RECENT ADVANCES IN ENHANCED FLOODED BATTERY

FOR SMART MILD HYBRID POWER TRAINS

By Debashish Mazumdar, Ashwini Kulkarni & Achim Luelsdorf
Exide Industries Ltd (EIL) ,R & D center, INDIA
CONTENTS
• ABSTRACT
• INTRODUCTION
• CHARACTERIZATION AND VALIDATION
• RESULTS AND DISCUSSION
• FUTURE CHALLENGES
• REFERENCES
• ACKNOWLEDGEMENT
 ABSTRACT

To serve the critical demand of battery for Smart Mild Hybrid Vehicles under tropical
climate, EIL has developed Generation-2 EFB technology which passed drive cycles of
SBA, NEDC and EUCAR satisfactorily. Our EFB is superior in terms of active material
formulation, special grid alloy, electrolyte additives which resulted in significant
increase in SBA cycle life, DCA and PSoC cyclic operation. Suppression of PCL effects
due to Grid interface passivation, Negative lug thinning and Softening of PAM/NAM
have been achieved.
Here, we throw light on the development and evolution of EFB battery technology
for major automotive players Suzuki, Nissan, VW and others in India.

Keywords: EFB, mild/micro-hybrid, SHVS, PSoC, LAB

 INDIAN SCENARIO
By 2021, Estimated
emission norms -113 g CO2/km - INDIA

In Indian Scenario, Densely populated

cities like Mumbai, Delhi, Bangalore,
Chennai have very high pollution levels
due to passenger cars, Heavy vehicles
etc.
Huge potential exists for mild / micro
hybrids (more economical compared
to fully hybrid / electric) in developing
countries like INDIA

Market driving forces:

•Govt. initiatives
(Subsidized schemes like FAME)
•Fuel economy
Fig: Comparison of global CO2 regulations for passenger cars, in terms of NEDC CO2/km. [1]
•Stringent emission norms
 OPPORTUNITIES IN INDIA
FAME (FASTER ADOPTION AND MANUFACTURING OF ELECTRIC/HYBRID VEHICLES) An INDIAN govt. Initiative

Target by 2020:
• 6-7 million hybrid/electric vehicle sale.
• 9500 million liters of cumulative saving .
• 2 Million ton reduction in pollution and green house gas emissions.

VEHICLE MINIMUM MAXIMUM

SEGMENT INCENTIVE INCENTIVE
Indian government has declared Tax
benefits with 50 % reduction in SCOOTER 1800 22000

Excise duty MOTOR CYCLE 3500 29000

AUTO RICKSHAW 3300 41000
CARS 11000 138000
LCV 17000 187000
BUS 3000000 6600000
Prices are in Indian rupees
 RELATIVE IMPORTANCE OF BATTERY CHARACTERISTICS IN
DIFFERENT MARKET CONDITION
BATTERY RELEVANCE WITH REGARD TO OPERATING CONDITIONS Indian Climatic condition, Road condition and
CHARACTERIS
TICS EUROPE / NORTH AMERICAN INDIAN MARKET driving pattern are different from the western
MARKET
countries as shown in table
SERVICE IMPORTANCE SERVICE CONDITION IMPORTANCE
CONDITION
AGM VS EFB
ENGINE
CRANKING
CAPABILITY Even though AGM gives more cycle life than EFB
(CCA)
HOT CLIMATE, in mild/micro hybrid application, in Indian
RESERVE COLD CLIMATE,
CAPACITY
context EFB has more relevance
PARASITIC LOAD,
PARASITIC LOAD,
HIGH TEMP
ENDURANCE
LOW SPEED, •In Indian tropical climatic conditions, under
HIGH SPEED,
CHARGE FREQUENT START-
bonnet temperature will be high. EFB
ACCEPTANCE LONG RUN, performance is less effected by the extreme
STOP, temperatures compared to AGM [2] J.Valencio
RECOVERY SMOOTH ROAD
FROM DEEP BUMPY ROADS et al [2]
DISCHARGE
VIBRATION •EFB is also very economical as compared to
RESISTANCE
the AGM technology
- NOT CRITICAL - CRITICAL - VERY CRITICAL
 INTRODUCTION
EXIDE CONSERVO DIN70-ISS BATTERY IN SUZUKI CIAZ:
INDIA’s FIRST DIESEL SMART HYBRID VEHICLE
HYBRID TECHNOLOGY USED IN SUZUKI CIAZ :
SHVS (Smart hybrid vehicle by suzuki)
FUNCTIONALITIES OF SHVS 12V SYSTEM:
• CRANKING
• IDEAL START-STOP
• POWER ASSIST
DIN70-ISS: Gen 2 - ISS Battery
• REGENERATIVE BRAKING
 ISS BATTERIES (Gen-2) UNDER SUPPLY

