MVKF25-vt17 Battery Pack Design

Battery Pack Design
MVKF25-vt17
Mechanical and electrical layout, Thermal

modeling, Battery management
25-27/4
Avo Reinap, IEA/LU

Goals
• Design and dimensioning of battery pack
Industrial Electrical Engineering and Automation
based on suitable models

– evaluate suitable battery technologies, specify cell
and packing, electric and thermal termination
– battery development and energy management
systems, predict state of charge, health, function, ..
– test battery compatibility to operating conditions,
current waveforms
Ageing model
Thermal model
Electrical model
Avo R MVKF25-vt17 Battery Pack Design 2

Background A
• Vehicular application
– Electrification improves energy
usage – hybrids
• use ICE at 35% instead of 10-
20% efficiency
• Reuse deceleration energy for
acceleration
– Pure renewable fuel/energy
• System view
– Charging, static vs dynamic
Battery and Propulsion – Compatability, AC current loading

Background B
• Part-III Battery usage

– Pack design (Ch5)
– Management (Ch6)
– State and degradation (Ch7)
• Part-I & II Li-ion battery
technology
– Cell components (Ch1)
– Cell materials (Ch3)
– Cell design (Ch4)

Fig.Ref.: EDPC’14, EDPC’15
Background C
• Electrical machine design

• Directly air-cooled cooled
laminated machine windings
• Indirect oil-cooled stator-core
and end-turns
• Enhanced winding thermal
Avo R conductivity MVKF25-vt17 Battery Pack Design 5
Content
• Design • Cell “virtual” packing

– path from topology • Electro-Thermal models
sketching to practical
realization • Packing examples
• Cell, Module, Pack/Bank • Thermal design
• Battery = Energy storage – Cells, modules, backs
[Wh] & Power supply [W]
• Battery Management System
– Applications: Vehicle/Grid
– Technologies: Li-ion
• Battery cell
– Geometries and dimensions
– Characteristics and
properties

Design
Energy Construction
Conversion Production
kg kW, kWh
• A cross-road of different disciplines

• Multi-dimensional (analysis) & multi-objective (synthesis)
• ..

Specific energy and power
• Specific energy originates

from material chemistry
– Capacity capability
• Specific power is related to
material physics and
production
– Internal power losses and
thermal constrains – durability
and safety

Fig.Ref.: B. Averill, P. Eldredge, “General Chemistry: Principles, Patterns and Applications”
Value chain for EV batteries

• From cell realization to recycling (excluding raw materials)

• Vehicle power (performance), energy (range) and integration (BMS)

https://www.youtube.com/watch?v=2PjyJhe7Q1g
Lithium-ion batteries:
How do they work?

B. Averill, P. Eldredge, “General Chemistry: Principles, Patterns and Applications”
Electrochemical cell
• Chemical reaction = two half-reactions: oxidation+reduction=redox

– Side reactions due to thermal loads, pressure?
• Active, electrodes, non-active, the rest including electrolyte,
components

R. Purkayastha, R.M. McMeeking, "A Linearized Model for Lithium Ion Batteries and Maps for their Performance and Failure" ASME
Lithium Battery Technologies

• Optimal performance and

lifetime capacity
• Case sensitive: application
vs cell configuration
Abbr Wh/kg
Lithium cobalt oxide LiCoO2 LCO
Lithium manganese oxide LiMn204 LMO 4.0V 114-159
Lithium iron phosphate LiFePO4 LFP 3.2V 114-138
Lithium nickel manganese cobalt oxide LiNiMnCo02 NMC 3.7V 93-171
Lithium nickel manganese aluminum oxide LiNiCoAlO2 NCA
Lithium titanate Li4Ti5O12 LTO

M. Yazdanpour, “A circuit-based approach for electro-thermal modeling of Lithium-Ion batteries”
Cell material properties example

