DAY 1 – 21 June 2022  

COST COMPETITIVE HOLISTIC VEHICLE DESIGN CONCEPTS FOR KEY CUSTOMER SEGMENTS Reducing Cost & Enhancing Efficiency To Maximize Energy Consumption

BREAKFAST BRIEFING; GLOBAL MEGA TRENDS  

0745 Evaluate Global Mega Trends To Gain A Holistic View On BEV Adoption Rates, Battery Pack Design & Customer Acceptance On Range For All Passenger Vehicle Segments  

The briefing commences with an analysis of consumer trends on B.E.V. sales in global markets, including India, China, Africa, North America, and Europe. Key questions will also be addressed, including –

• How are charging ecosystems evolving in developing world regions like India and Africa?
• For individual market segments, the acceptance rate on the real-world range versus published capability (once entertainment systems, air conditioning systems, and actual driving behaviors enter the equation)? 
• Do the first-time electric vehicle buyers always upgrade to more sophisticated B.E.V’s or do some go back to buying traditional internal combustion engine cars. If so, why and in which market segments?
• And how do the latest trends project buying behaviors within key segments, considering factors including gender, age group/demographics, and the traditional two-car home?
• How do customers view battery back designs where it is impossible to swap the battery cells  – from a practical and life cycle sustainability point of view?

0830 – 0845 Breakfast briefing Q&A

0850 Chair’s Opening Remarks For The Main Conference

NEW VEHICLE DESIGN CONCEPTS Battery Pack Integration & Thermal Optimization At The System Level What’s Going To Be Needed For The Future? How Cost Competitive Are The Solutions?

Optimizing Design & Selecting Technology To Improve Energy Efficiency & Offsett Battery Weight

STRATEGIC LEVEL PANEL SESSION - THE HOLISTIC VIEW ON DESIGNING COST-COMPETITIVE VEHICLES

0900 Evaluate New Vehicle Design Concepts Incorporating The Latest Ideas On Cost Competitive Battery Pack Integration & Thermal Optimization For Key Market Segments

The conversation starts by addressing the interlocking vectors of holistic whole vehicle design concepts for individual market segments. Is there now a divide in the technology depending on the vehicle’s requirements? If so, what are the emerging design philosophies for different classes of B.E.V.?  For example, what is an acceptable range for a city car versus a vehicle designed for a more extended distance, longer-distance applications?  How does this impact the design philosophy for the overall vehicle, including battery pack integration and thermal optimization?  And perhaps the most essential critical question of all, how do you incorporate cost optimization into your whole vehicle design concept to reduce the price of the vehicle for mass-market B.E.V’s? 

LONGER-RANGE BEV’S NEEDING LARGER BATTERIES – Balancing The Key Considerations & Trade Off’s At The Design Stage Including Battery Integration, Thermal Optimization, Aerodynamics & Ergonomics

• Whole vehicle design philosophies including technology selection for battery pack design & thermal optimization for larger, ultra-long distance vehicles  

Ehsan Baseri Staff Battery Design Engineer- Technical Lead, HV Systems Rivian

URBAN BEV’S REQUIRING SMALLER BATTERIES – Holistic Vehicle Design Considering Range, Aerodynamics, Battery Integration & Thermal Optimization Of All Components (20 minutes) 

• Design philosophies for urban BEVs with lower average speeds and reduced range requirements 

Simon Xu Engineering Group Manager Vehicle Optimization Advanced Vehicle Development & CAE  General Motors

DESIGN PHILOSOPHY IN ACTION – Insight Into Whole Vehicle Design Decision Making Process To Fully Optimize The Whole Vehicle Architecture For Electrification, Energy Efficiency & Weight Reduction (20 minutes) 

• Optimizing battery pack design, thermal optimization & the packaging of parts for a whole vehicle prototype

10.00 Extended Questions & Discussion  

10.30 Networking Refreshment Break In The Exhibition Showcase Areas  

NEW TECHNOLOGY BREAKTHROUGHS & INNOVATIVE MATERIALS TO MAKE FUTURE ARCHITECTURES COST COMPETITIVE   Improve Thermal Efficiency. Enhance Lightweighting & Integration Capability

NEW DISRUPTIVE TECHNOLOGIES FOR THE FUTURE B.E.V. ARCHITECTURE

10:50 Evaluate The Next Wave Of Potentially Disruptive Technologies To Make Future Architectures More Cost Competitive, Energy Efficient & Lightweight

We are examining some of the leading technology game-changers that go hand in hand with making future battery electric vehicle architectures possible.

TECH FOCUS ONE Cell To Chassis Technology – Evaluate Competing Approaches To Integrating The Battery Cell Into The Vehicle Structure (20 MINUTES) 

TECH FOCUS TWO Connected Battery Management Systems For Greater Energy Efficiency Utilizing 5g &  A.I.  (20 MINUTES)

TECH FOCUS THREE New Materials & Technologies To Cost-Effectively Reduce Weight From The Body In White   (20 MINUTES)

Dr. Lei Shi Chief Technology Officer Nuola Auto

11:50 Extended Questions & Discussion

12: 10 Networking Lunch Break In The Exhibition Area   

 

THE FUTURE OF BATTERY PACK DESIGN AND INTEGRATION AT A SYSTEM LEVEL

PANEL DISCUSSION - OPTIMAL BATTERY PACK DESIGN & MODULARITY

13:10 Evaluating Competing Battery Pack Design & Integration Concepts For Lightweight Efficiency

A Cost-Benefit & Technical Analysis Of Each Individual Approach – What Is The Optimal Way Forward?

