Marc Eichhorn, Product Marketing
Manager for Batteries,
Avnet Abacus
e-Mobility offers exciting opportunities for the future, not only for cleaner and more sustainable personal and public transport but also in a multitude of industrial applications such as mobile robots including Automated Guided Vehicles (AGVs) and drones. Here, Hagen Götze, Senior Director Marketing at Avnet Abacus, chats with Marc Eichhorn, Product Marketing Manager for Batteries, about how the latest developments in batteries are helping to make it happen.
Hagen Götze:
We are receiving increasing enquiries from customers that have imminent applications in many diverse markets such as warehouse automation, smart farming, professional lawn mowers, underwater exploration etc. which, we believe, is generally due to demands for more efficient supply chains, greater productivity and environmental concerns. The COVID situation, also, has focused attention on increasing automation.
Marc Eichhorn:
Yes, with regard to warehouse automation in particular the AGV market is predicted to grow by over 31% CAGR over the next five years, to more than US$13 billion. With the latest connectivity technologies and the ability to store and analyse big data, these vehicles offer tremendous opportunities to streamline and optimise processes. In addition, there have been some important advancements in battery technology that enhance cost-effectiveness and usability.
HG:
Historically, lead-acid batteries have been chosen to power a wide variety of small electric vehicles, like golf carts and forklifts. What’s changing?
ME:
Indeed, lead-acid is tried and tested and still offers a satisfactory solution in many cases. In particular, the cost is lower than alternatives such as lithium batteries and they are thermally stable. However, for new applications, or first-time electrification, lithium is usually the way to go and allows an extended operating envelope and lower cost of ownership. The energy density and cycle life are significantly greater, while weight is lower. Protection circuitry, of course, is mandatory, although smart functionality such as communication and system management are usually built-in too.
A mobile industrial robot in action
HG:
Can you comment on the best lithium chemistries for e-Mobility?
ME:
There are two main lithium technologies for e-Mobility applications: Lithium-Nickel-Manganese- Cobalt-Oxide (NMC), which is also widely used in consumer devices and power tools, and Lithium-Iron- Phosphate (LiFePO4). While NMC offers the highest energy density of the two, LiFePO4 batteries can deliver four-to-10 times the cycle life, so selection depends on performance priorities.
HG:
What other factors should be considered?
ME:
Whether to choose an off-the-shelf battery or bring up a custom design can have a major effect on the project outcome. A custom battery can be designed to provide a specific voltage or conform to a certain physical shape or dimensions. On the other hand, there are Non-Recurring Engineering (NRE) costs and product approval costs to consider. In addition, the whole process can be a distraction for the design team; if your organisation’s expertise is in, say, precision agriculture or materials management, you want to focus on your special competencies or market-specific IP that will make your end product stand out against the competition.
HG:
So, an off-the-shelf battery is probably the fastest to market and fastest to revenue, and the most cost-effective?
VARTA Easy Block and Easy Blade Application Specific Batteries
ME:
In most cases, yes. Also, you will be able to get samples immediately from stock and a matched charger that will work out of the box. I’m excited that VARTA has recently introduced two families of off-the-shelf batteries that cater for emerging e-Mobility applications very well. These Application-Specific Battery (ASB) families are available in both Li-ion and LiFePO4 chemistries and a choice of 24V and 48V nominal voltage. The Easy Block LiFePO4 family offers batteries with up to 14.5kWh capacity and cycle life up to 10,000 cycles. The second line, Easy Blade, benefits from the greater energy density of Li-ion chemistry to offer up to 37.5kWh capacity with about 1200 cycles lifetime.
HG:
What more can you tell us?
ME:
Since each is an off-the-shelf product line, they come with safety features built-in and are pre-certified according to IEC 62133-2:2017 and UN38.3. Of course, constituent cells are tested according to UL 1642. The batteries come ready to communicate with the charger using the robust CANOpen standard, which simplifies design-in.
HG:
What about the charger?
ME:
Actually, VARTA has partnered with Delta-Q to handle this. They have come up with a scalable solution based on a charger design that is supplied pre-loaded with firmware and allows stacking up to six units to address a wide range of system power requirements. It means customers can get a turnkey charger for next-day delivery if needed. As with the batteries, the charger is certified to relevant safety standards. These include UL 1564 and EN 60335.
HG:
And when they are out there in the field?
ME:
A typical application for VARTA ASB battery modules
Smart batteries like VARTA ASB enable remote monitoring and predictive maintenance, which we can support through our Avnet IoTConnect cloud solutions. This also enables future business models like “battery as a service”.
HG:
There is more to a complete electrification project than the battery. How else can Avnet Abacus help customers achieve a successful solution?
ME:
Key system-design challenges include suitable power switching and isolation around the battery, as well as ensuring simple and robust signal and power connections. Another of our suppliers, Kyocera AVX, has a solid-state switching solution for applications up to 48V that is a perfect companion to the VARTA ASBs. The switches sit between the battery BMS system, the vehicle and the charger to provide protection and safely disconnect the battery, electronically, when needed. These switches provide much faster acting protection for the battery than conventional mechanical relays and can support smart features such as pre-charging. They can be up to 85% lighter, have much longer cycle life, and are also silent in operation.
HG:
You mentioned signal and power connections?
Amphenol BSM battery-swapping modules
ME:
HG:Yes, battery-swapping modules like Amphenol’s BSM series address the challenges here. The smart features of lithium batteries call for both power and signal connections, so bringing these together in the same connector saves time mating and unmating. The BSM series provides self-correction for positional deviation up to ±2mm in X and Y directions and up to ±5mm in Z axis to allow fast and secure mating. They are available in various power ratings up to 600VDC and 100A.
The pace of battery-technology development is perceived as being quite slow. Is there anything new on the market to shake things up?
ME:
You’re right, progress does often appear glacial, although there are always improvements and optimisations that draw a little more from what we’ve got. But now VARTA has introduced a new line of Li-ion cells that address demands for rapid recharging, which is important in e-Mobility. These cells, called V4Drive, are 21700 (21mm diameter x 70mm height) cells that fully charge in under six minutes, while keeping temperature below +35°C and ensuring stable cycle life. They are designed to absorb regenerative energy efficiently and also have excellent low-temperature performance. At least one prestige vehicle brand is working with VARTA to design these cells into next-generation road cars. They are also ideal for applications like power tools and cordless appliances.
HG:
And Avnet Abacus can help customers take advantage of these technologies?
ME:
Yes, we are ready to supply the ASB lines and associated chargers, and our engineers work with customers and VARTA to handle the design-in needs. There is plenty of reference documentation including a comprehensive technical handbook and charger design-in guide, which are available with no commitment required on the part of the customer. For the V4Drive batteries, production will ramp up in 2022 for supplying key customers, and mass market availability will begin 2023.
HG:
That gives plenty to think about for upcoming e-Mobility projects. Thanks, Marc, for sharing your insights.
Want to learn more about solutions for AGVs and other commercial vehicle and non-automotive applications? Visit our non-automotive page to find products and resources to support your projects. Alternatively, if you have a question or want to discuss your design in more detail, get in touch with our team of field applications engineers in your local language.