Thermal Electrical
Thickness
material conductivity conductivity
[μm]
[W/mK] [S/m]
+ I collector aluminum 20 238 37.8e6
+ Electrode 106 1.58 (wet) 13.9 (wet)
Electrolyte wet
Separator 25 0.34 (wet)
- Electrode 111 1.04 (wet) 100 (wet)
- I collector copper 14 398 59.6e6
case 162 0.16

Thermal management system
• Historic usage affects availability of
energy and power in future

– BMS = preferred and “optimized”
usage
– BTMS includes temperature control
• Purpose of BTMS
– Maintain operational temperature
– Assure temperature uniformity
• Challenges
– Temperature increase at high power
load
– Heat-up time in prior to start-up

http://epg.eng.ox.ac.uk/content/degradation-lithium-ion-batteries
Battery performance degradation

• Degradation – deterioration of useful capacity and power

capabilities
• Identification of physical and chemical processes behind
degradation mechanisms . Origins related to technology and
usage.
• SoH – state of health remaining capacity due to ageing

Battery failure
• Safety=thermal stability
– BTMS is very important for
performance and safety
• Failure mechanisms
– External/internal – internal short
circuits
– Mechanical, electrical, thermal
– abusive conditions
• Failure propagation from cell
to module and pack

Thermal runaway
• Rapid temperature increase

– Most likely due to internal
spontaneous short circuits due to
impurities (that can grow during
time as side effect of chemical
reactions)
• Avoid thermal runaway
– Overcharge/discharge protection
activated by over pressure
– Current interrupt device (CID)
– Positive temperature coefficient
(PTC)
– Separator specified for PTC & CID,
layered separators for reducing
internal short circuits

Question 1.1
• What are the criteria for the design of suitable

thermal management system for a battery back?
– Battery (cell) design?
– Parameters related to heating?
– Factors influencing the heat transport and
dissipation?

Battery modelling A
• Simple approach @ limited data

• Cell voltage U=Eo-RoI where Ro is internal resistance
and Eo is open circuit voltage (OCV)
– Ignoring that Eo and Ro depends on SoC and temperature
• Heating power Q=(RoI)2 only Ohmic losses
– Ignoring reversible heat loss, Ro depends on SoC and
temperature
• Transient temperature rise T=QRh(1-e-t/RhCh)
– Thermal properties are not an easy target!

Equivalent circuit relations
Electrical Magnetic Thermal Cooling

Relation
circuit circuit circuit circuit
Potential U=E·l N·I=H·l =G·l P=·l
Flow I=J·A Φ=B·A Q=q·A Q=v·A
Conductive G=γ·A/
G=μ·A/l G=λ·A/l G=·A/l
element l
Ohm’s Law U=I·R N·I=Φ·R =Q·R P=Q·R

Battery modelling B
current Electrical power Thermal • Depth of discharge DoD {0 1}

model model
{max(Ucell) min(Ucell)}
temperature
voltage
DoD SoH • Inner voltage source (OCV)
Ageing model
E(DoD)=Ucell(I,DoD)Rdch(DoD)*I
• Charge Rch and discharge Rdch
resistors depends only on DoD
– Usually Eo and Ro available

– Also ∆U and ∆T

www.toray-eng.com
Cell construction
• Electrode arrangement: spiral
wound jelly roll, stacked electrodes,

bobbin type
• Geometry: Cylindrical, Prismatic,
Pouch, Button
• Components
– Case: plastic (PET) or metallic
(steel, Al)
– Core=active components
+collectors, separator
– Terminals

18650 Li-ion
• Standard (size)
cylindrical Li-ion cells
ø18h65mm

Prismatic Cells
• Some cell producers

– Hitachi, Samsung-SDI,
Panasonic (Sanyo)
Prismatic
L, [mm] W, [mm] T, [mm] M, [kg] U, [V] C,[Ah] p, [W/kg] c, [Wh/kg]
cell
Hitatchi-1 148 91 26.5 0.72 3.6 28 2300 140
SDI-1 37
SDI-2 60
SDI-3 94

