Development and Applications of Modular Product Strategy for Cobasys NiMHax? Product Line of HEV Battery Systems

摘要

As it continues its push towards the commercialization of high power, Nickel Metal Hydride battery systems for Hybrid Electric Vehicle applications, Cobasys has developed a flexible modular product strategy to meet the needs of today’s automotive and heavy duty transportation applications. This paper describes the development process and system integration methodology used to develop “plug-and-play” solutions for HEV battery systems including a series of high voltage and 42V hybrid electric vehicle battery systems. The products cover the range of transportation application needs from mild hybrid and full hybrid cars, trucks, and SUV’s, to large industrial/commercial hybrid applications such as buses, delivery vans and military vehicles. Performance data and application examples are also provided. The battery systems incorporate all necessary features to enable “plug-n-play” capability for most customer needs. System features include fully integrated battery management system hardware and software, safety devices, packaging, wiring, and integral or optional thermal management based on newly developed liquid cooling systems for optimized performance in high power HEV applications. Fully integrated control algorithms were also developed and implemented to help optimize the energy management functions and product durability.The product strategy focused on development of one standard system architecture, two systemlevel technologies and three core system products which combined resulted in over 10 application-specific solutions. Integration of heavy duty bus/truck requirements into a standard modular battery system product was a key driver. Furthermore, the Cobasys team integrated the technical requirements from several leading HEV integrators, which posed a unique challenge to the development team. Nominal voltage was selected for 3 core products: 144V, 288V and 336V in order to satisfy the maximum number of market applications and to provide compatibility with existing electric powertrain motor and inverter solutions. The above core products are being used in combinations of series and parallel wired packs to enable the application of 576V and 672V packs with power capability from 30kW to 240kW and energy storage capability from 1- 12 kWh to satisfy a wide range of applications. In addition, air-cooled 42V products were developed, providing 7-15kW options for mild hybrids. The development of the described product strategy is a key factor enabling the implementation of HEVs in global markets and enhances market development in heavy duty buses, trucks, off-road equipment as well as military applications.