TCO improvement of commercial electric vehicles using battery sizing and intelligent charge method

In order to democratize electric vehicles, automakers have to give a solution to reduce the total cost of ownership and bring it better than thermal vehicles one. This paper presents results of works on costs improvement of a 3.5t light-duty commercial electric vehicle. TCO (Total Cost of Ownership) were separated into investment costs and operating costs. The batteries of an electric vehicle were the most expensive element of the powertrain, which can represent until 45% of the vehicle price. What's more, contrary to the life of thermal vehicles, electric energy storage systems have a limited life around 5 years, highly dependent on conditions of use. Thus, study of batteries represents a capital step toward TCO improvement. Inspired by literature, battery aging model is proposed and identified by the calendar and cycling aging tests. A global multi-physical model of the battery, including ageing, were identified and incorporated inside the energetic vehicle model. Charging strategies were developed and adapted to operate according to the influence of the conditions of use. These models and strategies are integrated in a software tool. Taking into account the intended use of the vehicle, this tool, first, designates the most suitable battery solution dimensions, and then, associates the charging strategy to the requirements of use, in order to ensure the best battery life or the lowest TCO.