Kokam.com
Kokam’s SLPB cell

• SLPB – Superior Lithium

Polymer Battery
• Pouch type improved heat Kokam large cells
dissipation due to larger 260
surfaces 240
220
• Example 240Ah 4.8kg cell
specific energy, wcell [Wh/kg]

200
– Pheat=1.1kW @ 480A 180

SLPB160460330
– Acool=2x0.15 m2 160
140
– V=46.2x32.7x1.58 cm
120
100
80
60
0 500 1000 1500 2000 2500
specific power, pcell [W/kg]

Overview of cell producers for xEVs
• It is easier to find producer than product ;)

Battery back sizing
• Number of series connected cells

in strings
– Ns=Udc/Ucell
• Number of parallel connected
strings
– Np=Energy/(Ns*[Wh/kg]*[kg])
– Np=Energy/(Ucell*”cell capacity”)

Calculation example
• Ch4 – Cell data

• Ch5 – EV and HEV spec
– 300 V * 100 A
– Pmax = 2*30kW
– P/E ratio 2 and 20

Specification list
• Forced heating/cooling for battery back

– Concepts, topologies, realization ideas, …
• Battery cell
– Construction, properties, heat sources, thermal loads, …
• Heat conductor
– Thermal accessibility, thermal contacts, …
• Cooling plate
– Realisation, performance, …
Source Link Sink

Question 1.2
• Battery pack specification

– Power demand?
– Capacity?
– Weight or size?
Avo R MVKF25-vt17 BTMS

Battery Pack Design 30
Thermal design
Heat
Electricity
• Methods, models, calculation examples for thermal design

• Practical realisation examples from some car manufacturers

Thermal modelling
• Models 1D, 2D, 3D analytic or numeric

– Computation time vs accuracy, …
• Single cell, a module of cells, battery back
– Specification of equivalent cell volume with specific losses, …
• Assembling, heat transport and temperature distribution
– Mechanical assembly and thermal accessibility, thermal contacts
• Integration of active cooling circuits
– Realisation, estimation of coolant flow and performance, …
Source Link Sink

Thermal integration
• Direct cooling where it is

most needed in order to
minimize heat transport
through the solids that
causes interior temperature
rise and uneven temperature
distribution
• Consider the effects of
thermal cycling and
expansion
• Experiences from other
electric drive components

Thermal design simplifies control
and BMS
• Cells (EL+Chemi) – modules

(Heat) – battery pack (Duty)
• Battery thermal management
– Keep temperature & use
little energy for operation
– Keep it Simple is the rule of
the day
• Prototype development and
prototyping supported buy
models
– CAD (SW) – components
and parts (Ansys or Comsol
– fluids and solids) – system
(Simulink/Matlab)

Thermal model
Rcell Rlink
 cell  surf  fluid
• representing physical reality (?)

C cell P • Main focus on only on reasonable
cell surface temperature surf as cell
is remains unknown (?)
– surf = fluid + R*P
• Thermal resistances: simplifications
vs idealisation
d P surf  cell 1
cell    • Practical realization for fluid
dt Ccell Rcell Ccell dynamics
Ph • Thermography for rapid thermal
Q
  c   fluid ,out   fluid ,in 
assessment

Model library
• Impedance based equivalent

circuit models, dynamic
experiment based
• Physics and chemistry-based
models relay on model
parameterisation and properties
• Energy or power-flow models
are typically used on a system
level
• Empirical models black box
models suitable for control not
design

Avo R
MVKF25-vt17 Battery Pack Design
37
Cell library
• Selected cell examples:

cylindrical, prismatic, pouch
• This information is used for
virtual packing and rough
estimation on temperature
rise and distribution
Specific
Manufacturer configuration Geometry Voltage Capacity Weight
power
[mm] [V] [Ah] [W/kg] [g]
Panasonic Cylindrical Ø18.5x65.3 3.6 3.2 120 48.5
Hitatchi Prismatic 148x91x26.5 3.6 28 2300 720
Kokam Pouch 462x327x15.8 3.6 240 360 4780

