powertrain engineering
the 800-volt approach by presenting
its AVL demonstrator vehicle Coupe
800. Besides featuring an operating
voltage of 800 volts for all system
components and a system output
of 175 kW (around 238 hp), it was
already possible back then to demonstrate
1 2 F O C U S
the need for a sporty and
dynamic vehicle in the all-electric
vehicle segment.
SMART BATTERY COOLING SYSTEM
AND LOW ENERGY CONSUMPTION
Where range increase is concerned,
the first step to take involves ensuring
an optimal connection between
the cells and the cooling system: “To
this end, AVL has developed methods
that allow this to be done in a
way that is both cost-effective and efficient.
AVL has the necessary physical
understanding and the simulation
tools in place to support the development
process in its early phases with
foresight,” Klaus Küpper explains.
Expressed in terms of solutions and
the Connected Powertrain concept,
AVL develops predictive thermal
management strategies which, with
the aid of topographical data and remaining
range calculation, pre-condition
the batteries before reaching the
next charging station, so that fast battery
charging (800-volt or 1,000-volt
batteries) is guaranteed. This is most
importantly an issue where hybrid
vehicles are concerned, particularly
as data from advanced driver assistance
systems (ADAS) can contribute
substantially toward improving
both range and efficiency.
Another possible approach to optimizing
battery cooling involves addressing
the way in which the cooling
system is integrated. Gerald Teuschl,
AVL Senior Product Manager Powertrain
Electrification: “AVL focuses
on structurally integrated cooling. In
other words, no extra lines or connections
are needed inside the battery.
Instead, the cooling system is
integrated into the battery’s installation
structure. Together with the
vehicle structure, this forms the vehicle’s
load-carrying body-in-white.
The concept offers essential advantages
regarding weight, installation
space, durability, error-proneness,
assembly time or battery density.”
But battery cooling is not the only
factor to consider when assessing
ways to improve efficiency and range.
“Interior air-conditioning is another
important subject which AVL is investigating
closely. This is due to the
fact that in BEVs the heating of the
interior, in particular, requires a lot
of energy. In this respect, AVL provides
a broad range of solutions: In
order to avoid losses, passive thermal
management measures, such as thermal
insulation or reflective surfaces,
form an essential part of thermal development
and are complemented by
active elements, such as the targeted
use of energy-saving infrared heating
in the vehicle interior to lower energy
consumption. Even heat pumps are
successfully in use to heat the interior,
and these can even lead to significant
improvements in range. In order to
extend the range of BEVs even further,
efficient energy use in recuper-
» AVL IS A QUALIFIED PARTNER FOR EVERY OEM
AND SUPPLIER. WE HAVE THE COMPLETE PORTFOLIO:
FROM SIMULATION AND TESTING SOLUTIONS
TO COMPREHENSIVE ENGINEERING EXPERTISE. «
GERALD TEUSCHL,
AVL Senior Product Manager Powertrain Electrification