Energy Storage

The project reduces the model calibration and validation time by 60%, enabling more efficient electric vehicles.

The HiFi-ELEMENTS project is coming to an end after more than three years of research and testing in which CIDETEC Energy Storage has contributed to the development of a battery cell model that was used in the simulation of a full vehicle and has proposed a modelling methodology that reduces the time and means to calibrate and validate this model.  The project focused on the creation of a standard system architecture for Battery Electric Vehicle (BEV) development activities. This will reduce and facilitate the total development and calibration effort, which will accelerate the introduction of electric vehicles to the market.

During the project, four different cases were analysed in which the developed models were tested for verification and validation. The diversity of the four selected cases allows the conclusions to contribute to the improvement of the total powertrain system of the electric vehicles of the future.

Cases analysed in HiFi_ELEMENTS:

Replacement of the electric motor:

This case focused on the efficient integration of the electric motor of a BEV on the xMOD co-simulation platform, which was successfully verified. Variants were made between radial and axial flux electric motor models. The total effort for the development of real-time simulation component models for HiL (Hardware in the Loop) applications was reduced by 71%, while the total effort for model calibration was reduced by 60%.

Battery development (relevant participation of CIDETEC Energy Storage):

The validity of the battery virtualisation was tested using comprehensive testing and validation trials. For this, the process was carried out step by step in order to cover all stages of battery development: cell selection, module assembly, battery concept design, battery testing and calibration. Each of these steps was developed with its own virtualisation-simulation. For the battery testing procedure, two approaches were carried out and compared at the cell (Cell in the Loop) and module (Module in the Loop) level. This analysis was used to verify that the high-fidelity battery model was correctly calibrated and met the design objectives.

In this particular case, CIDETEC led the cell characterisation and modelling methodology as well as the Cell in the Loop activity, where different BMS functions and the behaviour of the cell model were tested.

Figure 1 – Conceptualisation of virtual cell testing (Cell in the Loop)

Figure 2 – Cell testing in climatic chamber

Co-optimisation of components: 

Another objective of HiFi-ELEMENTS was to demonstrate the rapid integration and interchangeability of models, between different suppliers and levels of fidelity, thanks to the standardisation of the modelling process and the built-in co-simulation tools. This objective was achieved, under the requirement of reducing consumption, using 2 different powertrain architectures and multiple combinations and variants among their components, using the co-simulation environment proposed by Hi-Fi.

Electric powertrain concepts

A conceptual design of an electric vehicle considering a wide range of electric powertrain concepts has demonstrated that the use of real-time reusable models (higher complexity) in the conceptual phase can aid decision making, thus contributing to greater efficiency in the final product. The electric propulsion concepts with higher power offered better operational efficiency compared to the concept with only the necessary rated power for basic operation. In the case of this electric motor, a key reason for improving operating efficiency with “overpower” was the increase in base speed and, therefore, a reduced possibility of inefficiency with weakened field. In addition, it has been shown that centralising the system’s power on one axis, as opposed to two axes, also improves the final efficiency. On the other hand, the motor concept implemented on the wheels compromises energy efficiency, so it has been concluded that its strengths should be found in other domains.

El centro donostiarra tiene activos tres proyectos que lo posicionan como estratégico para mejorar la capacidad del tejido industrial nacional

CIDETEC trabaja en tres proyectos de la Red CERVERA, promovida por el CDTI, que reconoce la excelencia de los centros tecnológicos seleccionados y fomenta las sinergias entre estos para generar nuevas capacidades que puedan ser transferidas a la industria, creando un alto valor añadido. ALMAGRID, ENERISLA y SURFERA son tres proyectos que permitirán introducir energías 100% renovables en la red eléctrica, desarrollar tecnología para hacer frente a la transición energética y optimizar productos a través de la ingeniería de superficies.