Cell “virtual” packing
• For 300V there is need of 84

series connected 3.6V cells
• First draft of 148x26.5 mm
prismatic cell arrangement where
5 mm distance is left between the
rows and groups of 7 cells
• First draft of ø18 mm 4 parallel
cylindrical cell arrangement with
cooling channel in between the
cells
• Not only visualization but a
parameterized model with coupling
to finite element analysis (FEA)
Electric connection of cells
• Series-parallel connections
• Connection-bars and cables
are part of heat generation
but also distribution
• Nickel plate + spot welding =
healthy low resistance
connections

Estimation of thermal conductivity
cond  ins
eff 
ins  k f  cond  1  k f 
L Lkf L  1  k f  L  ins  k f  cond  1  k f 

  
eff cond ins cond  ins
• Equivalent thermal conductivity of a coil is given by the filling

factor of the conductor foil (copper in this example) and the
thermal conductivity of the medium between the conductor foils
• jelly-roll:12% Al+Cu λ>200W/mK, 6% eparator λ<0.35W/mK,
rest λ~1W/mK
• Across coil or roll λ~1W/mK, along λ>>1W/mK

Using 2D FE for sketching
• FEMM electromagnetism,
heat transfer, electric

currents
• Easy to use, library of Matlab
functions
– Drawing the endpoints of the lines
and arc segments for a region,
– Connecting the endpoints with
either line segments or arc
segments to complete the region,
– Defining material properties and
mesh sizing for each region,
– Specifying boundary conditions
on the outer edges of the
geometry.
Battery pack with cylindrical cells
• “Empty” space between cells
• Cross-flow through battery

module
– Narrow spacing – expectedly no
cooling
– Large spacing for sake of better
cooling is often considered impractical
• CFD vs “fast” design approaches

Battery back with prismatic cells
• Temperature homogenization analysis

• Analysis of thermal runaway

Battery pack with pouch cells
• Coupled electro-thermal
FE+model order reduction
(MOR) simulation compared
to thermographic images
– A reduced order model (ROM)
based on singular value
decomposition (SVD)
• Direct air-cooled Li-ion
pouch battery cell in order to
improve the understanding
(modelling) and practical
realization of battery module

Vehicular
application

Avo R
MVKF25-vt17 Battery Pack Design
47
Chevy 104kW 20kWh
• GM Volt and Spark EV use

thin prismatic shaped cooling
plates in between the cells
with the liquid coolant
circulating thru the plate.
• The Volt cooling scheme is
very effective from a cooling
point of view but it is
complicated. The cells are
encased in multiple plastic
frames

Tesla S 285kW 70kWh
• Tesla snakes a flattened

cooling tube thru their
cylindrical cells resulting in a
very simple cooling scheme
with very few points for
leakage.

BWM i3 125kW 21-33kWh
• The BMW i3 cools the

bottom of the battery case
with refrigerant eliminating
the liquid coolant entirely.
• New energy dense lithium
ion cells (50% more)

Integration example by BMW

Integration example by Tesla
• 60kWh, 352V, 14 modules, 6216 cells in groups of 74=6x14

• 85kWh, 402V, 16 modules, 7104 cells

Integration example by Tesla

Accommodation of cylindrical cells

Cool-plate and
coolant
• Single stage heat transfer
insufficient hA vs UA

Coolant
Air H2 C02 H20 Tr Oil
, degC 20 120 20 120 20 120 20 120 20 120

c, kJ/kgK 1.00 1.01 14.2 14.5 0.85 0.94 4.19 4.25 1.71 2.11
, kg/m3 1.20 0.89 0.08 0.06 1.83 1.36 999 946 879 816
λ,mW/mK 26 33 178 227 16 24 594 686 111 102
, uPas 18 23 8 11 14 19 1000 200