Battery Customer\Vehicle Model DOI

DIN 70 ISS

•MSIL CIAZ Hybrid

Sept’15
• MSIL ERTIGA Hybrid

DIN 55 ISS
MSIL-Baleno
Dec’15
(Export- Europe)

N55 ISS
MSIL-Baleno
(Export- Japan) Dec’15

• AUTOMOTIVE SBU - TALOJA

 OPPORTUNITIES IN INDIA
CONSIDERING THE SUCCESS STORY OF MSIL,
ALL MAJOR CAR MANUFACTURERS OF INDIA HAVE ANNOUNCED HYBRID VEHICLE
LAUNCH PROGRAMME
 ISS BATTERIES (Gen-2) UNDER SUPPLY
EXIDE CONSERVO N55-ISS BATTERY IN 48V RETROFIT KITS BY M/S ALTIGREEN PROPULSION LABS

Altigreen technologies makes mild hybrid Retrofit kits, which won many international awards like
• IDTechEx Europe 2016 award for the Most Significant Innovation in Electric Vehicles.
• Altigreen had joined the list of Top 20 Automotive Tech Solutions of 2016 by CIO Review, USA.

N55 : Gen 2 - ISS Battery

FUNCTIONALITIES SUPPORTED
BY N55 BATTERY :
• IDEAL START-STOP
• POWER ASSIST
• REGENERATIVE BRAKING
 ON GOING PROJECTS

NEW PRODUCT DEVELOPMENT - OEM

Sl. No. Project Battery Type Present Status

1 TOYOTA ISS DIN60

2 TOYOTA ISS DIN 75

3 NISSAN ISS DIN 70 •Technical specifications of battery and test standards

4 FIAT ISS DIN 70 are received
• Samples have been submitted to few OEM for their
5 HONDA ISS 12V 60AH
preliminary test and validation
6 TML ISS 115D31L

7 M&M ISS 85D26R

8 M&M ISS 115D31R

9 CATERPILLAR ISS DIN 90

 EFFECTS OF PSoC APPLICATION ON THE BATTERY

Fig: The impact of HRPSoC on Battery capacity [3]

Fig: SEM images of NAM, a) healthy state b) sulfation State [3]

Under PSoC condition, Battery is subjected to various critical

conditions. With increase in cycles it may lead to the different
types of failure as shown in the figure as discussed in Jun
furukawa et al [5]

Fig: Failure modes of the lead acid batteries

 Why ISS Vehicles Require Advanced Battery?

Why different?
Parameter Modifications
(Hybrid Vehicle Feature)
To attain full state of charge (SOC) during short  Negative plate recipe
Charge acceptance  period between stops  Advanced corrosion resistant Ca Alloy
(Break Energy Regeneration)  Advanced Paste Technology

To achieve frequent and fast restarting of vehicle  Negative plate recipe

CCA  at lower SOC.  Advanced corrosion resistant Ca Alloy
(Idle Engine Start/Stop)  Advanced Paste Technology

To retain maintenance free characteristic .

 Optimization of Carbon content and adequate
Water Consumption  (Idle Engine Start/Stop, Break Energy
ratio with other expanders
Regeneration)

Many-fold use of battery in Hybrid vehicle than in

High endurance- Conventional vehicle  Advanced corrosion resistant Ca Alloy

Higher Cycle Life (Idle Engine Start/Stop, Break Energy  Special additive in Electrolyte
Regeneration, Power Assist)
 DESIGN PARAMETERS

PARAMETER Brief Remarks

ALLOY Base alloy C21 alloy (Ca,Ba,Sn,Al) Ca –Sn-Ag Both alloys are Highly corrosion and creep resistant [5]

POSITIVE PLATE Additives Additive ‘A’ Additive ‘E+A’

High paste Density- oxide mill particle size < 6 μm Effective utilization of active material

NEGATIVE Expanded Negative grid results in thinner plates Less internal resistance
PLATE
Additives ‘B’ | Carbon Black- Surface Area > 800sq.m/gm Carbon enhances the charge acceptance [6-7]
Max. Particle size <125 μm
‘C’ | BaSO4 - particle size < 0.8 ± 0.1 μm Controls the growth and porosity of PbSo4 crystals[8]

