Axeon
Axeon designs and manufactures advanced
lithium-ion battery systems for a variety of end
market applications:
Automotive (electric and hybrid vehicles)
Energy storage
Cordless power tools
Mobile products
E-bikes
Europe’s largest privately-owned independent
lithium-ion battery systems supplier,
processing over 70 million cells a year
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Axeon’s automotive experience
The world’s most powerful
passenger car battery for the
102EX Rolls-Royce Phantom
Experimental Electric
Volume production;
conversion of Peugeot
vehicles for the leading
British vehicle converter.
Range includes cars,
people carriers and vans
Designing and developing
Range Extended EV packs for
Jaguar Land Rover
Over a million vehicle miles
driven since 2007 = 20MWh
of batteries shipped
HEV sports car: developing
leading-edge technology for
premium European
manufacturer
Prototype
fully electric
Land Rover
Defender
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Industry Trends
Industry challenge is dominated by increased energy density (range)
Power = Battery Pack Power Density / Wkg
-1
*
HEV (Hybrid EV) e.g. Toyota
Prius. Internal combustion
engine (ICE) combined with a
small battery which captures
energy during braking and
reuses to boost acceleration.
Short range in pure EV mode.
EV (Electric Vehicle) e.g.
Nissan Leaf. Pure electric
vehicle with no ICE. Battery is
the only source of power and
is larger to deliver range.
PHEV (Plug in Hybrid EV)
e.g. Chevrolet Volt. Vehicle
still has ICE but with a battery
which can be charged
externally and hence support
longer EV range.
Range =
* Peter Lamp, BMW, AABC 2010
Industry challenge is greater for increased Energy Density (Range) than
Increased Power Density (Performance)
Note:- REEV (Range
Extended EV). Battery is
primary source of power but
vehicle has small ICE as a
back up generator for longer
range journeys.
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Energy density challenge is dominated by electrochemistry evolution
which is the domain of cell developers e.g. A123, Dow Kokam etc
2020+ ?
2015+ ?
2013
2015
Range =
Now
2014
Dynamite = 1375 Wh/kg
Wood
= 4000 Wh/kg
Petrol
= 12000 Wh/kg – highly energy inefficient
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Axeon projects/R&D are focussed on staying at the forefront of
electrochemistry evolution working closely with key partners
Axeon
Projects
Rolls Royce
ECC
IntelligentEnergy
TSB Partner
Range =
Axeon
Projects
Modec
Allied
Landrover
Caterpillar
IVECO
Sandvik
Ruf
IDIADA
Zephyr
REEV
Future Project (C)
TSB Project (A)
Cells (D)
R&D Programmes
TSB A - Pouch Cells/BMS
TSB B - TMO / Si-alloy
Cells - Sample cell testing
Future Project (C) – Li-S / Li-Air
TSB Project (B)
Consortia
Axeon, Allied and Ricardo
Axeon, St Andrews Univ, Nexeon, Ricardo
Envia Systems
To be confirmed (in discussions)
Status
Awarded
Awarded
Ongoing
Future
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High power density requires high performance cooling/control systems
Axeon has developed many technical solutions to deliver these projects
Axeon Technologies/Capabilities
Increasing power density requires high performance cooling
Power =
High performance Battery Management System (BMS)
Laser welding of cell terminals to bus bars
Design of complex cooling systems
Friction welding of dissimilar metals
Leak testing of fluid cooled modules
Cooling system performance testing
Aluminium salt-bath dip brazing
High voltage system/module test
Axeon Technologies/Capabilities
Critical jig location of multiple cells
Module pasting process for multiple cells
High performance charge and discharge testing
Simulated customer usage performance testing
Thermally conductive adhesive mixing and dispensing
Pressure testing of fluid cooled modules and battery system
Range =
Energy Density Wh/kg
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TSB-B Project includes the integration of positive and negative electrodes
from different vendors. This move Axeon further down the value chain
Operations ValueCellChain
Cell Raw
Materials/process
e.g. Lithium
Carbonate
e.g. FMC, Western
Lithium etc.
Electroactive
“Ingredients”
e.g. LiPF6,
LiFePO4, LMO,
Gr, etc.
e.g. Phostech,
Mitsubishi, etc.
Cell subcomponent
production/test
e.g. Electrodes,
electrolyte, etc
e.g. Samsung,
Sony, A123, etc.
e.g. MIT or
St. Andrews (UK)
Materials
Optimisation/
Integration
R&D
e.g. A123 or
Nexeon (UK)
e.g. Samsung,
Sony, A123, etc.