Conjugate heat transfer
• The character of flow is • and the coolant is described
described by Reinolds by Prandtl number

number,
cp
 1 Q Pr 
Re  vDh  Dh k
  Ain
• The hydraulic diameter is
• the heat transfer is related to the geometric
expressed by Nusselt layout of the cooling channel
number 4  area
Dh 
h qDh perimeter
Nu  Dh 
k k wall  bulk  in Pcool out
cQ
dcool
Pheat
hAcool
dcond
win
Lh
L
B. Sundén, “Introduction to Heat transfer”
Heat transfer mapping

220
Cooling power, p=cpQ(out-in) [W]
c=3500J/kgK, =900kg/m3
Reynolds number, Re=2dhQ/(A) [-]
700
13
200
• Driving parameters for cooling
00
220
11
100
out,Q)in at in
500
200
180
400
600
800
00
00
Nusselts number, Nu=f(Re,Pr) [-] p= c pQ(out
P=f(
cooling power, - ) [W]
10
200
outlet temperature, out [ C]
15
90
160
00
00
220
0
12
300
h=Nu k/D30
6.6
180
7
6.8
7.2
7.4
Heat transfer coefficient, [W/(m K)]
7.6
7.8
140 200 13
h • Flow (Re) and coolant (Pr)
8
10
0
160
70
220
1000
00
120 11
0
180 0 150 0
Temperature across
420
boundary, P 29 /(hA ) [C] characterization
0
140 0 440
200 90 cool cool
50
100 0
00
160 130
800
0
600
100
400
200
220
400 0
10
00
120 180 420 1100
4000
14
00
80 140 30
drop, dP28[Pa]
700
• Heat transfer
12
200 0
Pressure 900
16
8.2
100
12
0
7.8
13
80
160
7.6
40 5
7.4
0
00
7.2
0
40
7
8
6.8
6.6
60 220 700 420

120
1803 00
4000
6000
2000
8000
80 14
70
0
500
– correlations (Nu) and
00 [ C]
1000 0
140 80 300
0
Ideal cooling supply power, dPQ [-]
1400
40 200 100 27
10
00
100 400 300
00
0
160
60
60 220
16
0
100 100
120 10
Cooling power, p=c Q( - ) [W]
20 180
– coefficient h
outlet temperature, out
38
0
80
20
5000 600
100
150
00
100
8.4
800
0 100 140 200 300 400 700 800 900 1000 12

50
14
600
40 200 p out400 in 0
400
C]
0
0
26
00
100 360 flow rate, Q [L/min]

outlet temperature, out [20
160 80
1200
12
.2
60 250
8
120
20 180 38 100
• Wall and winding temperature
7.8
80100 700 0800 130

8
90
0
7.6
0 140200 300 400 500 600 900 0 1000 130

40
6
7.4
40
8.
7.2
1000
7
C]
00
outlet temperature, out [ 6.8
100
6.6
flow 3rate,
60 Q [L/min] 60
60 160
80 1500 25
200
300
8000
4000
6000
2000
120
1000 0
20 340 200 110 380

• Pressure
70 across cooling channel
80 700 0
40
0 100 140 200 300 400 500 600 700 800 900 1000
40 20 60 1300 00 100
00
100 flow rate, Q [L/min] 360 40 00
wall temperature, out [ C]
60
120 24
100
150
20
50
900 40 1100
0 80
100 150 200 300 400 50
500 0 600 20 700 800 900 1000 – Power for supply
120
40 100 flow rate, Q [L/min] 20