Since the last live BEVA USA conference in February 2020, new battery pack design and integration concepts have emerged. Structural battery pack engineering has received significant media attention. It is perhaps the leading example of a multi-function component that protects the battery cell and forms part of the vehicle body structure. How could the industry adopt such a concept, and does this approach represent the future? As many OEMs commit to unibody and skateboard-type configurations, what are the optimal strategies for evolving these more traditional battery pack designs to make them more lightweight and efficient?   

CASE STUDY 1 – New Developments In Structural Battery Pack Engineering To Improve Mass & Range & Help Address Structural Integrity Issues -  A Deep Dive Technical Analysis (20 minutes)

David Weir Senior Manager Vehicle Structural Integration and Battery Frames Jaguar Land Rover

CASE STUDY 2 – Multi-Material Selection & Joining Methodologies For Battery Attachments & Structures (20 minutes)

JOSE LUIS GALAVIZ Chassis Group Frames Technical Lead Stellantis

CASE STUDY 3 – Latest Developments In Quick Release Battery Swapping Mechanisms To Enable Maintainability, Serviceability, Fast Battery Swapping & Access To The Underbody (20 minutes)

14:10 Extended Questions & Discussion

PANEL: MULTI-MATERIAL SELECTION FOR BATTERY STRUCTURES-

1430 Optimizing Design Choices, Mult-Material Selection & Joining Techniques For Battery Structures & Enclosures

UNIBODY MATERIAL SELECTION Optimal Multi-Material Selection For The Battery Pack Based On Electrical & Mechanical Properties (15 minutes) 

SKATEBOARD MATERIAL SELECTION Evaluate Joining Techniques & Multi-Material Selection For Battery Structures (15 minutes)

• Examining the latest composite technologies versus lightweight metals

Okan Otuz CAE& Materials Specialist Mercedes-Benz

15:00 Questions & Discussion

15:10 Afternoon Refreshment Break

OPTIMIZING DESIGN OF THERMAL MANAGEMENT AT THE SYSTEM LEVEL

PANEL SESSION FEATURING CASE STUDIES AND EXTENDED Q&A

15:35 Design Of Thermal Management At The System Level To Optimize The Global Performance Of The Vehicle

Optimal thermal management must be considered at the system level as it is critical to the battery’s performance and the powertrain system.  Too often, however, conversations about individual thermal management design options do not consider the holistic design requirements and objectives of the overall vehicle architecture.  Efficient thermal management involves every system and sub-system to optimize the vehicle’s global cooling and warming performance. 

Moderator: Greg Fadler Wind Tunnel Lab Manager and Aerodynamics Technical Specialist 
Stellantis

SESSION 1 - THERMAL OPTIMIZATION DESIGN FOR LARGE CAR, LARGE BATTERY

Holistic Design For Thermal Efficiency - Evaluating New Breakthroughs & Innovations On Electrical & Thermal Insulation Materials To Balance The Global Performance Of The System (20 minutes)

SESSION 2 - THERMAL OPTIMIZATION DESIGN FOR A SMALL CAR, SMALL BATTERY

Compact Thermal Management Design To Optimize The Cooling & Warming Performance Of All Components & Subsystems For A Small City Car (20 minutes)

SESSION 3 – THERMAL OPTIMIZATION FOR HIGH-PERFORMANCE SPORTS CAR 

Implementing New Design Concepts & Technology Innovations For Effectively Managing The Thermal Behaviour Dissipated By Components & Subsystems On A High-Performance Sports B.E.V.

Karl Plattenberger Chief Engineer- Powertrain and Thermal Systems Mahindra Automotive North America

Each session above will focus on the holistic design of thermal management systems, including using simulation to aid the design process considering: 

• Design optimization of a thermal management system for battery modules, controllers, and electric motors
• Utilizing a combination of passive and active cooling systems and identifying potential failure modes
• Control strategies for temperature including target temperature, temperature fluctuation rate, airflow rate, and refrigeration power 
• Optimizing the health of the battery, including degradation rate and energy consumption
• Considering different driving cycles in high and low-temperature environments 
• Appraising different technology options, including electric heater technology versus pump technology and air conditioning innovation 
• Integrating multi-function components into thermal management systems
• Conclusions for optimizing the final thermal management design

16:35 Extended Questions & Discussion

COOLING STRATEGY FOR THE BATTERY ITSELF

16:55 Improving Cooling Performance & Energy Efficiency & Of The Battery System

While advancements have been made in electric vehicle batteries that allow them to deliver more power and require less frequent charges, one of the biggest challenges for battery safety is the ability to design an effective cooling system.

• Analyzing which cooling system works best in electric vehicles
• Examine the methods of cooling to manage the increased heat, maintain battery life and enhance safety without increasing the size of the pack
• Novel battery system testing to validate the safety and performance of new emerging cooling systems

17:20 Questions and Discussion

BATTERY PACK AND ELECTRONIC COMPONENTS INTEGRATION 

17:30 Evaluate The Potential To Further Integrate Transformers & Electronic Components Into The Battery Pack To Save Weight & Improve Efficiency

• Weighing up the value of further integrating electrical components within the battery pack
  • Combining functionality between fuses and transistors
  • Transformer inside or outside the battery pack?
  • Quantifying weight savings and benefits of using less wiring and needing fewer connectors
• Conclusions on weight savings and efficiency benefits

17:55 Questions & Discussion

18:05 Extended curated Q&A Session

18:15 Chairs Closing Remarks & Close Of Day 1

18:25 Networking Drinks Reception