ALMAGRID, que acredita a CIDETEC como ‘Centro de Excelencia Cervera’ en ‘Integración de tecnologías avanzadas de almacenamiento de energía para aplicaciones de red’, surge con el objetivo de desarrollar soluciones para dar respuesta a las necesidades de integración masiva de tecnologías de generación renovable en la red eléctrica. Los centros trabajan en nuevos materiales, componentes sostenibles y sistemas de almacenamiento optimizados para suministrar servicios de red estratégicos que permitan asegurar el requerido nivel de flexibilidad para la distribución y transmisión de la electricidad. Así mismo, se identifican nichos de aplicación de las tecnologías de almacenamiento que ofrecen nuevas oportunidades de negocio a la industria energética, empresas integradoras, fabricantes de baterías y componentes, así como gestores de residuos, entre otros. Bajo la coordinación de CIDETEC Energy Storage, colaboran en la Red ALMAGRID los centros Tekniker, ITE y Circe, ofreciendo acompañamiento a las empresas a través de servicios tecnológicos y de formación e internacionalización.

Por otro lado, y con el objetivo común de proporcionar herramientas que favorezcan la transición energética, en el proyecto ENERISLA se trabaja para poner en marcha microrredes aisladas alimentadas por fuentes renovables. De este modo, se pretende llevar a las empresas del mercado eléctrico español tanto el conocimiento como las nuevas soluciones que permitan mejorar su competitividad ante el nuevo panorama energético. Los resultados de ENERISLA contribuirán al proceso de transición energética, aportando nuevas técnicas y soluciones para maximizar el uso de las renovables en aquellos puntos con limitación de acceso a la red eléctrica, gracias al papel central de las baterías. Este proyecto, en el que, además de CIDETEC, participan Tecnalia, CTIC y Circe como coordinador, acredita a estos como centros de excelencia en el ‘Desarrollo de sistemas híbridos de generación y almacenamiento energético con uso exclusivo de tecnologías renovables, aplicables a productos, infraestructuras o edificios’.

Por último, el proyecto SURFERA está creando una ‘Red de excelencia en tecnologías de funcionalización superficial para aplicaciones en sectores industriales de alto impacto económico y social’. A través del desarrollo de tecnologías tractoras para revolucionar las superficies de los materiales a escala micro y nanométrica, se pretende lograr la excelencia en tecnologías de funcionalización superficial para sectores como el aeronáutico o la automoción. Dentro del consorcio, en el que también participan Tekniker, AIN e Idonial, CIDETEC Surface Engineering trabaja en el desarrollo de nuevas formulaciones medioambientalmente más sostenibles y que constituyan una alternativa real, viable y de calidad a los tratamientos de superficie actuales. Además, se desarrollará un sistema digitalizado de control y gestión en tiempo real de diferentes procesos de tratamientos de superficie electroquímicos, que se integrará en una novedosa planta demostradora resaltable por la constancia en la calidad de los recubrimientos y acabados de superficie que permitirá alcanzar.

Estos proyectos, que comenzaron a principios del 2020, suman un presupuesto conjunto de más de 10 millones de euros y estarán activos hasta finales de 2022. De este modo, CIDETEC refuerza su apuesta como empresa referente en el sector energético y en ingeniería de superficies aplicable a múltiples ámbitos.

The San Sebastián-based centre has three active projects making it strategic in improving the capacity of the national industrial fabric.

CIDETEC is working on three projects in the CERVERA Network, promoted by the CDTI, which recognises the excellence of the selected technology centres and promotes synergies between them to generate new capabilities that can be transferred to industry, creating high added value. ALMAGRID, ENERISLA and SURFERA are three projects that will add 100% renewable energies to the electricity grid, develop technology to address the energy transition and optimise products through surface engineering.

ALMAGRID, which accredits CIDETEC as a ‘Cervera Centre of Excellence’ in ‘Integration of advanced energy storage technologies for grid applications’, was created with the aim of developing solutions to meet the needs of the mass integration of renewable generation technologies into the electricity grid. The centres are working on new materials, sustainable components and optimised storage systems to provide strategic grid services to ensure the required level of flexibility for electricity distribution and transmission. They also identify niche applications for storage technologies that offer new business opportunities for the energy industry, integrators, battery and component manufacturers and waste managers, among others. Under the coordination of CIDETEC Energy Storage, Tekniker, ITE and Circe collaborate in the ALMAGRID Network, offering support to companies through technological services, training and internationalisation.

