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FEV-developed plug-in hybrid battery pack moves into series production

A plug-in hybrid vehicle has gone into series production with technology provided by FEV. In addition to using an innovative transmission concept based on a FEV patent, the PHEV also uses an FEV-developed battery pack. The pack offers a capacity of 10 kWh and yields an all-electric range of about 50 kilometers (30 miles).

FEV was responsible as a turn-key partner for the development of the battery hardware and software, throughout the development of the overall concept, as well as for testing and validation. Future production will be undertaken by suppliers in the Asian market.

FEV has been operating its own electric vehicle fleet since 2010. The experience with this fleet and the comprehensive vehicle and battery measurement data which is continuously sent to an FEV server via mobile communication are key elements used in the development of alternative drives.

In addition to about 65 electrified powertrain development projects, FEV has successfully completed about 20 battery projects over the past few years. In these projects, batteries were developed for nearly any kind of drive: whether it be water-cooled high performance plug-in hybrid battery or passively cooled pack for pure electric vehicles.

Our spectrum of competence consists of every phase of development, from the concept work and development of modules and battery packs to the manufacturing and testing of the battery and, eventually, the integration and certification for series production.

— Dr. Michael Stapelbroek, Department Manager Hybrid and E-Mobility at FEV

The quality of battery management system algorithms has as much influence on performance as the selection of suitable battery cells and an optimized layout of the overall battery.

The core system for the battery development is our own mature battery management system (BMS), now in its third generation, that together with optimized algorithms allows a very reliable and stable control of the battery.

—Dr. Stapelbroek

The system is highly mature and very flexible with the capability to accommodate any battery concept. The BMS consists of a central control system, a master circuit board, and one decentralized measurement unit for each battery module, the slave circuit board. The BMS itself can comply with the safety standard ASIL-D as specified in ISO26262. The BMS was developed according to all of the current and common automotive standards (e.g., AUTOSAR and CMMI), and is well cost-optimized, particularly with regard to future series production applications.

FEV has several cell and battery test benches worldwide for the testing and validation of developed battery packs as well as experience with series production testing for several well-known manufacturers, allowing FEV to be recognized as an internationally-operating engineering company that can guarantee a high degree of quality and series production readiness in its engineering developments.



Excellent e-range with small 10 kWh battery pack?


Not at all excellent! Assuming that the usable capacity is approx. 80%, that would equate to 50km/8kWh or 100km/16kWh. A TESLA has a consumption of approx. 20 to 25 kWh per 100km (depends on the driving style). Some compacts have a consumption of 10 to 12 kWh per 100km; that is excellent.


The most energy frugal (mass produced) small EVs, under ideal test conditions, are:

1. BMW i3 = 124 mpge or 81 miles with a 22 mWh battery
2. Nissan Leaf = 114 mpge or 84 miles with a 24 mWh battery
3. Mitsubishi i-Miew = 112 mpge or 62 miles with a 16 kWh battery
4. Smart 2/2e = 107 mpge or 68 with a 17,6 battery
5. Ford Focus-e = 105 mpge or 76 miles with a 24 kWh battery

The Teslas are not on this short list.

So, 3 miles per kWh of battery on the above PHEV is in the EXCELLENT category.

Eventually, small, lighter EVs with less drag will reach 4.0 to 4.8 miles per kWh of battery.

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