Domestic new energy vehicles are in full swing. For the whole vehicle companies, how to ensure that the key components of power batteries, motors, electric controls, etc. of new energy vehicles provide no less than 5 years or 100,000 kilometers of warranty and warranty. The cost is within the reasonable range of the entire vehicle, which is a big issue.
From the perspective of the battery system, it can be divided into three parts:
1) Battery module: including battery unit, current bus bar, cooling plate, sampling line, etc., as well as mechanical components connected by the module itself
2) Electronic system: battery management main unit, battery management subunit, current sensor, battery power distribution unit, etc.
3) Mechanical parts: battery base, battery cover, screws, fixtures, etc.
Figure 1 Outerland battery system
If we consider IPTV (WarrantyCondiTIonsper1,000Vehicles) for each component, it is assumed that the total IPTV of the battery system is in accordance with the usual life curve according to X1, X2, X3, X4 and X5 in the range of 1 to 5 years. It is estimated that the failure rate of the entire battery system is mainly concentrated in the module. The first reason is that electronic systems and mechanical systems can be designed to achieve very low failures through robust testing; for a battery system, there are different configurations (parallel and series), and various The failure condition, such as the capacity attenuation is particularly severe, or the internal resistance rises sharply, and the entire battery system is in a state requiring maintenance.
Figure 2 battery system separation diagram
In the design process, although it covers the heavy use of customers, after all, due to the cycle life and the rest life of the battery cells, the entire data accumulation is not sufficient for many vehicle manufacturers.
Figure 3 Customer usage distribution
Ok, then the problem is coming. At the beginning, the car manufacturer sold 1,000 cars and slowly started selling 10,000 cars to 100,000 cars. If the continuous warranty period is determined to be five years, how to ensure the whole repair process? In fact, there is an extreme case. Let us take the example of 800 E6 pure electric taxis from Shenzhen Pengcheng Electric Vehicle Rental Co., Ltd.:
The amount of related transactions in 2013 was 29.75 million yuan (21.64 million new energy products + charging equipment, 8.11 million for labor costs)
In 2014, the amount of related transactions in the year was 36.15 million yuan, all of which were labor costs.
This matter, I have not made any guess here, just to maintain the cost of the 800 cars, in 2014, the average of 45,100 yuan. If the private car is based on the cumulative strength of 10 to 30%, the cost of the entire maintenance can be estimated.
In the battery system maintenance method, it can also be divided into several types:
1) Battery replacement
The battery replacement package is actually the most popular in the early days. The 4S shop closest to a private customer can dispose of the customer's faulty vehicle as soon as possible by configuring a certain new battery pack or a repaired battery pack, and the time period of the required equipment and training personnel is undoubtedly the least. Then transport the damaged battery pack to the original battery pack or the after-sales battery processing plant by land.
The case of Nissan's treatment in the United States is the most typical, as shown in the following figure:
Figure 4 Nissan LEAF battery pack and 4S shop repair area
Advantages and disadvantages
+Responsive, 4S shop deployment is easy and low cost, and maintenance coverage is large
- The replaced battery pack requires a large shipping cost and is sent back to the factory in Smyrna, USA.
- From a global perspective, the cost of arranging factories is higher
Figure 5 Nissan's battery factory
2) Change battery module
For example, the BMWI series practices the deployment of electric vehicle after-sales systems in specialized 4S stores, mainly special tools for removing the battery, such as the battery lifting tool in the lower left picture; deploying some modules in the 4S shop, these modules are 25 kg each. , put it directly.
Advantages and disadvantages analysis
+More coverage
+ Short repair time, compared to 5 hours of maintenance, AcTIveE is 25 hours
+ Low maintenance manpower, a single technician can replace
- The capacity matching is difficult, and the battery system software and the battery itself are highly required.
-High deployment costs and high staff training requirements
Figure 6 BMW battery replacement
3) Change the monomer
This method is difficult to carry out in the 4S shop. The main difficulty lies in the welding of the battery cells and the busbar connection row, which is not possible for maintenance, and the maintenance module also involves the process problem.
After all, with the development of the new energy vehicle business, the future involvement of vehicle manufacturers in the battery and battery system business requires deeper consideration. In this case, throwing bricks to attract jade.
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