100
00
60 700 900
23 000 7
20
0
40
80
100
100
200 300 400 500 600 700
500
800 900 1000 700 • Expected
400 cooling power
200
8000
flow rate, Q [L/min]
P=f(w,Q) at in
60 300 0
20 500
0 100 200 300 400 500 600 700 800 900 1000 22
40 300 10 40
flow rate, Q [L/min] 300 00 00
150
100
50
50 100
20
0 100 200 300 400 500 600 100700 800 900 1000
100 21
flow rate, Q [L/min] 1000
0 1000
0 100 200 300 400 500 600 700 800 900 1000
20
0 5 10 15 20 25 30 35 40 45 50

Thermal analysis of cell assembly
• Geometric data
– Defined by German standard
DIN 91252
• Heat transfer inside the
cell
– From cell to module and
pack
Hitachi 3.6v 35Ah 0.8mΩ@10A – Cell = Jelly-roll (heater) +
155x27x118 incl terminals 810g
carrier (assembly)
• Heating power
– Worst case P=I2Ro=50W

Thermal accessibility of a cell
• Available thermal connection

areas
– Large long sides 2x134cm2
but low thermal conductivity
– Sides, lateral sides 2x24cm2
and Bottom side 39cm2
• Bottom and short sides have
expectedly better inherit
thermal contact

H. Lundgren et al, ”Thermal Management of Large-Format Prismatic Lithium-Ion Battery in PHEV Application”
Inside a battery cell

DIN SPEC 91252:2011

Lundgren et al 2016
• Cell dimensions are known, jelly-roll geometry only guessed

• Heat conductivity defined in-plane and cross-plane for whole cell
unit and jelly roll (including heat capacity)
• Important part for thermal models are termination and equivalent
jelly-roll

H. Lundgren et al, ”Thermal Management of Large-Format Prismatic Lithium-Ion Battery in PHEV Application”
Surface temperature response

• Thermal vs electric
power extraction and
comparison
• Thermal conductivity
– Through-foil
0.95W/mK
– Along foil 30.8 W/mK

2D FE over cross-sections
1 Qv=140W/dm3, surf=30oC
Temperature , [C] 2
30 36 42 48 54 60
λcell=20 W/mK Qbase Qlateral max

Case
[W] [W] [oC]
1 50 0 60
2 33 17 55
3 21 29 44
λcell=1 W/mK
Observations A
• Battery cell
– P=50 W heating, 1/R={0.6 0.5 0.28} K/W, ∆={30 25 14} K
• Heat conductor
– Ideal 1/R=0 K/W, ∆=0 K
• Cooling plate
– Ideal fluid=wall=surf=30oC
cell= surf+Δ surf=30oC wall=30oC fluid=30oC

Source Link Sink
50 W per cell
Realization A
• Mechanical assembly in “cross”

plane direction
• Thermal enhancement both in
plane directions
– Lateral clamp or forcing plate
– Battery to base contact
• ..

Cell clamped into heat conductor
1 Qv=140W/dm3, surf=30oC
Temperature , [C]
2
30 36 42 48 54 60
max
0.09
0.08 Qbase Qlateral

0.07 Case
0.06 [W] [W] [oC]
height, [m]
0.05
0.04
0.03 1 34 16 51
0.02
0.01
-0.08 -0.06 -0.04 -0.02 0

length, [m]
0.02 0.04 0.06 0.08
2 32 18 54
10μm gap ∆gap=3oC 3 27 23 72
Avo R
100μm gap ∆gap=21 oC
MVKF25-vt17 Battery Pack Design 66
1 Cell linked to cool-plate
Qv=140W/dm3, fluid=25oC
2
Temperature , [C]
30 36 42 48 54 60
Qbase Qlateral max

0.08
Case
0.06
[W] [W] [oC]
height, [m]
0.04
0.02
1-30 36 14 53
0
-0.02
2-h1 35 15 68
-0.1 -0.08 -0.06 -0.04 -0.02 0 0.02 0.04 0.06 0.08 0.1
length, [m]
h1=1000W/Km2 wall ∆wall=15oC 3-h2 35 15 148
Avo R
h2=200W/Km2 wall ∆wall=95 oC
MVKF25-vt17 Battery Pack Design 67
Transient heating
• 5 minutes between the frames (FEMM transient HT)

