Electric Mobility Flashcards
CV Standard Battery System dimension
960 x 687 x 302 mm
CV Standard Battery System weight
295 kg/pack
CV Standard Battery System energy content
35 kWh
CV Standard Battery System voltage range
280 - 400V (350 nominal)
Cell type
Prismatic NMC
Vehicle Interface Box weight
42 kg
Vehicle Interface Box Supply Voltage
12/24V
Vehicle Interface Box System Voltage
400-800V
Life Cycle Process steps
Innovation + market and competition - p - c - draft - market e - customer c - customer s - longlife s
Innovation + market and competition - prepare - concept - draft - market entry - customer contact - customer satisfaction - longlife study
PDCA
plan - do - check - act
Kano Model obj
analyzing customer requirements
Kano Model axes
customer satisfaction and degree of fulfilment
Kano model lines
features that delight
upgrade
Kano model lines
performance characteristics
punctuality
Kano model lines
fundamental requirements
safety
Kano model - min range
60
kano model - min charging
8 hours
Elements of the Overall Concept
c - p - w - s - d t - p- r - p - r - m
costs - package - weight - safety - development time - performance - reusability - producibility - recycling - maintainability
Product Specification (PS) - by
customer
customer’s fundamental and material technical requirements of the
product under development
____ Specification
product
System Specification (SS) - to
supplier
functional specification for cross-component systems. Can be a bridge between the requirements of the product and the requirements of the components. It is an internal document.
____ Specification
system
functional specification for in-house and third party developments. It is an
interdisciplinary document which includes the technical and non-technical requirements for all relevant subprojects of the components under development.
___ Specification
component
Functional specification iterative agreement
customer s re - f s (supplier) - n p (agreed specification) - implementation - verification of the results - approval of the customer
customer specify requirements - functional specification (supplier) - negotiate proposals (agreed specification) - implementation - verification of the results - approval of the customer
Contactor-fuse pairing (target) - to ensure safe disconnection of the HV battery
fuse opens before the contactor
Fundamental functional representation
- _ sample aim
A
Functional sample, conditionally driveable with limitations
* Voltage range, dimension, vibration/impact
resistance and appearance
X sample description
A
Design focus on functional or
geometric/haptic issues
_ sample hardware
A
Executable on a-sample hardware, includes at least the basic functionalities
_ sample software
A
Functional validation on a broad basis under
driving conditions
_ sample aim
B
Sufficient operational reliability of hardware and software for initial testing on the test bench and in vehicle, construction does not ensure production standard in all points
_ sample description
B
suitable for use in vehicle
_ sample hardware
B
All key functions done
_ sample software
B
Production-quality overall testing
_ sample aim
C
B sample
prototype
C samples
series
D sample
documentation and full speed
Structural shape and specification correspond to series production requirements, no technical limitations approved, unrestricted use in vehicle ensured
_ sample description
C
No changes to design-relevant components
_ sample hardware
C
Functions done and their overall scope
fully specified but can still exhibit errors (not suitable for customers). No further inclusion of additional functions. Production-quality status.
_ sample software
C
Ensure production needs are
met
_ sample aim
D
Samples for first article
inspection must be marked
_ sample hardware
D
Operational without restrictions (production standard)
_ sample description
…. and can be evaluated. All quality requirements are consistently assured.
D
All functions verified error-free
_ sample software
D
Design-to-cost levels (0-5 + R)
I, E, E, C, Pre-r f, I, R
Idea, Estimated, Evaluated, Confirmed, Pre-requisites fulfilled, Implemented, Rejected
Design-to-cost can be used for quotes to customer
L3 - confirmed
Design-to-cost visible in BOM
L5 - Implemented
BOM
Bill of Material
PDP
Product Development Process
PDP - milestone trails
H - S - Q - T - L - P p - P - P - F
HW - SW - Quality - Testing - Logistics - Production planning - Prototyping - Purchasing - Finance
PT
Production trials
…is intended to rapidly and successfully integrate product changes (as many as necessary & as few as possible) into development and the production process without delay, thereby contributing to reducing time and costs
Change management
The freeze divides the respective sample phases into 1. “Development” and 2. “Procurement, Construction & Testing”.
During the construction of a sample (x) the next sample (y) is being developed in parallel!
