Day Two - Thursday, June 20, 2019

Designing The EV Body Structure & Battery Pack To Avoid Safety Issues

09:00   Chair's Opening Remarks

KEYNOTE: DESIGNING TO AVOID SAFETY ISSUES

09:10   Understand Safety Requirements For EV Body Structure Crash Testing Including The Integrity Of The Battery Pack

  • Understand all safety requirements for EV body structure and battery protection system
  • Ensuring the structural architecture is optimized to be crash worthy to pass all safety tests
  • How can the energy in an impact be managed to protect the batteries? 
  • Designing to avoid safety issues and strategies to optimize crash testing costs

09:40   Questions And Discussion

REGULATORY COMPLIANCE AND TESTING

09:50   Crash Testing For EV Batteries And Battery Packs- What Are The Regulatory And Compliance Essentials In Different Countries?

  • What standards are in place on safety to protect batteries in an impact?
  • Which approaches and specification do OEMs use internally?
  • Where does the automotive community see the way forward from a safety standpoint?
  • To what extent can batteries be made to a universal standard?
  • Situation and lessons from overseas - the European and China markets
  • Assessing the extent to which regulation in different markets impacts business case

10:20   Questions And Discussion

ENHANCING E-DRIVELINE AND NVH PERFORMANCE

10:30   Optimizing EV Noise, Vibration And Harshness (NVH) - How To Achieve Excellence In Vehicle Handling

  • Key vehicle attributes and impact of electrification / battery integration - range, cost, NVH, safety, dynamics and thermal management
  • Strategies for enhanced crash protection, ride handling and vehicle stiffness for better NVH performance
  • New batteries, motors, and other components - best practices for integrating safety into those
  • What are the structural approaches that can be used to pass stringent safety tests
  • How California is leading on structural safety requirements
  • Where does the automotive community see we are going from a safety standpoint?

Dr. Saeed Siavoshani, Technical Specialist, Hybridization and Electrification, Professor, EV Engineering, Wayne State University (formerly GM, Ford)

11:00   Questions And Discussion

11:10   Networking Coffee Break

OPTIMAL BATTERY INTEGRATION

11:40   Integration Of Battery Cells, Components And Electrical Communication Within The Battery Structure

  • Examining the advantages, benefits and technical drawbacks of singular packs versus multiple battery configurations
  • Optimal methods of holding and protecting cells in a module
  • Making the battery pack denser - tighter packaging benefits in terms of increased range and reduced energy consumption by the system

12:10   Questions And Discussion

Comparing Different Approaches To Optimizing Thermal Management

PANEL: WHOLE VEHICLE THERMAL MANAGEMENT

12:20   New Technologies & Techniques For Simplifying And Taking Complexity Out Of Cooling Processes

Panellists will outline new design engineering innovations on thermal management strategies for specific vehicle segments including SUV, Sedan, City Car, Sports and Luxury EV.

  • Understand the heating and cooling needs of your particular vehicle segment from an entire vehicle integration perspective
  • Switching from air cooling to liquid cooling
  • Future of heat pumps vs. ceramic resistive heaters in terms of energy efficiency
  • Optimal heat exchange, heat management and cabin cooling
  • Conclusions for integration and optimisation
  • How are the batteries as well as cabling for passive cooling systems and thermal management of the battery being integrated
  • Reducing cooling process complexity by creating a temperature gradient just cooling from one side as opposed to all over the battery
  • Potential uses of aerodynamics for battery cooling

13:00   Networking Lunch

Ensuring Your Whole Vehicle Design Strategy Integrates All Inputs Including Design For Assembly, Manufacturing Innovation, Electrical Systems And Serviceability

14:00   Reducing EV Costs Through Design For Assembly And Manufacturability

  • The need to integrate the vehicle assembly method for lowest cost during the EV development phase
  • Avoiding void complex, expensive assembly processes
  • Taking into account safety concerns and considerations

Thomas Westrum, Senior Vice President, Head of Digital, Uniti

14:30   Questions And Discussion

14:40   Manufacturing Innovation Needs To Meet Body Structure Evolution With Automated, Connected, Electric And Shared Vehicles

  • Manufacturing implications of next generation EVs
  • Taking account of the components and material life cycle
  • Joining modern materials mechanically and electrically
  • New types of welding technologies that can used for joining battery frame to the structure to avoid distortions and compromising the design
  • Ultrasonic welding's potential with aluminium and steel
  • Case study on EV manufacture with aluminum and carbon fiber

Dr. Fei Xiong, Vice President, Product Engineering, Electric Vehicles, Qiantu Motors

15:10    Questions And Discussion

15:20   Networking Coffee Break

15:50   Evolution Of Electrical-Electronic Architecture - Is The Future Centralised Or Decentralised?

  • Understanding where the market is going from a voltage standpoint - Are we okay with 400V or going to 800V?
  • Electrification and how it integrates into vehicle structures
  • Will the battery need its own architecture?
  • What does this mean for vehicle design?

16:20   Questions And Discussion

    INTEGRATION OF SERVICEABILITY INTO DESIGN

16:30   Strategies For Servicing The Battery When Highly Integrated In The Vehicle Structure And Managing Impacts On Connectivity And Components

  • Importance of improving ways in which the battery is connected to the vehicle for maintenance and servicing
  • How do you access the cells and modules in the battery pack? 
  • Enhancing the connectivity and lightweighting of cooling, heating and insulation plumbing
  • Consideration in battery design and development for battery swapping

Dr. Aida Rahim, Field Applications Engineer, Luna Automotive

17:00   Questions And Discussion

17:10   An OEM View On Planning For Battery Recycling And End Of Life - Reuse Vs. Recycle?

  • Strategies for dealing with the batteries at the end of life
  • Comparing the costs and benefits of battery re-use versus recycling
  • What are the regulations on vehicle and battery recyclability and how does the EV designer factor these in?
  • What will be the impact of the growth in fleet users?

Oliver Kuttner, Chief Executive Officer, Edison2

17:40   Questions And Discussion

17:50   Chair's Closing Remarks - Apple TV And Champagne Draw

18:00     End Of Conference

400

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