Establishment of a Pilot Manufacturing Line for Lithium Ion Modules for Use as Building Blocks for Battery Systems in Electric Vehicle Applications

Quallion, LLC performed major construction of a set of low-humidity rooms within existing facilities for the installation of the equipment needed for the pilot lithium ion module automated assembly line. Quallion defined, procured, installed and validated the equipment required to fabricate and assemble industry leading 18650 lithium ion battery cells. Multiple battery cells were assembled with a unique design into Battery Modules for use in electric vehicle platforms. To support battery module operations and testing, the Battery Management System electronics were designed and built under a separate CEC Grant (ARV-12-010).

Quallion's battery modules and Battery Management System electronics were integrated into the RailScout electric vehicle provided by Land Systems Corporation for field deployment. The RailScout is an unmanned, battery powered railroad track inspection vehicle developed as an alternative to the gasoline and diesel fueled rail track inspection vehicles currently in use. The unmanned RailScout is expected to provide higher efficiency and safer inspection capabilities compared to existing operator manned inspection vehicles.

Light duty and medium duty electric vehicles are expected to reduce toxic and criteria pollutant emissions continually by using battery power instead of gasoline or diesel fuel. The greenhouse gas emission reduction is estimated to be 4 - 19 metric tons carbon dioxide equivalent per year per vehicle, depending on implementation. Additionally, the project increases awareness of electric vehicles as alternatives to non-traditional vehicles that use hydrocarbon fuels.