1、中美企业在锂电池电动自行车合作中获取的经验教训Lessons Learned About USA/China Enterprises Cooperation on Lithium E Bikes AECF(现为宇劲美国),苏州星恒和玮辰电动车合作为美国市场生产大功率的锂电池电动自行车。出现了很多问题。损失了很多钱。得到了很多宝贵的经验教训!中国的电动自行车用锂电池在出口方面的问题和解决方案 AECF(Now Ultra Motor USA),Suzhou Phylion,and Wettsen Ebikes cooperated to produce a high power,lithium
2、ebike for USA Market.Many problems occurred.Much money was lost.Many lessons were learned!Problems and Solutions in Export of Chinese Lithium Batteries for EbikesPhylions Vision:Provide the Best Media Between Grid and E-Appliances星恒的展望:提供电网和电器设备的最佳媒介PHYLION:Builds a complete Value ChainEngineeringMa
3、ss ProductionPowderCellCustomizedSolutionsFundamental Research星恒:打造完整的价值链工程规模生产粉末电池定制方案基础研究 USA distributor,sold to Ultra Motor Experienced team Ed,Mike Experienced assembler Wettsen/Percy Ultra Motor Strong in Indian Distribution,Technical and Design Team.Strong technical resources unusual for dist
4、ributor USA DistributionAECF/UM Intro 美国经销商,被宇劲收购 经验丰富的团队 艾德.本杰明,麦克.弗瑞斯 经验丰富的整车厂玮辰/简敬修 宇劲在印度拥有优秀的销售，技术和设计团队 技术资源强大 一般经销商不具有的优势 美国销售AECF/宇劲简介 Taiwanese invested,Longkou location,experienced builder of ebikes in Taiwan and China.Lee Iacoccoa experience.Percy Chien,Mike Fritz,Ed Benjamin all friends.We
5、ttsen Introduction 由台湾投资，坐落于龙口，是台湾及大陆地区经验丰富的电动自行车 制造商。Lee Iacoccoa 经验。简敬修,麦克.弗瑞斯,艾德.本杰明是朋友。玮辰简介Existing Wettsen Lead Acid Model Converted to Lithium Battery现有的玮辰铅酸电池模型转为锂电池Heinzmann brand German made motor.24V,able to demand high amperageChinese controller from WettsenBattery from Phylion 36 V 10 AH
6、 Li-Manganese,with BMS,packaging and charger.Users are USA people,taller,heavier,than Chinese.Power on Demand,not pedelec.Often used in hills in California.Users not knowledgeable about ebikes.Technical Outline of Product 德国产Heinzmann 牌24伏电机，可承受高电流量。中国产玮辰控制器 星恒电池 36 伏 10 安时锂锰电池,带有电池管理系统,包装 和充电器。消费者是
7、美国人，与中国人相比更高，更重。随选动力式，而非助踩式。经常在加州的山区使用。消费者并不了解电动自行车。产品技术概要We know a lot.We are strong.We will create a new world.We are the best.We are good partners.Product Development 2005.我们知道很多。我们很优秀。我们可以创造一个新世界。我们是最棒的。我们是很好的合作伙伴。产品开发 2005.Late 2006 Problems!Product no good！Supplier No good!0 voltage batteryBMS
8、 heatingBMS shutdown2006年 年末问题!产品差！供应商差!电池出现零电压BMS 发热BMS 停止工作AECF(UM)Blames Wettsen and PhylionThey should solve the problem,it is their problem!0 voltage batteryBMS heatingBMS shutdownAECF(宇劲)指责玮辰和星恒他们应该解决这个问题,这是他们的问题!电池出现零电压BMS 发热BMS 停止工作Wettsen Blames Phylion,Phylion Blames Wettsen and AECF!They
9、should re-design the product to reduce the cost.0 voltage batteryBMS heatingBMS shutdown玮辰指责星恒,星恒指责玮辰和AECF!他们应该重新设计产品来降低成本。电池出现零电压BMS 发热BMS 停止工作Conflict Between Partners Stalls Solving the Problem!We do need to solve the problem.We should work together.0 voltage batteryBMS heatingBMS shutdown三方的争端拖延
10、了问题的解决！我们需要解决问题。我们应该共同努力。电池出现零电压BMS 发热BMS 停止工作 Low voltage battery Why low voltage battery?Because the battery is over-discharged.Why battery is over-discharged?Because the data recorder continues to consume the power.Power consumption by data recorder should have been part of original specification
11、s.Why a problem?The work current of the data record is twice higher than its spec.This was not known before.It is only 2 mA more.But it is twice the spec,and causes big problem and loss of money.电池低电压 为什么电池会出现低电压?因为电池被过度放电。为什么电池被过度放电?因为数据记录仪继续耗电。数据记录仪耗电应在原有规格中体现，为何会存在问题？数据记录仪的实际工作电流是原有规格的两倍高。这一点以前并不