• Hot side of the scale (usually presented in between 20-30oC)
• One dominating heat capacitance only

Summary
• Battery cell
– ∆b={30 25 14} K @ 50W – actual load is lower
• Heat conductor
– Insufficient thermal contact 0.1 mm air ∆c=20K @ 50W
• Cooling plate
– Insufficient heat transfer h2=200W/Km2 wall ∆wl=95oC
cell= surf+Δb surf= wall+Δc wall= fluid+Δw fluid=30oC

Source Link Sink
50 W per cell
Evaluation of direct forced cooling
• Cooling channel
arrangements
• Thermography of heat
transients
– 300 A DC
– 400-500 L/min
• Location of hot-spots
– “turns” of the layer
edges where the
cross section is less
than 10 mm2
– Edge layer 1 is
closest to air-gap

Thermal control and management
• ..by thermal design and active cooling

• J. Li, Z. Zhu, “Battery Thermal
Management Systems of Electric
Vehicles”, MSc Chalmers 2014
• 29.5/17.7 kWh
• 1700/270 kg

Energy Management
Battery management system
Information
Energy
• Monitoring – measure what is important

• Control – keep it optimal and constrained
• Diagnosis – keep battery cells healthy

Battery Management System - BMS
• Best and safe use of energy

• Voltage U+∆U and temperature
+∆ management: cell balancing
or equalizer, check margins
• Charge/discharge
– Integration of current – SoC
– Power and capacity fade – SoH

Charge and discharge control
• maintain the voltage limits while respecting the

current and temperature limits
• LOW Constant current charging followed by voltage
and temperature control
• HIGH current for constant voltage charging
• Combined CV+CC
Avo
Avo R
R MVKF25-vt17 Battery Pack Design 74
Cell balancing
• Voltage equalization,
which is to fill up energy
and maximize capacity
and life by ”removing”
unbalanced weak links
• Active/passive –
taking/wasting energy

https://www.altera.com/solutions/industry/automotive/applications/electric-vehicles/battery-management-system.html
BMS development
• Overall functional safety is better match to global

FPGA than to local micro processor units
– parallelism for performance with fail-safe logic
Ageing model
http://www.avl-functions.de/Battery-Management-S.30.0.html?&L=1 Thermal model
Electrical model
BMS function structure

• I/O, monitoring, decisions and safety relevant funtions

http://mocha-java.uccs.edu/ideate/courses.html
BMS control sequence

• Intelligent batteries due to base functions of a battery

management system

http://www.mdpi.com/1996-1073/4/11/1840/htm
BMS basic functions

• Cell protection, charge

control, demand
management, SoC and
SoH determination, cell
balancing,
authentication and
identification,
communication – are
some objectives for
BMS

http://www.mpoweruk.com/bms.htm
BMS Scope and Failure

Consequences

http://www.electronicproducts.com/Power_Products/Batteries_and_Fuel_Cells/Battery_management_architectures_for_HEVs.aspx
BMS architectures for xEVs

• Communication, reliability and accuracy

• Practical attachment, number of components and connections
• Few architectures with different features in connections and
communication

Practical implementation
• Added intelligence, where and how? Sharing

information, history and communication

http://www.linear.com/product/LTC6802-1
Multicell Battery Stack Monitor

• Component name LTC6802-1, Up to 12 cells, 13 ms

measurement interval, up to 1000V, passive cell
balancing
http://www.nxp.com/products/automotive-products/energy-power-management/can-transceivers/reference-design-mm9z1-638-4-cell-
BMS sensor module

MM9Z1 638 4-Cell Lithium Battery BMS unit

•battery stack monitor IC can measure a number of cell
voltages and provide for the discharge of individual cells
to bring them into balance with the rest of the stack
Some future trends by Bosch

Back to Battery modelling
• power_battery, power_pattery_temperature
• State of the art model for concept development and
evaluation

