Attachment 01_Requirement Document.pdf

Electric Motor Vehicle Battery Requirements

1.Introduction Provide a brief overview of the purpose of the custom battery and the specific Tesla motor application. The battery will be applied to a military electric vehicle sustaining high speeds and accelerations.

2.Threshold Requirements

2.1. Power and Voltage

2.1.1. The battery pack shall be capable of supplying 1000A continuously for:

Threshold: 20s Objective: 40s.

2.1.2. The battery pack’s nominal voltage shall be 400VDC +- 15VDC 2.1.3.

2.1.4. The pack shall have the capacity of completing a minimum of 5 discharge cycles between charging cycles.*

2.1.5. The battery pack Shall be able to be fully charged from a depleted state in:

Threshold: 12 hours.** Objective: 3 hours.**

*A discharge cycle is defined as 1000A for (Threshold)20s, (Objective) 40s.

**A depleted state is when the battery no longer has the charge to support 1000A for (Threshold)20s, (Objective) 40s..

2.2. Operational Requirements

2.2.1. The battery pack shall have the following built-in safety systems (typically implemented through a battery management system (BMS)).

a) Cell overvoltage protection

b) Cell undervoltage protection

c) Thermal protection

d) Short-circuit protection

e) Insulation breakdown detection

f) Overcurrent protection

g) Cell balancing

h) Pack health monitoring

2.2.2. The pack shall maintain built-in safety functions while not in use and when stored.

2.2.3. The pack Shall be capable of being safely charged without immediate supervision

2.2.4. The pack shall have a lifecycle of:

Threshold: 1000 charge/discharge cycles* Objective: 20000 charge/discharge cycles*

* Performer to provide maximum charge and discharge capacity for delivered lifecycle specification.

2.3. CAN Interface Requirements

2.3.1. The pack shall be able to interface over CANbus for communication and data logging

2.3.2. The CAN message structure Shall be able to support at least 8 packs on the same bus

2.3.3. The pack Shall report the following information over CAN

a) Pack voltage

b) Cell balancing state

c) Pack health and capacity

d) Pack charge state

e) Pack temperature readings

f) Discharge limit

g) Charge limit

h) Instantaneous current draw

i) Negative current draw implies charging

j) Charging State

k) Discharge State

2.3.4. The pack Shall report the above information at a rate of at least 5Hz.

2.3.5. The pack shall accept a heartbeat command over CAN.

2.3.5.1. The pack shall respond to heartbeat commands over CAN to indicate presence of the pack.

2.3.5.2. If the pack does not receive a heartbeat command within 1 second, the pack shall disable the high voltage output without degradation to the pack.

2.3.6. The CAN message structure and documentation shall be provided.

2.4. Electrical Interface Requirements

2.4.1. The pack shall be compatible with the North American Charging Standard (NACS) consistent with Tesla vehicles.

2.4.2. The pack and charger shall be capable of stopping charging once the battery pack has been fully charged.

2.4.3. The pack’s discharge terminal shall be a mil-standard connector and be accessible

2.4.4. The pack’s discharge terminal shall be properly insulated to prevent accidental short circuits or shock hazards.

2.4.5. The pack shall not have any exposed high voltage that may lead to shock, electrocution, or short circuit.

2.5. Thermal Requirements

2.5.1. The pack shall be able to operate at a minimum of at least -5C without external heating sources and a maximum operating temperature of at least 90C without external cooling sources.

2.5.2. The pack shall be able to be stored at a minimum of -30C and maximum of at least 55C.

2.5.3. The pack Shall have the ability to have coolant piped through from an external source. The pack coolant shall accept 50/50 mixture of ethylene glycol and water. The connection should be a barb style connector capable of interfacing with flexible tubing secured with hose clamps.

2.6. Physical Specifications

2.6.1. The Battery Management System (BMS), battery cells, and protective and safety equipment shall all be integrated into one housing.

2.6.2. The housing shall have an Ingress Protection (IP) rating of at least IP65*.

2.6.3. The housing shall be capable of withstanding mounting in the following manner*

2.6.4. The housing shall have a footprint of

Threshold: 32 inches wide by 50 inches long by 7 inches tall Objective: 32 inches wide by 40 inches long by 5 inches tall

2.6.4.1. The battery should be able to accommodate shock and vibe.

2.6.4.2. The battery shall be mounted to a plate on the topside of the battery

2.6.4.3. The battery enclosure shall accommodate spot welded studs such that the battery can be sufficiently supported from the top surface of the enclosure**.

2.6.5. The entire battery (including all components and enclosure) shall weigh less than 720lbs.

2.6.6. The batteries shall have the charging port accessible and on the apposing side of the pack from all other ports.

*CAD drawings detailing mounting requirements will be provided.

** The studs shall be placed in a grid pattern which can be provided upon request.

3. Objective Requirements

3.1. The pack shall give an auditory and visual warning when safety or protective intervention is needed. These scenarios include but are not limited to:

a) Potential or active thermal runaway

b) Overvoltage or undervoltage

c) Pack falls below minimum temperature

d) Pack falls below minimum Depth of Discharge and charging is required to prevent damage.

3.2. The pack shall have a “dry contact” to enable the high voltage discharge output.

When the dry contact is open circuit, the high voltage output is shut off.

3.3. A single charging station shall be able to service two to four battery packs through multiple charging cables.

3.3.1. The charging cables must be at least 30ft long.

3.4. Charging station shall be capable of operating from 208VAC 3-phase on a 100A circuit.

3.4.1. The charger should utilize a higher amperage when available.

4.Deliverables

4.1. Maintenance and Serviceability

The following shall be provided for maintenance and serviceability of the battery pack

4.1.1. Recommended maintenance schedule

4.1.2. Access for maintenance and service of the pack

4.1.3. Test procedures for acceptance, performance validation, safety, and compliance

4.1.4. An operator’s manual

4.1.5. Installation and wiring guide

4.1.6. Warranty information (number of years)

4.2. Deliverables

The final product shall be delivered with the following

4.2.1. A quantity of 8 Battery packs with integrated equipment (assembled, tested)

4.2.1.1. All applicable warning and hazard labels

4.2.2. Documentation package

4.2.2.1. Test reports

4.2.2.2. Certifications

4.2.2.3. Technical Manuals

4.2.2.4. Mechanical Drawings (PDF, and STEP)

4.2.2.5. CAN Data files (.DBC)

4.2.3. Charging equipment