12、清楚。只高两毫安。但是原有规格的两倍,造成大问题和经济损失。BMS heatingWhy BMS heating?Soft ware and heat sink cannot handle heat generated by BMS.Why so much heat is produced inside BMS?Because the current is higher than expected.Why BMS is designed like this?The current information is wrong.No enough good self-protect function
13、 in BMS.Original information is wrong,and without additional testing,problem was not foreseen.BMS 发热为什么BMS 会发热?软件和散热器无法应付 BMS产生的热量。为何BMS内部会产生如此多的热量?因为电流强度比预期要高。为什么如此设计BMS?电流相关信息错误。BMS自我保护功能欠缺。原有信息错误，没有进一步的测试，未能预见问题。BMS shutdownWhy BMS shut-down?Because of the self-protection function of the BMS.Why
14、self-protection inside BMS?Because unlike other batteries,good performance of lithium ion battery can only be obtained during specific conditions of charge/discharge.BMS Design wrong for this customer.Entire system(motor,controller,battery)needed evaluation and testing.BMS停止工作为什么BMS停止工作？因为BMS的自我保护功能
15、。为什么BMS内部有自我保护功能?因为不同于其它电池，锂离子电池只有在特定的充放电条件下才能有良好表现。为客户设计的BMS 错误。整个系统(电机,控制器,电池)需要评估和测试。Solutions found,but costs are high for all partners!Many Lessons Learned.Costs of Lessons Very Large!0 voltage battery solved.BMS heating solved.BMS shutdown no more.找到了解决方案，但三方都付出了高代价！吸取了很多教训!教训的代价非常高！电池零电压问题解决。
16、BMS发热问题解决。BMS停止工作问题解决。Developing Communications,Testing,Learning to Trust Each Other,Working Together0 voltage battery solved.BMS heating solved.BMS shutdown no more.加强沟通加强沟通,测试测试,学会相互信任学会相互信任,共共同努力同努力电池零电压问题解决。BMS发热问题解决。BMS停止工作问题解决。Leadership was key.Bosses of all three companies good communicators
17、,determined to solve problems.Created more communication multi channel,multi level.Boss to boss,technology person to technical person,sales people to sales people.Question every detail.Listen to every answer carefully.Improve testing and rely more on test data than opinion.Bosses focused on keeping
18、team going,keeping everyone thinking about results not who is to blame.Face to face meetings in Suzhou,Longkou,Los Angeles helped a lot.Everyone learning to admit mistakes and discuss honestly and focus on how to fix.Wettsen and Phylion willingness to spend money and effort to fix.Group learned that
19、 many original ideas about specification and use patter were wrong.Change batteries and BMS several times.Still failing in field.Finallychange battery cells to higher power that suits high power motor.Add capacitor.How Problems Were Solved领导是关键。三方领导沟通能力强；有解决问题的决心。更多的沟通和交流。多渠道，多层面。领导之间,技术人员之间，销售人员之间。
20、询问每一个细节，仔细倾听每一个答案。改进测试，更多的依靠测试数据，而非意见。三方领导专注于保持团队前进，使每个人思考结果-而不是思考到底是谁的问题。在苏州，龙口，洛杉矶面对面的交流帮助很大。每个人都学着承认错误，诚恳的交流，专注于如何解决问题。玮辰和星恒愿意投入金钱和精力来解决问题。三方意识到原来许多对规格和使用模式的认识是错误的。数次更换BMS和电池。在实际使用过程中仍出现问题。最终提高电池功率适应大功率电机。安装电容器。问题是如何解决的 2 years of unsatisfactory sales in USA market.Sale of company complicated by
21、battery problems.New high power batteries working well but expensive for Wettsen and Phylion All three companies and all staff involved much more capable than before!Costs of Problems Were Huge!两年来美国市场的销售额不尽人意。电池问题使公司出售复杂化。新的大功率电池运行良好，但对玮辰和星恒是昂贵的。三家公司及参与员工的能力比以前大有提升！为出现的问题付出了巨大的代价！If we can learn fr
22、om our mistakes and experiences,we can benefit in the future.AECF,Phylion and Wettsen have all learned a lot.Here are some of the lessons learned from our experience and from other experiences at Phylion,AECF and Wettsen.Lessons Learned Together 如果我们现在吸取经验教训，将来定会受益。AECF,星恒和玮辰都从中学到了很多。下面是从这次经历以及星恒，AE
