1.
ELECTRIC VEHICLE
CHASSIS AND BATTERY
SYSTEMS
TESLA, VOLT, PRIUS, OTHERS
By F. Lopez

2.
PURPOSE
• The purpose of this PowerPoint is to provide a better
understanding of the chassis and battery systems of
common Electric Vehicles. The PowerPoint is
intended for the layperson versus the technician or
engineer.
Footnote: The author retrieved this compilation of information from public domain websites
provided in the reference section. Some information may need updating for accuracy.

3.
POPULAR ELECTRIC VEHICLES
Electric
vehicle
Battery
Chevy
Volt
16kWh, liquid cooled
Li-manganese, 181kg (400lb)
Toyota
plug-in
Prius
3 Li-ion packs, one for hybrid; two
for EV, 42 temp sensors
Mitsubish 16kWh; 88 cells, 4-cell modules;
i iMiEV
Li-ion; 109Wh/kg; 330V
Nissan
LEAF
24kWh; Li-manganese, 192 cells;
80Wh/kg, air cooled; 272kg
(600lb)
Tesla
56kWh, 6,831 Li-cobalt computer
Roadster cells; liquid cooled
Range
advertise
d
Range
in real world
Charge times
64km,
40 miles
45km, 28 miles;
149hp electric &
1.4 liter IC engine
10h at 115VAC;
4h at 230VAC
20km,
13 miles
N/A;
80hp electric &
98hp IC engine
3h at 115VAC;
1.5h min 230VAC
128km,
80 miles
88km, 55 miles;
13h at 115VAC;
highway speed, mountain
7h at 230VAC
pass
100km, 62 miles
160km,
at highway speed with
100 miles
heater on
8h at 230VAC;
30 min high ampere
224km, 140 miles;
352km,
172km, 108 miles driven
220 miles
sports car
3.5h at 230VAC high
ampere
Ford
Focus
23 kWh capacity lithium-ion
battery
76 mi
TBA
full recharge using the
car's 6.6 kW charger
takes 3–4 hours @ 240
Volts AC
Classis
EV II
nickel metal hydride (NiMH)
"Ovonic" battery pack
160
miles!
TBA
8 hours, (though an
80% charge could be
achieved in between 1
to 3 hours)

4.
TESLA CHASSIS AND BATTERY SYSTEM
• Enables rapid
battery swapping –
the future

5.
TESLA CHASSIS AND BATTERY SYSTEM
• The 7,000 Li-ion cells store
53kWh of electrical power and
deliver a driving range of
320km (200 miles).
• Liquid cooling prevents the
cells from exceeding 35°C
(95°F).
• To achieve the five-year
warranty, Tesla charges the Licobalt cells to only 4.10V
instead of 4.20V/cell.
• The electronics circuits inhibit
charging at freezing
temperatures.

6.
NISSAN LEAF
• The Leaf includes a
24kWh lithium-ion battery
with a city driving range
of 160km (100 miles).
• The battery fits under the
floor of the car, weighs
272kg

7.
CHEVY VOLT
• The battery chemistry is based on a
Li-ion polymer technology.
• Li-ion polymer was chosen over a
nickel metal hydride chemistry (used
in the Toyota Prius) because the
energy storage is two to three times
higher, and the battery is safer,
cheaper, and more durable.
• The Volt uses a total of 288 prismatic
5×7 inch Li-ion cells. Prismatic cells
are rectangular; the other common
shape is cylindrical. Three cells are
connected in parallel, for a total of 96
series connect groups of cells. The
target output is 360 V

8.
FORD FOCUS
• The electric car is powered by an
electric motor rated at 100
kilowatts (130 hp) and uses a 23
kWh capacity lithium-ion battery
pack, which together deliver 92
kW.
• Ford used a complete electric
drive train developed and supplied
by Magna International, and the
advanced lithium-ion battery
system is being engineered by Ford
in cooperation with supplier
Compact Power, Inc., a subsidiary
of LG Chem.

