THE FUTURE OF DRIVING IS ELECTRIC

FRAUNHOFER SYSTEM RESEARCH ELECTRIC MOBILITY

Prof. Dr.-Ing. Matthias Busse | Cooperation in India | New Delhi 2017

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Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

 Charging, infrastructure

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

© Fraunhofer
Fraunhofer at a Glance
The Fraunhofer-Gesellschaft undertakes applied research of direct utility
to private and public enterprise and of wide benefit to society.

€2.1 billion
Major infrastructure capital
€1.9 expenditure and defense
billion research
24,500 staff Almost 30%
is contributed by the
German federal and
Länder Governments

Contract Research
Finance volume
More than 70%
is derived from contracts
with industry and from
publicly financed
research projects.

69 institutes and research units

2016

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Fraunhofer fields of research

Health and Environment Mobility and Transport

Communication and Knowledge

Energy and Resources

Security and
Protection

Production and Supply of Services

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Growth in inventions and patents
2012 – 2016

2012 2013 2014 2015 2016

Active patent families at 6103 6407 6625 6573 6762

year end*
Invention disclosures 696 733 736 670 798
reports per year
Patent applications per year 499 603 563 506 608

* Portfolio of active rights (patents and utility models) and patent applications at year end.

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Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

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Upcoming changes in automotive supply industry

In a battery electric vehicle (BEV) nearly every component from the

conventional drivetrain will be eliminated, i.e.

 Internal combustion engine

 Tank system
 Transmission
 Clutch
 Exhaust system
 …...

The battery electric vehicle

will be cheaper than
conventional cars!

Sources: BMW, Mercedes

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Dependency of large German Automotive Suppliers on
the Combustion Engine Technology

Revenue in Billion €, share in %

Online, 21.6.2017

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New business fields for Automotive Industry

 Sensor integration, connectivity

 Alternative Drive technologies (electric, hydrogen)
 Battery systems and electricity storage
 Charging infrastructure
 Intelligent Mobility:
 Mobility platforms with all types of vehicles and transportation
on offer: rental cars, rental bikes, rental scooters, but also taxis and public
transportation – all billed within a single payment system
 Carsharing: stationary or free-floating
 Autonomous Driving!!!
 Still a lot of research necessary
Other »non-automotive« companies push into the market

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E-Mobility in Germany today

www.focus.de

www.stadtwerke-osnabrueck.de

K. Jahn

K. Jahn

www.bosch.-de
www.berliner-verkehrsseiten.de

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Production and market indices for electric mobility

Competitive situation of the world‘s leading automotive countries in 2017

(Source: Roland Berger). Index range from 0 to 5

2 Production
Market
1

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Fraunhofer Portfolio Electric Mobility in China

Fraunhofer Workinggroups in China

This image cannot currently be displayed.

Lightweight Energy, Grid Energy- Technical Technical

Vehicle- storage Training
Production concepts Charging Systems-
Batteries integration Academy

Projects: Projects: Projects: Projects: Projects: Projects:

• Leightweight- • In wheel • Grid- • Battery- • AutoTram • Concepts
design motors Integration systems • E-Buses • Corporate
• New • Battery- • Power- • Battery- • Traffic Trainings
materials systems electronics management systems • ......
• Surfaces • ….. • …. • …. • …..
• …..

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Example: Cooperation with VW et.al. in China
 Concept for a »Fraunhofer Lab Factory« with VW and Tongji University:
Vehicle concepts – Hightech for Low Cost (HiTLoC)

Tongji

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Indian Automobile industry –
- from the Fraunhofer perpective

• India has become a major automobile manufacturer, producing almost 3.3

million cars and over 13 million two-wheelers in 2012, Indian car industry
contributes 5.2% global share in 2012 (OICA estimates)
• India has also become the second largest two-wheeler market in the world,
closely trailing China.
• From Fraunhofers perspective, the deployment of EVs in India offers
four broad advantages:
• Reduced oil dependency
• Job creation and economic development
• Reduced urban pollution
• Lower GHG emissions

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Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

 Charging, infrastructure

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

© Fraunhofer
Profil Fraunhofer IFAM: Electrial Energy Storage

„From Powder to Battery Cells of next generation batteries“

Competence: Competence:
Materials & Analytics Processing and manufacturing

 new materials and component  Manufacturing process for electrodes

development (Extrusion, Thick- / Thinfilm)
 Special analytic methods („In Situ“-  Cell assembling and battery design
Methods)
 Aging and operating strategies

