2022 Kia EV6

The 2022 Kia EV6 is an interesting vehicle, perhaps mostly because of the specifications around the battery pack. Specifications that have been achieved with some small steps in design.

This platform is shared with the Hyundai Ioniq 5.

Hyundai Ioniq 5 / Kia EV6

The 2021 Hyundai Ioniq 5 pack had 30 modules and a total of 72.6kWh.

In this design you can clearly see spaces where 2 extra modules enabled the pack upgrade that went into the EV6 and then into the Ioniq 5.

Metrics

  • Energy Density
    • 162 Wh/kg
  • Power Density
    • 530 W10s/kg
    • 394 Wcont/kg
  • Usable Energy = 74.6 kWh (Total = 77.4 kWhtotal)
    • Usable SoC Window = 96.4%
  • Nominal Voltage = 697 V
  • Voltage Range = 806 V to 480 V
  • Nominal Capacity = 111.11 Ah
  • Cell Configuration = 192s 2p
    • Total = 384 Cells
  • Pack DCIR = 0.1248 Ω10s (est from cells)
  • Power
    • Peak = 239 kW10s
    • Continuous = 188 kWcont
  • Charging = 188 kW peak

The platform itself is quite conventional and designed as an electric vehicle from the ground up.

Electric Global Modular Platform (E-GMP). The Kia EV6 is the first vehicle based on the Kia E-GMP platform. The new longwheelbase platform is a clean slate. It introduces a flat floor, facilitating new comfort and utility choices. Its modularisation gave our engineers more options to meet tough performance, maintenance and safety objectives. In terms of performance, their aim was to achieve greater power, driving range and control, as well as shorter charging times.

Kia [3]

Charging

The peak charging power is quote as 188kW, but most interesting is the real life appraisal [1] and this summary of the charging performance:

  1. 0 to 10% in 3 minutes (8 kwh total energy put into battery in 3 min)
  2. 0 to 20% in 5 minutes (16 kwh input)
  3. 10% to 47% in 7 minutes (~30 kwh ~ 180 km range in 7 minutes)
  4. 10% to 57% in 10 minutes (~38 kwh ~ 238 km (147 miles) range in 10 minutes)
  5. 0-63% (50kwh total put into battery) in 16 minutes, with a 17.2 kWh per 100 kilometers efficiency (an optimistic rating though), 230-290 km range in 16 minutes.
  6. 0-82% in 26 minutes (66 kwh total put into battery)
  7. 10-90% in 33 minutes (74 kwh total put into battery)
  8. 0-98% in 43 minutes (81 kwh total put into battery, actual max capacity is 77 so ~ 7 kwh is lost or spent for cooling during charge)
  9. 10-98% in 40 minutes (73-8=65kwh total put into battery, may be an actual 60 kwh added)
  10. 20-90% in 28 minutes (57 kwh input, an actual 52 might be added, so 230-290 km range in 28 minutes)

Structure

  • Pack Mass = 477.1 kg
    • Cell Mass = 331.2 kg
    • Pack-Cells = 145.9 kg
    • Cell to Pack Ratio = 69.4 %

The pack enclosure is aluminium and fabricated from extrusions.

The cooling plate is underneath the pack enclosure, this removes the risk of coolant leaks inside the HV battery pack.

This post has been built based on the support and sponsorship from: Thermo Fisher ScientificEatron TechnologiesAbout:Energy and Quarto Technical Services.

Cooling

32 module ioniq 6 and ev6

The serpentine coolant flow from front to back of the pack will result in higher cell to cell temperature differences. In some ways this offsets the significant gains in how they have connected the cell to the coolant bottom surface of the enclosure.

Edge cooling pouch cells schematic
Pouch Cell Design and Edge Cooling

The Kia/Hyundai pack design is most interesting in terms of the cell, module and cooling design.

This development of edge cooling has brought the cell much closer to the cooling medium.

The changes in cell and module design give an improved design and lower cost.

Module

Hyundai Ioniq 5 module
  • Modules = 32 Number
    • 12 Cells/module
  • Fixings shared between modules
  • Plastic based module housing with no base plate

Image [6] shows the base of the Ioniq 5 module and clearly shows the open base with a strap used to support the sides of the module and hence pressure.

Cell

  • SK Innovation
  • Chemistry = NMC
  • Format = Pouch
  • Nominal Capacity = 55.6 Ah
  • Nominal Voltage = 3.63 V
  • Nominal Energy = 201.8 Wh
  • Mass = 0.8625 kg
  • Gravimetric energy density = 234 Wh/kg
  • DCIR = 0.0013 Ω [10s 50% 25°C] [5]

Tabs biased to cooling side of cell, heat generated in tabs where all of the cell electrodes connect is more easily conducted to coolant.

Single wrapped outer to remove crimp, gives flatter edge, bringing cell more uniformly in contact with cooling and lowers overall height.

SK Innovation pouch cell

References

  1. Incredible Charging Speed But Not Without Issues? Kia EV6 Prototype Charging Testing From 0-100%, Out of Spec Reviews, YouTube
  2. 2022 Kia EV6 Platform and Drivetrain, DPCcars, YouTube
  3. Kia EV6 Overview Brochure, Kia
  4. 2022 Kia EV6 Specifications, Kia
  5. Lim, J.; Lee, S.-E.; Park, K.-Y.; Kim, H.-S.; Choi, J.-H. VxG Pattern-Based Analysis and Battery Deterioration DiagnosisEnergies 202114, 5422
  6. Hyundai Ioniq 5: Integrated cooling plate | Battery Pack Breakdown, Munro Live, YouTube

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