Normal process
Once the respective sample has been frozen changes become subject to approval and must be released . change management is always necessary here! For each change following a freeze the corresponding
sample phase starts again
➢Development changes can be done only in A- and BSample phase. C and D-Sample is only for optimization of series production process
process with product changes
The person responsible for components is responsible for the development of a
component in terms of engineering, costs and meeting deadlines. He is responsible
for fulfilling the requirements of the component specification and the time schedule, as central documents.
Person Responsible for Components
PRC
Person Responsible for Components
defines the interface between customer and supplier during the development process and it describes the transition between requirements and the result (product).
V model
V-A Cycle calibration reason every 6 months
summer and winter
Functional Safety Volumes 1 - 10
1 - Glossary, 2 - Management of Functional Safety, 3 - C Phase, 4 - S Development, 5 - H Development, 6 - S Development, 7 - Production and Operations, 8 - Supporting Processes, 9 - Security Analyses and Overlapping Issues, 10 - Guideline
3 - Concept Phase, 4 - System Development, 5 - Hardware Development, 6 - Software Development
ASIL
Automotive Safety Integrity Level
ASIL Levels
Severity, Exposure, Controllability
ASIL E4
High probability
ASIL C1
Easy to control
ASIL S3
Fatal Injuries
ASIL D
Overcharging
Exterior light, Seat heater - ASIL
B
Vehicle dynamics control, HV-Contactor control - ASIL
C
ASIL Electric steering lock, Over Voltage protection
D
Window lifters, Sliding roof - ASIL
A
Interior light, Exterior mirror (elec. adjst.) - ASIL
QM
ASIL - most expensive
D
- Ensuring the completeness and correctness of the specification
- Ensuring that the requirements are implemented
Verification
Methods of verification
Review, analyses, simulation, testing
Verification steps
Test planning, test specification, test performance, test documentation, test evaluation
3 levels of product safety
active, passive, cell
- No safety hazard caused by
- Simple improper use
- Unintended misuse
- No flying parts
- No explosion
- No fire
product safety objectives
Cooling
Interlock
Autom.
shut off
Error memory monitors
temperature, cell voltage,
insulation resistance
active safety
Sealing
Insulation
Fire protection
Fuse
Stable housing
IT network
passive safety
Deformation
Shock
Vibration
Short circuit
Deep discharge
Over charging
cell safety
- Short circuit → no fire, no leakage
- Crush test → no fire, no leakage
- Shock → no fire, no leakage
- Thermal propagation → no propagation
safety testing on battery level
- Over charging → no fire
- Direct exposure to flame → no fire for minimum 60 s
Safety testing at cell level
Battery = IT net (“Isolé Terre”), Fuse, Relay, Insulation monitoring, Interlock, IPxxB protection
Battery electrical safety
Bettery Thermal Safety
Avoid propagation
Types of Tests for HV Batteries
Type and individual testing
Determination of the characteristics of a
specific battery type
type characterization
Check whether specific battery type
fulfils the requirements in the
specification
validation
Check whether specific battery type fulfils the applicable regulations for placing it into circulation
certification
Information on the characteristics of all batteries of a certain type
type testing
Determination of the characteristics of a specific battery
(interim) diagnosis
Check whether a specific battery fulfils all of the relevant requirements for delivery to customers
End-of-line testing
No destruction of battery (product will be sold afterwards)
Information on the characteristics of one specific battery
individual testing
__ models are needed to…
▪ … quantify the microstructure of material samples
▪ … compare different (e.g. new and aged) scenarios
▪ … generate input for electrochemical simulations in 3D
stochastic
Patent ___
Publish, to hinder third parties from asserting proprietary rights
*State-of-the-art is achieved through national application
* The public perceives the number of initial applications as a measure of a company’s innovative strength
Safeguard all technologically relevant R&D results
Verifiably publish, to hinder third parties from asserting proprietary rights
- National application is sufficient
- Low external costs (approx. €2,000/invention)
Safeguard all technologically relevant R&D results
Freedom to operate
Patent ___
Published to earn money
* Worldwide protection and corresponding supplier contracts are necessary
* Preparedness to enforce rights vis-à-vis competitors and suppliers is necessary
Assuring technological and innovation leadership
- High quality
- Transnational protection is necessary
- High costs (over €50,000/invention)
Prohibiting or licensing of technologies
Exclusiveness
Shorter development times
Structured development process
Integration of lessons learned