9.
MITSUBISHI I-MIEV
• Battery16 kWh / 58 MJ (Li-ion battery)
Range160 km (99 mi) (Japanese cycle)
• The 16-kilowatt-hour (58 MJ) lithium-ion
battery pack consists of 88 cells placed
under the base floor. The pack has 22
cell modules connected in series at a
nominal voltage of 330 V. There are two
4-cell modules placed vertically at the
center of the pack and ten 8-cell
modules placed horizontally.
• Developed by Mitsubishi and GS Yuasa
for both high specific energy and high
rate discharge and manufactured by
Lithium Energy Japan, a joint venture of
GS Yuasa Corporation, Mitsubishi
Corporation and Mitsubishi Motors
Corporation

10.
CLASSIC EV-I & II
• 1997 EV1 Gen-I
• Valve Regulated Lead
Acid Battery system
• 1999 EV1 Gen-II
• Nickel Metal Hydride
battery system

11.
CLASSIC EV-I & II
•
The Gen I EV1 models, released in 1996, used leadacid batteries, and weighed in at 1,310 lb (594 kg).
The first batch of batteries were provided by GM's
Delphi branch; these were rated at 53 amp-hours at
312 volts (16.5 kWh), and initially provided a range of
60 miles (97 km) per charge. Gen II cars, released in
1999, used a new batch of lead-acid batteries
provided by Panasonic; some Gen I cars were
retrofitted with this battery pack.
•
The Japanese batteries were rated at 60 amp-hours
(18.7 kWh) at 312 volts, and increased the EV1's
range to 100 miles (161 km).
•
Soon after the rollout of the second generation cars,
the originally intended nickel metal hydride (NiMH)
"Ovonic" battery pack, which reduced the car's curb
weight to 2,908 lb (1,319 kg) entered production; this
pack was also retrofitted to earlier cars (both battery
pack designs were led and invented by John E.
Waters under the Delco Remy organization). The
NiMH batteries, rated at 77 amp-hours (26.4 kWh) at
343 volts, gave the cars a range of 160 miles (257
km) per charge, more than twice what the original
Gen I cars could muster.

12.
TYPES OF LITHIUM-ION
BATTERIES
GENERAL OVERVIEW
Summary By F. Lopez

13.
PURPOSE
• The purpose of this PowerPoint is to help the
layperson understand the common types of Lithium
batteries.

14.
Chemical name
Material
Abbr,
Short form
or
Nickname
Comments
Lithium Cobalt Oxide
LiCoO2
(60% Co)
LCO
Li-cobalt
High capacity; for cell
phone laptop, camera
Lithium Manganese
Oxide
LiMn2O4
LMO
Limanganese,
or spinel
Most safe; lower
capacity than Li-cobalt
but high specific power
and long life. Power
tools, e-bikes, EV,
medical, hobbyist.
Lithium Iron Phosphate
LiFePO4
LFP
Li-phosphate
Same as above
Lithium Nickel
Manganese Cobalt
Oxide
LiNiMnCoO
2
(10–20%
Co)
NMC
NMC
Same as above
Lithium Nickel Cobalt
Aluminum Oxide
LiNiCoAlO2
9% Co)
NCA
NCA
Gaining importance
in electric powertrain
and grid storage
Lithium Titanate
Li4Ti5O12
LTO
Li-titanate
Same as above

15.
REFERENCES
• Battery University
• Battery University™ is a free educational website that
offers hands-on battery information to engineers,
educators, media, students and battery users alike.
• The tutorials evaluate the advantages and limitations
of battery chemistries, advise on best battery choice
and suggest ways to extend battery life.
• Notes: The author of this PowerPoint worked in the battery and
automotive industry for approximately five years prior to his existing
career position.

16.
ACKNOWLEDGEMENTS
•
•
Tesla
• http://www.teslamotors.com/models/features
• http://en.wikipedia.org/wiki/Tesla_Motors
Nissan Leaf
• http://www.karoto.gr/static/media/2013/07/Nissan-Leaf_2014_1000ad-5.jpg
•
EV1
• http://www.cleanmpg.com/forums/showthread.php?t=1642
•
Volt
• http://www.driveforinnovation.com/volt-teardown-the-battery-pack/
•
Ford Focus
• http://boronextrication.com/tag/battery/
• http://www.ford.com/technology/electric/howevswork/
•
Mitsubishi i-MiEV
• http://johndayautomotivelectronics.com/software-reliability-testing-for-mitsubishis-imiev/
• http://en.wikipedia.org/wiki/Mitsubishi_i-MiEV
•
GM EV – I & II
• http://en.wikipedia.org/wiki/General_Motors_EV1#Battery

17.
ABOUT THE AUTHOR
• Felix holds a Master’s Degree in Business, Bachelor’s Degree in Science, Green Six Sigma,
Certificate in Urban & Regional Planning, and Certificates in Advanced Power Quality and
Energy Management. Enjoys basketball, rugby, cricket, chess, and helping regular
people understand different things. For questions or clarification send email to
felixlopezmail@gmail.com