ir ing Tim de Langeir ing Tim de Lange
�� System IntegrationSystem Integration
�� Power electronics, storage, controls and Power electronics, storage, controls and
transmissionstransmissions
�� www.innosysdelft.comwww.innosysdelft.com
Goals Innosys Delft BVGoals Innosys Delft BV
�� System integration:System integration:
�� Delivery of systems with battery packs, power Delivery of systems with battery packs, power
electronics, motors, chargers and controlselectronics, motors, chargers and controls
�� Engineering, simulations and design of drive systemsEngineering, simulations and design of drive systems
�� Production and onProduction and on--site installing drive systemssite installing drive systems
�� Sustainable Entrepeneurship:Sustainable Entrepeneurship:
�� Charging facilities all over the worldCharging facilities all over the world
�� Cooperation with utility companiesCooperation with utility companies
�� Establishement of Establishement of ‘‘All Electric SocietyAll Electric Society’’
Projects: Nuna 1Projects: Nuna 1
Projects: Formula Zero H2 KartProjects: Formula Zero H2 Kart
Projects: InnoCarProjects: InnoCar
Projects (April 2010: 70.000km)Projects (April 2010: 70.000km)
Projects: InnoCarProjects: InnoCar
Projects: InnoCarProjects: InnoCar
Projects: Lotus Electric 200BHPProjects: Lotus Electric 200BHP
Projects: Volkswagen GOLF Projects: Volkswagen GOLF
100BHP100BHP
City CarCity Car
Current activityCurrent activity
�� Development of 100hp budget drive trainDevelopment of 100hp budget drive train
�� 2011: Electric broad cast vehicle olympic 2011: Electric broad cast vehicle olympic
gamesgames
�� October 2010: Smart Grid charger for low October 2010: Smart Grid charger for low
voltage EVvoltage EV’’s and high voltage EVs and high voltage EV’’s, 5s, 5--
10kW, 1&3 phase (auto detection)10kW, 1&3 phase (auto detection)
�� EV to DC sustainable network EV to DC sustainable network
compatibility: all DC networkscompatibility: all DC networks
Conversion ChallengesConversion Challenges�� SpaceSpace
��Weight distributionWeight distribution
�� Dynamic behaviorDynamic behavior
��WaterproofWaterproof
�� Battery temperature managementBattery temperature management
��Modularity and serviceabilityModularity and serviceability
��Wire harness productionWire harness production
�� SafetySafety
�� Compatibility electric grid (cos phi, EMI)Compatibility electric grid (cos phi, EMI)
SpaceSpace
Weight DistributionWeight Distribution
Dynamic behaviorDynamic behavior
WaterproofWaterproof
Batt. temperature managementBatt. temperature management
�� Temperature distribution across packTemperature distribution across pack
�� Use in winterUse in winter
�� Use in summerUse in summer
�� Charging vs Lithium platingCharging vs Lithium plating
�� Regenerative brakingRegenerative braking
�� Drive control as function of battery statusDrive control as function of battery status
Modularity and serviceabilityModularity and serviceability
�� Different battery packs all over the car?!Different battery packs all over the car?!
��Motor overhaul?Motor overhaul?
�� External people working on carExternal people working on car
�� Component replacementComponent replacement
�� Price reduction for broken partsPrice reduction for broken parts
�� Safely working on live partsSafely working on live parts
Wire Harness ProductionWire Harness Production
�� About 500 connections in the Drive train About 500 connections in the Drive train
wire harness only (!)wire harness only (!)
�� Around 70 sub harnesses (!)Around 70 sub harnesses (!)
�� Not only 12V but also HVDC!Not only 12V but also HVDC!
��Waterproof connectorsWaterproof connectors
�� Cable quality: status after 5Cable quality: status after 5--10 years?10 years?
�� Handling of extension wireHandling of extension wire
�� Small series production: hand labour!Small series production: hand labour!
�� Voltage ratings / Color codesVoltage ratings / Color codes
SafetySafety
SafetySafety
SafetySafety
�� Battery position in chassisBattery position in chassis
�� Ventilation toxic gassesVentilation toxic gasses
�� Flame retardant materialsFlame retardant materials
�� Compare with fuel tank bay, but only 10 Compare with fuel tank bay, but only 10
times less contained energy!times less contained energy!
�� Switch gear strategy when crashing: Switch gear strategy when crashing:
safety contactorssafety contactors
SafetySafety
�� Original ABS functionality (inertias drive Original ABS functionality (inertias drive
train might change)train might change)
��Mechanical safety between motor and Mechanical safety between motor and
transmisiontransmision
Compatibility electric gridCompatibility electric grid
Compatibility electric gridCompatibility electric grid
Compatibility electric gridCompatibility electric grid
�� All electric society vs good old ac networksAll electric society vs good old ac networks
�� DC advantages: DC advantages:
-- Always power factor 1Always power factor 1
-- No reactive power billingNo reactive power billing
-- No distortionNo distortion
-- Higher efficiency due to solid state Higher efficiency due to solid state
electronicselectronics
-- Smaller equipmentSmaller equipment
-- Easier network management: EV is bufferEasier network management: EV is buffer
ICTICT�� AC: AC:
-- Monitoring reactive & active powerMonitoring reactive & active power
-- FrequencyFrequency
-- DistortionDistortion
-- Power balancePower balance
DC: DC:
-- Monitoring active power onlyMonitoring active power only
-- Power balancePower balance
-- Different vision peak shaving due to bufferDifferent vision peak shaving due to buffer
ICTICT�� AC: AC:
-- Intens!Intens!
-- System is subject to collapse!System is subject to collapse!
DC: DC:
-- ICT can focus on relevant challenge: ICT can focus on relevant challenge:
sustainable power implementation!sustainable power implementation!
-- InnoSys: ICT controlled chargingInnoSys: ICT controlled charging
ConsiderationsConsiderations��Make EVMake EV’’s more automotive; compact, etcs more automotive; compact, etc
�� EVEV’’s use energy but 100% compatible with s use energy but 100% compatible with
sustainable energy sourcessustainable energy sources
�� Is AC the future? DC is more likely!Is AC the future? DC is more likely!
��Managing the AC/DC networks is definitely Managing the AC/DC networks is definitely
optimized with ICT.optimized with ICT.
Questions?Questions?
�� Site: Site: www.innosysdelft.comwww.innosysdelft.com
�� EE--mail: mail: [email protected]@innosysdelft.com