On the other hand, and with the common objective of providing tools that favour the energy transition, the ENERISLA project is working to implement isolated microgrids powered by renewable sources. The aim of this is to provide companies in the Spanish electricity market with both knowledge and new solutions to improve their competitiveness in the new energy landscape. The results of ENERISLA will contribute to the energy transition process, providing new techniques and solutions to maximise the use of renewable energies in areas with limited access to the grid, thanks to the central role of batteries. This project, in which, in addition to CIDETEC, Tecnalia, CTIC and Circe also participate as coordinators, accredits them as centres of excellence in the ‘Development of hybrid energy generation and storage systems with exclusive use of renewable technologies, applicable to products, infrastructures or buildings’.

Finally, the SURFERA project is creating a ‘Network of excellence in surface functionalisation technologies for applications in industrial sectors of high economic and social impact’. Through the development of breakthrough technologies to revolutionise the surfaces of materials at micro and nano scale, the aim is to achieve excellence in surface functionalisation technologies for sectors such as aeronautics and the automotive industry. Within the consortium, in which Tekniker, AIN and Idonial also participate, CIDETEC Surface Engineering is working on the development of new, more environmentally sustainable formulations that constitute a real, viable and quality alternative to current surface treatments. In addition, a digitalised system will be developed for the real-time control and management of different electrochemical surface treatment processes, which will be integrated into a novel demonstration plant, in which the consistency in the quality of the coatings and surface finishes that will be achieved is particularly noteworthy.

These projects, which started in early 2020, have a combined budget of more than €10 million and will be active until the end of 2022. Thus, CIDETEC reinforces its commitment as a benchmark company in the energy sector and in surface engineering applicable to multiple fields.

A powertrain test bench, 30 m³ walk-in climatic chambers or vibration tables are just some of the new facilities found at MUBIL’s electromobility hub

CIDETEC Energy Storage, a centre specialised in battery research, has recently set up a new laboratory in MUBIL’s electromobility hub in Tolosa, an initiative promoted by Gipuzkoa Provincial Council. The new facilities are an upgrade to CIDETEC Energy Storage’s resources in San Sebastián and will provide a service for battery users and developers alike, ensuring optimisation and allowing the optimal characteristics to be selected for each application.

The equipment installed at MUBIL will allow a range of batteries to be tested, simulating the conditions of the required applications and even running them on a powertrain test bench, which characterises all of a vehicle’s electric traction elements under near-real conditions. The tests will be carried out at cell, module or complete battery pack level, and rounded off with post-mortem analyses in order to correct any causes of battery faults through the implementation of preventive measures in manufacture or use.

The capabilities deployed will allow CIDETEC Energy Storage to offer new R&D and battery testing services for companies and technology agents, making it easier to select technologies and fine-tune electromobility and stationary applications. The range of available tests includes performance, durability, cyclability, mechanical (both vibration and mechanical shock), abuse and safety analyses. A powertrain and power electronics test bench rounds off the range of available tests for electromobility products.

Testing capabilities range from cell level up to 1200 V and 250 kW battery packs, including climatic and environmental chambers up to 30 m³. The equipment is rounded off with a laser soldering station, essential for module and battery pack prototyping.

A team with over 15 years’ experience in battery testing will be in charge of the facilities, which are now even more complete thanks to this new plant with accumulated testing power of 1.25 kW, making it one of the best and most complete at European level. 

Novel solid electrolytes based on hybrid block polymers stable to high voltage cathodes will be developed during the PhD project.

A PhD Fellowship in Energy Storage is available at the Basque Center for Macromolecular Design and Engineering, POLYMAT Fundazioa. The successful candidate will be hired by POLYMAT. The research activity will be carried out at POLYMAT and CIDETEC.

The main goal of the PhD thesis is to develop novel hybrid block polymers stable to high voltage cathodes (> 4.5V vs. Li/Li⁺), with special attention to micro homogeneity, self-healing, and Li protection. The most promising materials will be used for the development of SPE with wide electrochemical stability window, good mechanical properties, good compatibility with lithium metal anode, and high ionic conductivity. Special attention will be paid to the development of an unambiguous evaluation method of the electrochemical stability of the synthesized solid polymer electrolytes. Finally, the developed SPE will be evaluated in high voltage solid-state batteries with lithium metal anode and thick high voltage cathodes.

Detailed information for applicants here.