23、CF和玮辰的以往经历中总结的经验教训。共同吸取的教训 Battery must be first determinant of performance and power.Motor,Controller,Battery must be considered as one system!Not parts that can be bolted together.1.Build the Bike Around the Battery!2.Consider the Whole System!电池是决定性能和功率的第一要素。电机，控制器和电池必须作为整体通盘考虑!而非固定在一起的部件。1.以电池为中
24、心制造整车！2.通盘考虑整个系统!Example of Whole System AnalysisBattery(Phylion)10Ah/1C5Ah/2C(suspected root cause for shut down/turn on operation)BMS(Phylion)Thermal relay protection(75C)Over current protection(30A)(Been complained but not likely by jump wired)Over discharge protection(2.7V/cell)(BMS variation su
25、spected)(EMC issue suspected)Controller(Wettsen)Over current protection(Successful functioned)(18A+/-2A or more variation)Low voltage warning(33V)Low voltage cut off(31.5V)(12 sec average calculation)Thermal relay protection(Protection function been removed)Motor(Heinzmann)Thermal relay protection(1
26、45C)(Protection function been cut off)Demagnetized by over heat at non-gear side suspectedOver temperature failure by large current over 10 cycles(20A/20min)discoveredDemagnetizing found after 3 cycle.Vehicle(Wettsen)32kph top speed with 12A current consumption in normal conditionOn vehicle 296 rpm/
27、4.5A/40.4V no-load整体系统分析Battery(Phylion)10Ah/1C5Ah/2C(suspected root cause for shut down/turn on operation)BMS(Phylion)Thermal relay protection(75C)Over current protection(30A)(Been complained but not likely by jump wired)Over discharge protection(2.7V/cell)(BMS variation suspected)(EMC issue suspec
28、ted)Controller(Wettsen)Over current protection(Successful functioned)(18A+/-2A or more variation)Low voltage warning(33V)Low voltage cut off(31.5V)(12 sec average calculation)Thermal relay protection(Protection function been removed)Motor(Heinzmann)Thermal relay protection(145C)(Protection function
29、been cut off)Demagnetized by over heat at non-gear side suspectedOver temperature failure by large current over 10 cycles(20A/20min)discoveredDemagnetizing found after 3 cycle.Vehicle(Wettsen)32kph top speed with 12A current consumption in normal conditionOn vehicle 296 rpm/4.5A/40.4V no-loadPossibl
30、e reason to trigger BMS over discharge protection functionTrigger BMS over discharge protection functionElectro Magnetic field inference(from wire harness arrangement or power system compatibility)Motor deteriorate(demagnetized by over heat or aging)BMS variation or instabilityCell unbalanceOther Mi
31、nor reasons(controller variation)可能启动BMS过度放电保护功能的原因Trigger BMS over discharge protection functionElectro Magnetic field inference(from wire harness arrangement or power system compatibility)Motor deteriorate(demagnetized by over heat or aging)BMS variation or instabilityCell unbalanceOther Minor rea
32、sons(controller variation)Suggestions for corrective actionsBMS over discharge shut down before end of capacityLarger Capacitor(Help on EMC issue)Larger Capacitor(Help to prevent voltage drop due surge current)High power battery(eliminate capacity decrease due to high C discharge)Restore motor therm
33、ostat(prevent high temperature demagnetize)No Jump wire(keep battery protection function)High power rating motor(meet US customer requirement and higher efficiency,no over heat)US side more statistic informationUS office more detail investigation programConduct full scale test program before shippin