Topics

 Lithium Ion Batteries

 All Solid State Batteries
 Metal Air Batteries

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Key activities batteries

 Electrode manufacturing
 Thick film, Thin film, shape technologies

 Cell assembling
 Pouch-Format (Lithium-Ionen-Batteries, DLC)
 Strategies for manufacturing (flexible, bendable,)
 Sensor integration in LiBs

 Battery aging, life time, safety

 Battery-/Aging tests und state of health determination
 Recycling, Second life use

 Polymer based Solid State Batteries

 Development and manufacturing of polymer based composites
 Cell concept

 Metal/ Air -Batteries

 Development and test of components

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 Modul concept with heat conducting glue

Bonding with heat conducting glue: IFAM Modul

48V / 40 Ah
 mechanical fixing
 good heat transport
 dense packaging
 simple assembling
 no screwed joining necessary

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 All Solid State Batteries

 Promising technology :
 High energy density,
 safety, non-flammable (intrinsically safe batteries)
 Lithium metal & high voltage cathodes
 Compact , reducing passive components
 Packaging, more flexible form factor
 Rigid (bulk type) or flexible (as thin film)
 Processing of Polymer Electrolytes and Composites
 Melt extrusion for mixing and forming of polymer based
electrolytes and batteries
 Solvent free processing
 PECVD and physical vapour deposition inside Glovebox
(Lithium Metal)
 Challenges: Up scaling, solid- solid interfaces LLZO in PEO Composit

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Our offer to batterie technology

 R & D project, Workshops, Academy

 Evaluation of batteries,

 Test and evaluate battery components &

materials,

 Expertise and studies to electrical energy

storage (technologies, markets, applications)

 Concepts for and economical calculation of

charging systems, consultant

 Planning of battery production lines

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Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

 Charging, infrastructure

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

© Fraunhofer
Smart grid for electric vehicle fleet
Being able to charge up to 30 electric
cars at once requires some ingenious
energy management. Researchers are
incorporating a mix of renewables into
the design of a smart grid for
Germany’s largest charging station.

© Victor S. Brigola/Fraunhofer IAO

Electric buses are an eco-friendly

alternative to diesel.
With several project partners,
Fraunhofer researchers have
developed a concept to swiftly recharge
buses while they operate routes.
System testing in Dresden has been
underway since November last year.
© Fraunhofer IVI

© Fraunhofer
High Power and fast Charging
charging time [min]

 Li-Titanoxide Anode (LTO),

„Scale up“ Solution-Combustion
Synthesis: Process development with
higher throughput and cost reduction

 Double Layer Capacitors (EDLC),

Electrode fabrication with novel
carbons and electrochemical
analysis

Smart Grid / Fast Charging / Vehicle-to-Grid / Consumer Acceptance

Intelligent Energy System * Intelligent Electrical Vehicle * Intelligent Transportation System

E-Storage EV * NPE Report

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Inductive Charging of Electric Vehicles

 Bidirectional inductive charging:

 Project ´DRAHTLOS´ - Wireless coupling of
electric vehicle and smart home: bidirectional
inductive integration of battery-electric vehicles
as quasi-stationary battery storage system in DRAHTLOS
buildings 01/2016-12/2018

& Next Energy (now DLR), AUKOS,

B2M, ENASYS, E-GO-Mobile

 Dynamic inductive charging:

 Test track with incorporated coil within the
road. In 2014 the electric test vehicle FreccO
from IFAM demonstrates driving and charging
along the road (~30kW). Fraunhofer IVI charges
an autotram of about 60kW.

Source: INTIS GmbH

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Grid Services

 E-cars = storage for electrical energy produced by renewable energies

sources (photovoltaic plants, wind power plants, water power plant etc.)
 E-cars = mobile energy storage devices  relief for public grid

www.dukosi.com
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Powergrid: Multi-Grid-Storage

Biogas- Gas- Natural gas

facility Storage source

Gas-
GAS
Gas powered Grid
faclilty
Gas-
Heaters
Photo- Power to
voltaics Heat
Gas from oil
Unit
Power-
Gener.
Windenergy HEAT

Electr.- Heat- Heat from

Energy Grid electrical Grid Biomass
from coal Heater

other
powerplants ELEKTRICITY
Electr.- Heat-
Storage storage

Heat- Heat from

Pump Enviroment

© Fraunhofer IFAM
Kontakt: Prof. Dr. Matthias Busse, Tel.: 0421-2246-100
Matthias.Busse@ifam.fraunhofer.de
Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

 Charging, infrastructure

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

© Fraunhofer
INTRODUCTION CAST COILS
Motivation and general idea
Motivation
 Increase slot filling factor and improve
thermal characteristics
 Enhance power and torque density of
electrical machines
 Reduce material and production cost
 Develop production processes for high-
volume production of electric drives
General idea:
 Realization of the casting process using a
flat conductor, spiral-geometry
 Utilizing the inherent advantages of the
casting process, such as:
 Geometrical flexibility and precision
 Mass production capability
 Integrability in the design process
Geometry of cast coil compared to
wound copper coil

