Low-Voltage Power Demands Are Driving New Battery Solutions
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HANOVER, Germany — Electrification trends, including the shift of auxiliaries from hydraulic and air pressure systems to electric ones and the implementation of drive-by-wire and steer-by-wire, are creating new demands on the low-voltage power network in heavy-duty vehicles.
“The software-defined vehicles were coming. We have started to see them on the roads, and we’re starting to see more functions and features get introduced,” said Brian McKay, chief technology officer for Clarios.
Increased electrification, along with increased demands from advanced driver assist systems, camera technology, connectivity and driver comfort features also are creating more power needs. Demand is expected to double in the next few years, requiring more robust batteries and creating new challenges surrounding battery architecture.
“Historically, we’re talking about alternators producing hundreds, 150 amps, so let’s say 1,000 watts to 1,500 watts,” McKay said. “Now when we sit in front of customers, we’re talking about 4,000 watts of continuous power. If we have an espresso machine, a microwave and a refrigerator all on at the exact same time and reaching the peak power, that is not even [hitting] 4,000 watts.”
In addition to requiring increased power, today’s trucks need redundancy in the electronic architecture to ensure critical safety systems aren’t disrupted.
“Now it is life or death, and redundant systems need to be in place,” McKay said, adding that systems are continuously connected, requiring software updates that draw on the battery and creating new needs for storage and cycling.
As part of the test process, Clarios activates loads on the battery and monitors the discharge. (Mindy Long/Special to Transport Topics)
What’s more, most systems continue to use the battery even when the engine is off because the truck never sleeps. McKay said there are “vampire loads” that are constantly drawing power.
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Federico Morales-Zimmermann, vice president and general manager of global customers, products and engineering at Clarios, said OEMs are turning to the company for battery solutions to support their emerging vehicle technologies.
“Why are they relying on us? They’re looking for partners, like Clarios, who have a deep understanding of battery architecture,” he said. “These are very, very complex systems.”
Batteries are put through a rigorous testing environment at the Clarios battery manufacturing facility in Hanover and are placed in chambers to replicate exposure to extreme cold. (Mindy Long/Special to Transport Topics)
Twenty years ago, a low-voltage battery was an afterthought, but today Clarios engages with OEMs four or five years ahead of time on new models to understand loads, software, electronics and help define the battery specifications, Morales-Zimmermann explained.
However, there is only a limited amount of space for batteries, which means battery manufacturers have to pack more power into each battery.
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“The OE is already running into the problem with the lead acid that you cannot put more lead acid battery into that tray. That’s where lithium ion can help out,” said David Patel, Clarios’ vice president and general manager for energy systems.
Morales-Zimmermann said the company is exploring future technologies, including sodium ion, which likely will replace lithium ion. Sodium ion has several benefits, including reduced supply chain risks, an abundance of cell materials and the potential for a 15-20% cost savings.
Lead is transformed on the production lines within the Clarios battery production facility in Hanover, Germany. (Mindy Long/Special to Transport Topics)
Clarios takes a chemistry-agnostic approach and works with equipment manufacturers to develop the battery systems they need using a range of technologies, including lithium ion and advanced glass batteries.
The battery manufacturer also is using “super capacitors” that provide instantaneous peak power. Active chassis systems, for example, require short bursts of power.
“The DC converter cannot respond quickly enough, so you need this system in there to pulse the power,” McKay said.
Adding super capacitors to low-voltage batteries also can reduce carbon emissions and increase fuel efficiency.
During IAA Transportation 2024, Clarios announced a new agreement to develop 24-volt lithium-ion batteries for heavy-duty applications together with a major European commercial truck manufacturer.
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