Battery
Assembly
and test
e.g. SBLiMotive,
A123, Axeon, etc.
Battery pre
conditioning
e.g. Jaguar,
Landrover etc.
TSB-B Project moves Axeon further down the value chain
R & D Value Chain
Energy Storage
Materials R & D
Cell
Assembly
and test
Cell Design for
Manufacture/
Process
R&D
e.g. A123 or
AGM (UK)
Cell Testing,
Validation &
Qualification
e.g. A123 or
Axeon (UK)
Battery
R&D
Application
R&D
e.g. A123 or
Axeon (UK)
e.g. BMW or
JLR/TATA (UK)
TSB-B Project
Partners
Si based alloy based next generation of negative electrodes
High volumetric and specific energy
Problem – particle fracture due to large volume expansion
Fix – Accommodate stress/strain of volume expansion via nanostructure
Further BMS development (smaller/cheaper)
Coupled with Li-TM-Silicate positive electrode
Overall = High energy density 250-300 Wh/kg, low
cost.
Cell Chemistry characterisation
BMS calibration
Pack Engineering and Construction
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Evolution of Battery Pack Level Requirements
Typical Drive Cycles
Typical Drive Cycle Constraints
Test Track (Performance)
Ambient Temperature
Zero to Vmax
Coolant system availability
Traffic Light Test
Temperature
NEDC
Flow rate
Heat rejection
Outputs from Requirements Analysis
Cell Chemistry and Form factor
Cell Configuration (Series/Parallel/Modularity)
Coolant System Requirements
Concept Volume, Packaging, Weight
Consideration of Crash, Crush, Mechanical Safety
Reliability/Life Predictions
Typical Pass/Fail Criteria
Vehicle Range
Power/Current/Voltage
State of Charge (Range/Absolute)
Cell Temperature (Range/Absolute)
Heat rejection requirements
Regenerative Energy Recovery
Usable State of Charge vs. Time
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Case Study : High performance RE-EV
Requirements
Cell Test Simulation
Axeon Confidential
Parameter
Specification
Cell Capacity
4.4 Ah
Series
122
Parallel
6
Module Configuration
14 x (9S5P) [2 Banks of 7]
No of Cells
732
BMS
14 VTBMS / 1 BCM
Total Cell Mass
150.6 kg
Nominal Energy
10.63 kWh
Const Current /Cell
200 A
Peak Current /Cell
260 A
Nominal Voltage
402.6 V
Max Voltage (415 V)
439 V
Min Voltage
(250V)
244 V
Const Current /Battery
1200 A
Peak Current /Battery
1560 A
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Axeon Core competencies& capabilities : Technology Roadmap
AXEON CAPABILITY
Concept
Customer
Research
Demonstrator Prototype
Series
Production
Axeon BMS
Battery Management System
Ricardo Gen 1 BMS
Ricardo Gen 2 BMS
LiFePO4 / Prismatic & Cylindrical
Cell Technology / Chemistry
TSB : NCM / Pouch
TSB : TMO|Si-Alloy / Pouch
Li-Sulphur / Li-Air?
Simulation & Modelling
ECHem / Thermal / CFD
Lightweight Materials /
Crash Structure
E.g. FP7 : SmartBatt
Recycling / Second Use /
Design for Disassembly
E.g. Sharp + Future TSB
2008
2010
2009
2012
2011
2014
2013
2015
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Axeon Summary
Axeon has extensive real world experience of EV and HEV batteries
including a range of cell chemistries and Battery Management Systems.
Axeon is “Cell Agnostic” but well connected to cell vendors and
participates in joint research and development programs.
Axeon has Multi-disciplinary engineering teams with electrochemical,
performance and thermal capabilities to allow for a complex
understanding of cell performance as well as integration and calibration
of BMS.
These processes enable Axeon to design, develop and manufacture
bespoke battery solutions for demanding applications tailored to
integrate effectively into EV/HEV and PHEV vehicle platforms
Axeon has a future view of these rapidly developing technologies
backed up by real research and development programs and real end
customer development projects.
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Axeon
Nobel Court
Wester Gourdie
Dundee DD2 4UH
Scotland, UK
Tel: +44 (0)1382 400040
Fax: +44 (0)1382 400044
www.axeon.com