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APPLICATION EXAMPLES
A: Water jacket cooled motor for Hybrid Electric Vehicle
 In collaboration with German OEM,
a prototype machine for a hybrid electric
vehicle motor was built
 Cast copper coils, 0.8 mm conductor
height,14 turns
 A slot filling factor of 72% was reached
in prototypes, considering all tolerances;
up to 80% are reachable in serial
production
Stator and cross-sectional view of cast coil

Test bench results:

 In low speed operation, the continuous
output torque is increased by up to 42%
 The efficiency rises by >1% in
+42%
continuous operation

Source: C. Junginger: Design, Integration and Measurement of a Hybrid Machine with Cast Coils, EDPC 2014

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APPLICATION EXAMPLES
C: Direct-cooled coil with integrated cooling channels
Institut für Antriebssysteme
und Leistungselektronik
General idea: Lamination stack
 Integration of axial cooling channels in the Cooling channels
conductors
Coil
 U-shaped conductors, upper and lower side of
each conductor form cooling channel
 Cooling channels reach from end winding to end
winding, allowing cooling fluid to flow through
the machine in axial direction
Results of preliminary tests:
 Current densities up to 100 A/mm² can be
reached, compared to 12 A/mm² in
conventional systems with water-jacket cooling
 Power and torque density can be increased
significantly

Top: CAD-model of coil with integrated cooling

channels

Bot.: Prototype coil

Institut für Antriebssysteme

© Fraunhofer
und Leistungselektronik
APPLICATION EXAMPLES
B: Air-Cooled Wheel Hub Drive
 For an air-cooled wheel hub motor, an
electric drive system was equipped with
cast aluminum coils
 Use of aluminum reduces motor-weight
 Inorganic coating with minimized
thickness for insulation
 High slot filling factor and good thermal
connection allows power density
comparable to conventional water jacket
cooled applications
 Drive System Data:
 Permanent magnet synchronous
machine with 36 Slots and 30 poles
 Peak Torque: 400 Nm
 Test bench measurements currently
ongoing

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Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

 Charging, infrastructure

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

© Fraunhofer
Advanced Training with Fraunhofer

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CORPORATE LEARNING DEVELOPMENT WITH BMW IN THE FIELD
OF FIBER-COMPOSITE TECHNOLOGY

Source: BMW

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TARGET GROUPS AND SPECIALIZATION

Technical Technical
Target Group Experts Executives
Nontechnical Management

Technology Update Technology Awareness

Specialization
Business Awareness
(Management)

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Fraunhofer IFAM Training Program for Electric Mobility
Concept with 3 Modules

Electric Mobility for Specialists

 Electric Drivetrains
 Electro-chemical Energy
Electric Mobility Storage Systems
for Advanced  Electric Mobility and Housing
 Didactics of Technology – Electric
Electric Mobility  Subject Matter Expert Mobility in Vocational Training
for Starters Electric Mobility
(»Fachkundige Person  Systems Solutions –
Elektromobilität«), Lightweight Solutions for the
 Overview Automotive and Supplier Industry
incl. TÜV Certificate
Seminar

Starter Advanced Specialist

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Contents

 Fraunhofer

 Worldwide situation, future challenges

 Battery technology

Charging, infrastructure

 Powertrain

 Fraunhofer Academy

 Cooperation opportunities

© Fraunhofer
Development cars and charging infrastructure until 2030

 Reduction of (batterie) costs and weight

 Continous increase of power and
energy density of traction batteries
 Increasing lifetime
 Standard Range of E-cars > 500km
without charging (today: > 200km possible)
 Charging power on public stations:
up to 250kW (today: 120kW possible)
 Bi-directional charging of e-cars will be standard
 Using traction battery as storage device
 Intelligent charging when car is connected
to grid
 Inductive charging (stationary and dynamic)
common in public areas

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Fraunhofer as a strategic partner for future-oriented
mobility issues

Prof. Dr.-Ing. Matthias Busse

Director
Fraunhofer Systems Research Electromobility

Fraunhofer Institute for Manufacturing Technology and Advanced

Materials IFAM
Matthias.Busse@ifam.fraunhofer.de

Fraunhofer offers: Fraunhofer‘s partners are:

 Feasibility Studies  Government and administration

 Consulting Services  Large industrial enterprises
 R&D Services  Small and medium enterprises
 Training  Scientific and academic institutions
on all aspects of mobility

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