Modular battery pack solves voyage phobia of electric vehicles

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Looking at the various new energy vehicles that have been introduced on the market today, whether plug-in hybrid (PHEV) or pure electric vehicles, basically do not give consumers a choice of “battery capacity”, the only one with this skill. Tesla's Model S has 60 kWh and 85 kWh two different versions. There is no doubt that electric cruising range is a crucial measure of whether a user purchases an electric car. If the electric cruising range of a model cannot meet the requirements of use, Say Goodbye can only be regretted.

You said that today's traditional power cars basically have different powers to choose from. How can electric vehicles not take this move?

Electric vehicle power selection

A group of scientists from the German Aerospace Center (DLR) had this question and quickly conducted a survey on this subject in Germany. The results of this survey have caused them to call out to automakers that if you want to promote the development of the new energy vehicle market, you can increase the sales of PHEVs or EREVs (enhanced program electric vehicles), then you should The research and development of modular battery design will be carried out as soon as possible so that one model can have different capacity versions, so that customers with different needs can purchase it. Instead of “forcing” customers to accept cars that have been set for cruising range, they use various methods to “fudge” them into buying. This, too, is of great benefit to promoting the development of electric vehicles.

Before them, there have been countless pioneers who have studied the impact of battery capacity on PHEVs on their use costs and CO2 emissions, and DLR researchers believe that there are some key factors missing in these studies:

1. In previous studies, there were no separate calculations for different driving behaviors. It was necessary to know that the energy loss under different driving behaviors was different.

2. They did not consider that those with higher annual mileage actually spent more time on high-speed kilometers. This shows that most of them are driving faster than those with lower annual mileage. , and the different speeds affect the energy loss;

3. So far, no one has considered the technical differences between different hybrid structures, such as parallel and series hybrid structures, which have different effects on the final power conversion efficiency;

4. In some studies, the degradation and aging processes of the batteries were not taken into account, and this means that as the battery capacity decays, the energy they consume and the energy conversion rate are also different.

In short, in previous studies, some factors were more or less taken into account: the influence of different driving behaviors, the influence of battery capacity decay, and the influence of different hybrid technologies. Therefore, DLR's research team focused on these influencing factors.

The greater the capacity of the battery, the energy consumption increases with the mileage?

The research team conducted a study on the German market to calculate the minimum use cost of the new energy vehicles with PHEV and EREV power forms and consider the carbon dioxide emissions of these models. The data analyzed in the study, such as energy consumption and battery costs, is based on existing models.

The PHEV and EREV categories are due to the fact that these researchers believe that PHEVs and EREVs are the two most promising candidates for replacing all conventional electric-powered car classifications because they combine the zero emissions and traditions of electric vehicles. The characteristics of the unlimited cruising range of the power car.

In the study, they selected three typical driving behaviors in Germany: A - 7,500 kilometers per year, B - 15,000 kilometers per year, and C - 30,000 kilometers per year.

Car cost

The research results show:

1. The greater the capacity of the battery, the higher the energy consumption of the PHEV than the EREV, and the greater the difference in the battery capacity, the more significant the difference.

2. In the power system, the higher the proportion of electric drive, the cost of the unit energy consumed will decrease as the battery capacity increases;

3. For a fixed battery capacity, the higher the user's mileage, the higher the unit cost of energy consumption;

4. In the three cases of A, B, and C, for EREV, the battery costs are lower at 2.0 kWh, 6.0 kWh, and 13.0 kWh respectively, and their respective electric cruising ranges are It is 8 km, 24 km and 51 km.

5. In the PHEV, the lowest cost consumption is 1.5 kWh, 3.5 kWh, and 5.0 kWh for the battery capacity (corresponding to the three cases of A, B, and C).

From this we can see that the choice of battery capacity is a key factor in satisfying customers' needs and competing with traditional power in terms of cost. Researchers said that car manufacturers do not need to enter the error zone, but only need to provide large, medium and small battery capacity based on different cruising miles, which can basically meet the needs of most people. The study of the modular design of the battery pack will help automakers to meet changes in vehicle models at less expense and with fewer modifications to other parts of the car.

According to the survey, the researchers also came to the conclusion that the higher the battery capacity, the lower the overall CO2 emissions. If for the government, reducing greenhouse gases, that is, environmental protection is the main goal, then car manufacturers can be encouraged to develop high-capacity battery packs (either PHEV or EREV).

There are two different ways to achieve this result:

1. From the user's point of view, the financial subsidies can be used to directly reduce the cost of purchasing an electric car, or set a corresponding tax deduction to reduce the user's car purchase burden according to the size of the battery capacity. For a traditionally powered car, it can be increased accordingly. Taxes to increase prices

2. From the perspective of automakers, it is possible to add a regulation to the local CO2 emission regulations: through the use of zero-emission vehicles in these cases, subsidize reduced CO2 emissions based on electric cruising range (as in California. The same zero emission regulations apply). Of course, in the end, this part of the electricity used for the PHEV to run in pure electric mode should be generated using renewable energy to be fully conducive to environmental protection.

What needs to be reminded is that in this study, the object of assessment is an idealized and rational consumer, and his choice is based on minimizing the cost of use. However, in reality, our buying behavior cannot be entirely rational. It may be because of the appearance, or seldom long-distance travel to decide what car to buy. The DLR research team will continue to do research to analyze how consumers choose an electric vehicle under actual conditions, and will select the most influential factors and the final results through research.

Sleeping someone to give a pillow

The research results of this DLR were not released long ago, but there was a response.

At the end of September, Boston Energy, a manufacturer of lithium battery, issued the latest technological achievements: a modular battery pack with standardized components, the Ensemble Module System, which can be used by car manufacturers or battery assembly suppliers. A relatively simple and cost-effective method for assembling large-capacity battery packs.

How does the Ensemble modular system achieve battery modularity? The key is that Boston Energy adopts a novel method of pressure connection for assembly of modules rather than the traditional welding method which is both time-consuming and costly. The system has now been thoroughly tested by the OEM standard, and the test results prove that it can be assembled or disassembled in a shorter time than the traditional method, and at the same time has the same assembly density, reliability and thermodynamics as the traditional method. performance. In other words, this method does not reduce the battery's performance and reliability, of course, has not improved, and its biggest advantage is quick-release quick release. A 5300 milliampere hour, 19.3 watt hour battery cell has a weight energy density of 207 Wh/kg and a bulk density of 490 Wh/L.

Ensemble Module System


This modular battery technology is based on a flat, prismatic battery cell design, with the cell's external dimensions equivalent to two 18650 lithium cells. This battery unit, which Boston Energy calls a Swing 5300, can be used on pure electric vehicles, plug-in hybrids, light commercial vehicles, community electric vehicles, and energy storage systems.

For car manufacturers, if you want to design large-capacity battery packs, most of them will spend a lot of time on the design, safety and qualification of the battery packs, and even customize the specific solutions for users to meet different requirements. The existence of the Ensemble modular system is equivalent to providing a semi-customized battery unit. The automakers only need to select a good capacity, achieve rapid production and assembly, and save most of the time from proof of concept to marketization. It can also reduce early-stage investment, project risks, labor costs, and so on.

What automakers need to do is to create several battery modules of different sizes for their users based on previous user usage data.


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