34、g改进建议BMS over discharge shut down before end of capacityLarger Capacitor(Help on EMC issue)Larger Capacitor(Help to prevent voltage drop due surge current)High power battery(eliminate capacity decrease due to high C discharge)Restore motor thermostat(prevent high temperature demagnetize)No Jump wire
35、(keep battery protection function)High power rating motor(meet US customer requirement and higher efficiency,no over heat)US side more statistic informationUS office more detail investigation programConduct full scale test program before shipping Bicycle Industry model of buying parts from many sour
36、ces assembled by non ebike experts does not work for ebikes.Electric system must be integrated carefully.Parts are NOT interchangeable.Normal bicycle or motorcycle manufacturing ideas do not work well for ebikes.Skill in Bicycles or Other Products Does Not Carry Over to Ebikes!自行车的产业模式-多处采购零部件，由非电动自
37、行车专家组装并不适用于电动自行车。电子系统必须仔细整合。部件不可相互转换。正常的自行车或摩托车的制造理念并不适用于电动自行车。自行车及其他产品的技能并不适用于电动自行车!Dropping supplier after one problem means all lose no chance to learn from mistakes,and no good alternative suppliers that can solve problem instantly.Need Strategic and Long Term Relationship 出现一个问题便更换供应商意味着没有机会吸取教
38、训，并且没有其他供应商能够迅速解决问题。需要建立长期战略合作关系 Bike buyer may be testing batteries,but battery company needs to be testing the proposed bike at the same time.Specifications May Not Be Enough Information 自行车买家也许会测试电池，但电池厂家同时也需要测试自行车。仅有规格是不够的Not just language.Also internal politics,cultural differences,technical is
39、sues.Must consider and work on all aspects of communication find correct person,find what is real issue.Communications are the Key Issue 不仅仅是语言。还有公司政治,文化差异和技术问题。沟通必须从各方面着手找到正确的人和问题的关键。沟通是关键 Most expensive cost is a failure in the market.Price is Not the Way to Choose!高昂的成本在市场中会遭遇失败。脱离实际的价格不是正确的选择 Sa
40、me testing equipment,same process,same way of reporting results.Everyone Need to Speak Same Technical Language!同样的测试设备,同样的测试过程,同样的测试结果表达方式。所有的人需要用相同的技术语言沟通！Lithium Is the Future Of Ebikes锂是电动自行车的未来 Lead Acid vs.Lithium issues Assemblers and distributors usually do not understand Li batteries.Complex
41、ity demands care and caution.Safety issues very important.Battery Management System,Charger very important.E Bike Not Simple,Lithium Bike Even More Complex 铅酸 与锂 组装厂 和经销商通常不了解锂电池。复杂性需要谨慎。安全问题非常重要。BMS和充电器非常重要电动自行车复杂,锂电动自行车更复杂 Lead Acid Price Going UpBattery PriceLithium Price Coming DownLithium ion e
42、-bike battery,2001US$1.15 per watt hourLithium ion e-bike battery,2008US$0.49 per watt hour 铅酸价格上升电池价格锂价格下降锂离子电动自行车电池2001每瓦时US$1.15锂离子电动自行车电池2008每瓦时US$0.49uLi-ion Cellu Electrical Performanceu Safetyu Cycle lifeu Calendar life Lithium Battery is More Complicated Than Most People KnowSystem Integrati
43、on Key to SuccessModule systemu Electrical Performanceu Safetyu BMSu EMCu Thermal management.Testu Electrical performance.u Safety testu Life verificationu Combined life TestModelsu Battery modelu Thermal modelu Life Prediction Modelu System model EC systemu Cathodeu Anodeu Electrolyteu Interface MotorMotor controller Li ion Battery Battery charger u锂离子电池u 电气性能u 安全u循环寿命u 使用寿命锂电池比大多数人想的复杂系统整合是成功的关键模组u 电气性能u 安全性u BMSu EMCu 热管理测试u 电气性能u 安全性测试u 寿命确认u 综合寿命测试模型u 电池模型u 热模型u 寿命预测模型u 系统模型EC 系统u负极u正极u 电解u 界面 电机电机控制器 锂离子电池电池充电器Thanks!72Thank you!