Physics coupled equivalent
circuits
• Battery equivalent circuit models

– Rint model Eo, Ro
– First order (adds) R1, C1
– Second order (adds) R2, C2
• Impedance model
– Electrochemical impedance
spectroscopy (EIS)
– Coupled to pfysics (?)

http://batteryuniversity.com/learn/article/testing_lithium_based_batteries
Testing batteries
• Electrochemical dynamic
response
– Respons is related to ion-
current/diffusion rate in the cell
– Slower response for weaker
batteries
• Characterization
– LF dubbed diffusion
– MF charge transfer
– HF migration
• Batteries with faded capacity
suffer from low charge
transfer and slow active Li-
ion diffusion.
Useful links and Aknowledgement
• mpoweruk.com
• Batteryuniversity.com
• liionbms.com/php/cells.php
• Aknowledged authors and their results shown on the

previous pages (with some links and references)

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Battery Pack Design

Mechanical and electrical layout, Thermal

Avo Reinap, IEA/LU

based on suitable models

Avo R MVKF25-vt17 Battery Pack Design 2

Avo R MVKF25-vt17 Battery Pack Design 3

• Part-III Battery usage

Avo R MVKF25-vt17 Battery Pack Design 4

• Electrical machine design

• Design • Cell “virtual” packing

Avo R MVKF25-vt17 Battery Pack Design 6

• A cross-road of different disciplines

Avo R MVKF25-vt17 Battery Pack Design 7

• Specific energy originates

Avo R MVKF25-vt17 Battery Pack Design 8

Value chain for EV batteries

• From cell realization to recycling (excluding raw materials)

Avo R MVKF25-vt17 Battery Pack Design 9

Avo R MVKF25-vt17 Battery Pack Design 10

• Chemical reaction = two half-reactions: oxidation+reduction=redox

Avo R MVKF25-vt17 Battery Pack Design 11

Lithium Battery Technologies

• Optimal performance and

Avo R MVKF25-vt17 Battery Pack Design 12

Cell material properties example

Avo R MVKF25-vt17 Battery Pack Design 13

energy and power in future

Avo R MVKF25-vt17 Battery Pack Design 14

Battery performance degradation

• Degradation – deterioration of useful capacity and power

Avo R MVKF25-vt17 Battery Pack Design 15

Avo R MVKF25-vt17 Battery Pack Design 16

• Rapid temperature increase

Avo R MVKF25-vt17 Battery Pack Design 17

• What are the criteria for the design of suitable

Avo R MVKF25-vt17 Battery Pack Design 18

• Simple approach @ limited data

Avo R MVKF25-vt17 Battery Pack Design 19

Electrical Magnetic Thermal Cooling

Potential U=E·l N·I=H·l =G·l P=·l

Flow I=J·A Φ=B·A Q=q·A Q=v·A

Ohm’s Law U=I·R N·I=Φ·R =Q·R P=Q·R

Avo R MVKF25-vt17 Battery Pack Design 20

current Electrical power Thermal • Depth of discharge DoD {0 1}

– Usually Eo and Ro available

Avo R MVKF25-vt17 Battery Pack Design 21

wound jelly roll, stacked electrodes,

Avo R MVKF25-vt17 Battery Pack Design 22

Avo R MVKF25-vt17 Battery Pack Design 23

• Some cell producers

Avo R MVKF25-vt17 Battery Pack Design 24

Kokam’s SLPB cell

• SLPB – Superior Lithium

specific energy, wcell [Wh/kg]

– Pheat=1.1kW @ 480A 180

Avo R MVKF25-vt17 Battery Pack Design 25

• It is easier to find producer than product ;)

Avo R MVKF25-vt17 Battery Pack Design 26

• Number of series connected cells

Avo R MVKF25-vt17 Battery Pack Design 27

• Ch4 – Cell data

Avo R MVKF25-vt17 Battery Pack Design 28