‘D’| Vanilex-N Prevents the solidification of spongy lead [8]

ASSEMBLY COS Pb-Sb alloy

PAM/NAM RATIO 1.2-1.3 More amount of NAM plays a role in increasing the CA

PE ENVELOPE Special Grade

 TESTS CONSIDERED FOR ISS APPLICATION
1 CHARGE ACCEPTANCE @ 90% SOC , ROOM TEMPERATURE

2 SBA LIFE CYCLE| SBA S 0101 : 2006

3 EUCAR POWER ASSIST PROFILE LIFE CYCLE

4 NEDC LIFECYCLE

5 17.5% DOD| CYCLE LIFE @ 27 °C

6 50 % DOD | CYCLE LIFE @ 40 °C

 SBA LIFE CYCLE

SBA S 0101 : 2006 SBA S 0101:2014

TEST CONDITION
Test Standard ± 2S º0101
: 25: SBA C (ROOM
: 2006 TEMPERATURE) NEW SBA CYCLE 2014:
AIR WIND VELOCITY < 2 m/s
Charge

STEP -1 : DISCHARGING @ 59 SEC14.0V

100A

45 A 18.3 x I20

STEP-2: DISCHARGING @ CONSTANT 14 V , 1 SEC

1 CYCLE 300 A
60sec
300 A
45A
STEP-3: CHARGING @ CONSTANT 14 V , 60 SEC
300A 1sec
100 A 59sec 100 A
Discharge

STEP- 4 : AFTER 3600 CYCLES – REST FOR 40-48 HRS

Battery is discharged to lower SOC in new SBA

STEP -5 : TOPPING UP WITH WATER ONLY AFTER 30000 cycles

NOT MENTIONED MENTIONED

LIFE CYCLE IS STOPPED ONCE TEST BATTERY REACHES 7.2 V

 EUCAR POWER ASSIST PROFILE

EUCAR TEST:
EUCAR POWER ASSIST PROFILE :
STEP-1: Discharge @ C2 up to 60% SOC
STEP-2: Start EUCAR profile | run for 10K cycles (1 unit)
STEP-3: Recharge @ 16V/12.6A for 20 hour
STEP-4: Discharge at C2 rate upto 10.2 volts (note down C2 capacity)
STEP-5: Recharge at 16V/12.6A for 24 hrs
REPEAT: Again repeat from step-1 to step -5
END CONDITION : C2 capacity ≤ 50% of initial value/ Voltage drop ≤ 8.4V

FOR example,
N55 ISS BATTERY | C20 = 45 AH | C2 = 25.2 AH
CYCLE LIFE TEST parameters
EUCAR MODIFIED
OPERATING TEMPERATURE 25 ºC 40 ºC
C2 (Current, A) 12.6 A 18 A
5 C2 63 A 90 A
 NEDC LIFE CYCLE

150
NEDC
CHARGE

NEDC DAY MODE

100 CURRENT (A)
•Test Temperature = 25 ºC
50
Initial condition : 100%SOC
0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250
DISCHARGE

-50
•NEDC(Day + Night mode)
-100 should be run up to six days
(i.e.,432 cycles)
-150
-200 TIME (S) •Rest period for a day, then
the NEDC is repeated again
NEDC NIGHT MODE
125 CURRENT (A)
End condition:
CHARGE

75 •Voltage reaches (V) ≤ 8.0 V

Or
25 Internal resistance(Ω)≥ 10 Ω
-25 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
OEM requirement for mild
DISCHARGE

-75 hybrid vehicle

≥ 4000 cycles
-125
-175
-225 TIME (S)
 1. CHARGE ACCEPTANCE

CURRENT V/S. TIME FOR 1 MIN OF CHARGING

N55 ISS CA TEST AT 90% SOC , 25 °C, IMAX CHARGE = 100A Sample A
120.00
Sample B
100.00
Current in Amps

Sample E
80.00
Sample F
60.00
40.00
20.00
0.00
1 5 10 15 20 25 30 35 40 45 50 55 60
Time in sec
CURRENT V/S. TIME FOR 1 MIN OF CHARGING
DIN70 ISS CA TEST AT 90% SOC ,25 °C, IMAX CHARGE = 100A
Sample A
120.00 Sample B
Sample E
100.00
current in Amps

Sample F
80.00
60.00
40.00
20.00
0.00
1 5 10 15 20 25 30 35 40 45 50 55 60
Time in sec
 2. SBA LIFE TEST
SBA LIFE TEST N55 ISS
N55 ISS VOLTAGE AFTER 1 SEC DISCHARGE @ 300A
12.00
10.00
1 sec voltage