Trouble-free production start-ups
Exoneration in product liability cases
Delivery reliability
FMEA Benefits and Aims
___ FMEA (product)
Aim:
Measures to ensure requirements are met
Design
____ FMEA (production)
Aim:
Measures to assure the processes
how to produce the battery
Process
____ FMEA (cross effects)
Aim:
Measures to safeguard the cross effects between the product and the process
put together design and process
System
5 steps FMEA
Structure Analysis
Functional Analysis
Failure Analysis
Measurement Analysis
Optimization
Occurrence high - FMEA
10
Occurrence improbable - FMEA
1
Detection impossible - FMEA
10
Very High Detection - FMEa
1
Significance Dangerous without early warning - FMEA
10
Significance Inconsequential - FMEA
1
RPN =
S * O * D
If the RPN > __, measures for reducing the RPN are necessary
125
FMEA categories
Significance, Occurence, Detection
OEE availability
(𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑡𝑖𝑚𝑒 − 𝑑𝑜𝑤𝑛𝑡𝑖𝑚𝑒) / 𝑎𝑣𝑎𝑖𝑙𝑎𝑏le 𝑡𝑖𝑚𝑒
OEE performance rate
(𝑟𝑢𝑛𝑛𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 − 𝑝𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑙𝑜𝑠𝑠) / 𝑟𝑢𝑛𝑛𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
OEE quality
(𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑒 𝑡𝑖𝑚𝑒 − 𝑞𝑢𝑎𝑙𝑖𝑡𝑦 𝑙𝑜𝑠𝑠 𝑡𝑖𝑚𝑒) / 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑒 𝑡𝑖𝑚𝑒
OEE
availability * performance rate * quality
takt time
Total available working time / customer demand
𝑚𝑎𝑥. Cycle time
Target takt time * OEE
Production perfomance parameters - 6 partners
Mind Power, Machine, Material, Method, Management, Medium
Types of manufacturing organization - prototypes
manual
Types of manufacturing organization - series
hybrid
Types of manufacturing organization - mass
flow lines
Types of manufacturing organization
Workshop, group, flow lines, construction site
Types of manufacturing organization - Sorted by same processes
workshop production
Types of manufacturing organization - Sorted by neccessary production steps for one good
group production
Types of manufacturing organization - Setting up the machines according to the work sequence of a workpiece group
flow lines
Types of manufacturing organization - Stationary workpiece until it is completed
construction site production
A person who is neither a qualified electrician nor a person trained in electrical engineering is a layman in electrical engineering. A qualified electrician is only considered to be such a person in the trained field, in all other fields he/she is also considered to be a layman in electrical engineering. [DIN VDE 1000-10]
Electrotechnical layman
A person trained in electrical engineering is a person who has been instructed by a qualified electrician about the tasks assigned to him/her and possible dangers in the event of improper behavior and, if necessary, has been trained and instructed about the necessary protective equipment and protective measures.
Electrotechnically instructed person
a person with appropriate professional training, knowledge and experience, so that he or she can recognize and avoid dangers that can be caused by electricity
qualified electrician
For the professional management of an electrotechnical company or part of a company, a responsible qualified electrician is required. This is a qualified electrician who assumes the technical and supervisory responsibility and who has been hired for this purpose by the entrepreneur. Unless special legal regulations apply, the skilled electrician responsible for compliance with the electrotechnical safety specifications may not be subject to any instructions regarding compliance with these specifications from persons who are not considered to be the responsible skilled electricians according to this standard.
responsible electrician
7 x waste
overproduction, inventory, waiting, motion, transportation, reworks, over processing
Unnecessary movement of people, parts,
machines within a process
motion
unnecessary movement of people or
parts between processes
transportation
A process is a sequence of activities that converts
inputs into results
… and 6 process analysis issues in addition:
▪ Input? (What goes into the process?)
▪ Output? (Process monitoring)
▪ With what? (Equipment, facilities)
▪ With whom? (Person responsible, people involved, capabilities/knowledge)
▪ What? (Performance indicators, key figures)
▪ How is it implemented? (Process, instructions, methods)
Turtle diagram
Process aproach - turtle diagram
input, with what, how, with whom, what, output
FMEA
medium time
kano
early time
brainstorming
early time
voice of customer
early time
design for six sigma
early and medium time
six sigma
late time
statistical methods
late time
PDCA
plan-do-check-act
built team - describe problem - develop and implement immediate measure - perform root cause analysis - develop sustainable corrective measures - introduce corrective measures - verify effectiveness - anchor lessons learned
8D-report
