RDVS and consortium begin new TSB project

Work has begun on a new Technology Strategy Board project. ‘Sustainable Lightweight Low Cost Battery Systems for Extended Life Cycles’ (EV-Lite) aims to improve the manufacturing process of Lithium-Ion battery packs for electric vehicles, reducing costs and weight.

RDVS is excited to be working with a number of new partners, as well as a few well known faces. The following is the press release by the Manufacturing Technology Centre who will be leading the project:


Press Release: December 2012

Sustainable Lightweight Low Cost Battery Systems for Extended Life Cycles (EV-Lite)

We are pleased to announce the commencement of Sustainable Lightweight Low Cost Battery Systems for Extended Life Cycles (EV-Lite) – a two-year project co-funded by the UK’s innovation agency, the Technology Strategy Board. The project consortium is formed of The Manufacturing Technology Centre, Unipart Manufacturing, Electrovaya, RDVS, CRR, Bluebird Innovation Group, Loughborough University and Cenex.

This project aims to create a volume manufacturing facility for electric vehicle battery packs in the UK, with the goal of bringing electrical vehicles to the masses.

The high cost of battery packs prevents increased uptake of electric vehicles. An EV battery pack can cost in excess of £16k, making electric vehicles more expensive than their internal combustion engine counterparts.  The additional cost is due to over-engineering, performance requirements, manufacturing issues and a lack of volume manufacture. This exciting and ambitious project aims to address manufacturing issues associated with lithium-ion battery packs for electric vehicles and, by doing so, greatly reduce their cost and weight.

Innovative design and manufacturing ideas will help the consortium to achieve cost reduction of around 50% and weight saving of 30% without sacrificing functionality. Battery pack components, excluding the cells, are in focus. These components make up around 50% of the battery pack by weight. The redesigned battery pack will be completed with a whole-life planning approach to take into account design for assembly, disassembly and 2nd/3rd life applications.

Electrovaya is providing a Maya 300 which will be deconstructed by the project team. Launched in 2009, the Maya is an electric vehicle powered by Electrovaya’s lithium-ion SuperPolymer® battery. Alternative battery pack designs will be evaluated and this will include: building the battery as the vehicle floor plan, using polymers to create the battery structure and using electron beam deposition to create part of the structure. During the project the battery pack will be subjected to rigorous testing to ensure that it operates within control limits and typical cycles.

The project consortium has a broad spectrum of capabilities, ranging from manufacturing and assembly to reuse and recycling. The consortium will be led by The Manufacturing Technology Centre and is formed of Unipart Manufacturing, RDVS, Electrovaya, Bluebird Innovation Group, Centre for Remanufacturing and Reuse, Loughborough University and Cenex.

The CRR is responsible for the dissemination of the EV-Lite project and will be keeping you up to date with the projects progress through our quarterly newsletters and the CRR website.

For additional information about the project please contact:

Mark Ireland (Project leader),
Project and Resource Co-ordinator, Manufacturing Technology Centre, Pilot Way, Ansty Business Park, Coventry, CV7 9JU

Tel: +44 (0)2476 701654

Email: mark.ireland@the-mtc.org

Website: www.the-mtc.org

Dr Josie Arendorf,
Technical Consultant, CRR c/o Oakdene Hollins, Pembroke Court, 22-28 Cambridge Street, Aylesbury, UK, HP20 1RS

Tel: +44 (0)1296 337165

Fax: +44 (0)1296 330351

Email: josie.arendorf@remanufacturing.org.uk

Website: www.remanufacturing.org.uk