficient set part concept

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› Prospect

Increase of Energy density (electrical range > 50 km)

Decrease of cost

2013 2014 2015 2016 2017 2018

100

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300

400

500

600

25 Ah 28 Ah

37 Ah

Lithium-Ion Battery for Audi A6 PHEV -...

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