Lukas Iloson and Robert Sugumaran present teir master thesis project

Examiner: Johan Malmqvist, IMS

Abstract: 

The electrification of the transportation industry has accelerated in recent years, continuously adding electric vehicle (EV) batteries to the road. At 80% state of health, the electric vehicle batteries are considered retired. Volvo Energy has the role of driving Volvo Group towards a more circular business model. By enabling a second life for the retired EV batteries Volvo Group takes a step closer towards a circular business model and in achieving the net-zero emission goals of 2050. This thesis introduces a product concept enabling a second life for retired Volvo Group EV battery modules. A comprehensive understanding of the requirements for a second-life battery energy storage system (BESS) was established through a literature review, daily meetings with Volvo Energy employees, competitor benchmarking, study visits, and a customer needs study. Using a three-step systematic design process, a feasible and cost-effective product concept was developed using mostly off-the-shelf components. A detailed 3D CAD model was constructed to verify physical characteristics and dimensions along with thermal and structural analysis. The development effort resulted in a robust product concept enabling a second life for retired Volvo Group EV batteries. This project shows promise in enhancing Volvo Energy's circularity and sustainability efforts. With further development and testing, a second-life BESS could become a viable option for Volvo Energy's product portfolio.

Tags: Product development, second-life batteries, stationary energy storage system, design