THE HIGH VOLTAGE BATTERIES OF THE BMW i3
AND BMW i8.

AABC 2014, FEBRUARY 3TH- 7TH, ATLANTA

BMW

GROUP

© 2014 Advanced Automotive Batteries

AGENDA.

■ BMW approach to sustainable mobility: BMW

■ Project targets and requirements

■ Technical concepts and solutions

Summary

BMW i - SUSTAINABILITY DRIVES THE LIFECYCLE.

New vehicle concepts

New materials Production concept New electric

and recycling of the future drivetrain

Integrated approach of BMW i - BORN ELECTRIC.

New processes Employees Pioneering design ? New customer focus

© 2014 Advanced Automotive Batteries

THE PURPOSE DESIGN LIFEDRIVE CONCEPT.

Life-Modul with CFRP passenger compartment

Lithium-Ion Battery Fuel tank

Electric motor with Power Electronics Internal combustion engine with transmission

Two separate, independent functional units:

■ Life module

High-strength and extremely lightweight passenger cell made from carbon
fibre-reinforced plastic

■ Drive module

Ideal integration of suspension and eDrive System

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ELECTRIC POWERTRAIN: THE BMW eDRIVE SYSTEM.

In-house development

Key components developed at BMW
(power electronics, electric motor and
high voltage battery)

In-house production

Electric motor and high voltage battery
assembled at BMW

High efficiency

Increase range and reduce battery costs

Low weight

In accordance with the light weight concept i3

© 2014 Advanced Automotive Batteries

REQUIREMENTS FOR THE HIGH VOLTAGE BATTERIES.

■ High power density

Enabling BMW typical driving dynamics

■ High efficiency & low weight

Increase range and reduce battery costs

■ Lifetime

Battery warranty of 8 years

■ Safety

No risk in any situation

■ Sustainability

Choice of materials & second life use

© 2014 Advanced Automotive Batteries

BMW HIGH VOLTAGE BATTERIES: TECHNICAL DATA.

BMW i8 high voltage battery

BMW i3 high voltage battery

Technical Data

BMWi3

BMWi8

Nominal voltage

360 V

355V

Max. current

409 A

320A

Energy content

22 kWh

7.1 kWh

Discharge Power peak

147 kW

105kW

Total number of cells

96 (Ip, 96s)

Weight

(with connections)

233 kg

98 kg

Charging time

<0,5 h for 80%
(DC charge)

2h

(AC charge)

Cooling

Refrigerant

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Specific battery power /10OO kg vehicle weight

BMW BATTERY SYSTEMS HAVE A UNIQUE POSITION IN
TERMS OF POWER / ENERGY DENSITY.

BMW i8

BMWActiveHybrid 5

IT M

HEV

PHEV

<0

//

&

1

Q,

BMWActiveE

Specific battery energy /1000 kg vehicle weight

Competitors HEV
Competitors PHEV
Competitors BEV

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TECHNICAL CONCEPT - BATTERY PACK.

Concept identical for PHEV / EV application

■ Distributed E/E design (BMU, S-Box, CSC)

■ Structural rigidity by overall mechanical design

■ Light-weight housing (aluminum extruded/diecast)

■ Direct refrigeration (single/multi-layer)

■ All components serviceable, easy access,

(high voltage is protected against contact within
battery housing)

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TECHNICAL CONCEPT-E/E.

CSC CSC CSC CSC

■ Modular kit HW: same electronic components in both systems

■ Modular kit SW: same software and algorithms in both systems, diversity by calibration

■ BMU (Battery Management Unit), S-Box (Switch Box) and CSC(Cell Supervising Circuit)

■ BMU contains battery management software (e.g. SOC,SOH, diagnosis)

■ CSC for cell voltage/temperature measurement

■ S-Box: fuse, contactors, current and voltage measurement

© 2014 Advanced Automotive Batteries

TECHNICAL CONCEPT - CELL MODULE.

EV cell module (12 cells)

PHEV1 cell module (16 cells)

■ Cell number per module (12v.s. 16): trade-off between package, electronic
components and transport regulations

■ Cell module is a serviceable unit

■ Validation on module level guarantees high quality and reduced costs for derivates

■ Meeting UN38.3 standard

■ Possibility to use EV and PHEV1 modules for further projects

© 2014 Advanced Automotive Batteries

TECHNICAL CONCEPT - REFRIGERANT COOLING.

Phase 1 Velocity
Streamline 1
15.000

12000

■ Cell Lifetime

Cooling performance is key factor for lifetime

■ Weight & performance

Highest cooling performance at minimum weight
and costs (no extra installation in vehicle, use of
existing A/C system)

■ Heating option

Available for maximum comfort and performance
without losing range

■ Complexity of direct cooling

Intensive validation and simulation is necessary for
complex designs (multi-layer)

© 2014 Advanced Automotive Batteries

Battery weight / Energy installed

LIGHTWEIGHT-A KEY FACTOR FOR FUTURE BATTERY
SYSTEMS.

High voltage battery BMW Active E High voltage battery BMW i3

mechanic
cooling

cells

mechanic,E/E,
cell modules

E/E cell
module

cells

battery weight distribution
(BMWi3)

Electric range for EV (based on BMW i3)

Today:

160km /10Omiles

Target (2025):

480km / 300miles

targets based on battery pack 250Wh/kg / 450Wh/lt [P. Lamp, ABAA 6, Chicago 2013]

© 2014 Advanced Automotive Batteries

SUMMARY.

BMW i as a holistic approach to sustainable mobility

In-house development of high voltage batteries in third generation

Purpose design vehicle architecture allows ideal integration in terms of weight & costs

■ Powerful, long-lasting and safe high voltage batteries

■ Modular kit approach, possibility of use for further electric powertrains at BMW