8.00
6.00
4.00 SBA life cycles achieved:
2.00
0.00 • N55 ISS- 36000 Cycles
• DIN70 ISS – 64800 cycles
7200

10800

14400

18000

21600

25200

28800

32400

36000
No. of cycles

DIN70 ISS SBA LIFE TEST DIN 70 ISS

VOLTAGE AFTER 1 SEC DISCHARGE @ 300A
12
10
1 sec voltage

8
6
4
2
0
3600

7200

10800

14400

18000

21600

25200

28800

32400

36000

39600

43200

46800

50400

54000

57600

61200

64800
No. of cycles
 3. WATER LOSS TEST

DIN70 ISS
0.77 0.74 0.80

TEST CONDITIONS:
Water loss (gms/Ah)

@40 °C,14.4 V, 28 DAYS

REQUIREMENT:
weight loss ≤ 1 gm/Ah

Loss of weight (gm/Ah)

1 2 3
Sample
 4. EUCAR - Life Expectancy based on Discharge Energy

Cycles achieved :
• 46000 cycles
 CUT OPEN ANALYSIS AFTER EUCAR

POSITIVE COULD BE ROLLED

SPIDER DIAGRAM
 FIELD RESULTS
FAILURE MODE ANALYSIS
Failure mode of DIN70 ISS batteries tested on fleet vehicles

Sr. Kilometers Major Failure modes Observation:

completed Positive Grid corrosion is major
1. 45000 •PAM softening cause of battery failure
2. 40000 •Positive Grid corrosion
3. 90000 •Positive Grid corrosion
•Sedimentation
4. 46680 •Positive Grid corrosion
•Sedimentation
5. 57000 Positive Grid corrosion
 FUTURE CHALLENGES

EUROPEAN MANUFACTURERS ABIDING BY EN 50432-6 STANDARD

TEST LEVEL M1 LEVEL M2 LEVEL M3

MICRO-HYBRID TEST Normalized mean Rdyn increases ≤ 1.5 after 8000 cycles
U(EOS) ≥ 9.5 Volts.
Ce ≥ 50% after 8000 cycles

17.5% DoD CYCLE TEST ≥9 units ≥15 units ≥18 units

50% DoD CYCLE TEST ≥150 cycles ≥240 cycles ≥360 cycles

•Dynamic charge acceptance EN 50342-6, clause 7.3

Test under going, Target is to achieve IDCA ≥ 0.40
 17.5 % DOD cycle test

17.5% DOD - TEST PROCEDURE

Step-1 : Discharge the battery
for 2.5 Hours @ 4 x I20 , 27 °C

Step-2: Perform cycle A 85

times. Cycle A

Step-3 : Charge for 18 hrs @ Charge for 40 min @

7×I20 , 14.4 V
2×I20 , 16V, 27 °C
Discharge for 30 min @
Step-4: perform the capacity 7×I20
test C20
Step- 1 to 4 is counted as 1 unit
MEETING LEVEL M1 as per EN 50432-2006
SWITCH OFF CRITERION AT
EACH END OF STEP IS V ≤ 10 V
 REFERENCES

[1] The International Council on Clean Transportation Website ( www.theicct.org )

[2] J.Valencio, M.Fernandez, F.Trinidad, L.Sanz, Journal of power sources 187 (2009) 599-604.
[3] Jun yang, Chen Hu, Hao wang, kai Yang, Jing Bing Liu and Hui yan, International journal of Energy Research (2016)
DOI:10.1002/er 3613
[4] Article name : What is Fame Indian scheme ? (www.atthenergy.com)
[5] Kenji Nakano, Syuhei Takeshima and Jun Furukawa. Furukawa Review, No. 32 2007
[6] Ellen Ebner, Daniel Burow, Alexander Borger, Michael Wark, paolina Atanassova, Jesus Valencio , Journal of power sources
239(2013) 483-489.
[7] Patrick T. Moseley, David A.J.Rand, Ken Peters, Journal of power sources 295 (2015) 268-274.
[8] Pavlov.D, Lead Acid Batteries : Science and technology, Copyright 2011 , Elsevier B.V.
 ACKNOWLEDGEMENT

The Authors acknowledge the contributions made by other R&D colleagues

Mr. SS Vaze, Ms. Asma Khan and Mr. Mohan Tirukoti in compiling and interpreting
the test results & graphs.
Thank you