Impact of Driving Cycles and Terrain on the Performance and Cost of EV Battery Chemistries: A Comparative Analysis and Evaluation

The widespread adoption of electric vehicles (EVs) faces significant cost challenges, primarily driven by battery pack expenses. Key attributes such as energy density, longevity, power density, safety, and cost can vary greatly depending on battery chemistry, including variations in anode, cathode, and electrolyte compositions within the same chemistry, which directly affect vehicle performance, range, and pricing. This study offers a comprehensive comparison of the cost and performance of various battery chemistries, including lithium-ion (Li-ion), sodium-ion (Na-ion), and solid-state batteries (SSBs), in the context of EV applications. The comparison involved configuring entry-level and premium EV batteries with capacities of 42 kWh and 85 kWh, respectively, using standardized cell sizes for each chemistry. Powertrain consumption was simulated under different driving conditions such as highway, urban dynamic, and urban aggressive across various road slopes using MATLAB/Simulink and AVL CRUISETM M software. The results highlight the influence of gravimetric energy density on energy consumption rates, vehicle purchasing cost per mileage considering cycle life, and the impact of terrain types on vehicle range. Notably, our findings indicate that battery chemistries with lower energy density can be a cost-effective alternative, especially in regions with flat terrain.