In House Practical Training

On
Battery management in HEVs
Submitted to
Amity University Uttar Pradesh

Guided By: Submitted By:

Dr. Ravindra Kannojiya Apoorva Singh
A23100220001

AMITY UNIVERSITY UTTAR PRADESH

GAUTAM BUDDHA NAGAR
2022

1
 Declaration
I, Apoorva Singh, student of B. Tech 4 ME-1 Y(3 Continent), hereby declare that the project, “Battery
management in HEVs.” conducted by me and submitted to Department of Mechanical Engineering, Amity
School of Engineering Technology, Amity University, Uttar Pradesh, Noida, in partial fulfillment of requirement
for the award of the degree of Bachelor of Technology in Mechanical Engineering.
I attest, that the permission to use any copyrighted material has been obtained including articles and scholarly
reports and writings.

Date:
Mr. Apoorva Singh.
A23100220001
4 ME-1 Y (3C)

2
 CERTIFICATE
This is to certify that Mr. Apoorva Singh, student of B. Tech in Mechanical Engineering has carried out the study
presented in the project of the term paper, titled “Battery management in HEVs”; as a part of Third year
programme of Bachelor of Technology from Amity School of Engineering and Technology, Amity University,
Noida, Uttar Pradesh under my guidance.

Dr. Ravindra Kannojiya

Amity School of Engineering and Technology

3
Index-
1. Abstract……………………………………………………………. 5
2. Introduction………………………………………………………... 6
i) Batteries………………………………………………………... 6
ii) Vehicle Configuration…………………………………………. 8
• MPC……………………………………………………. 8
iii) Thermal Control of batteries…………………………………... 9
3. Literature Review…………………………………………………... 10
4. Conclusion…………………………………………………………. 13
5. Bibliography………………………………………………………... 14

4
 Battery management in HEVs
ABSTRACT-
The knowledge and understanding regarding electric vehicles and its subsets could be traced back to mid -1890s,
particularly with the first Hybrid Electric Vehicles (HEVs) debuting in 1901 at the age of automobile revolution
and progress. However, due to extreme low price of gasoline and little concern about environmental impacts back
then made the competing gas engine vehicles more desirable, moreover, the then primitive battery cells limited
the performance of electric vehicles which would have been addressed at a much later date.
The foundation of HEVs could be seen from the “Lohner–Porsche”, the first hybrid vehicle of its kind boasting a
revolutionary drivetrain that would be utilized in other projects in the same vein, however, more priority to
gasoline-based vehicles due to above mentioned factors would be given. But, HEVs would see resurgence in lates
90s and early 00s due to sudden spike in fuel prices in oil crisis, now, they form a core segment among
commercially available vehicles in today’s market.
Much breakthrough has been made in Battery Management Systems (BMS) such as improved batteries, better
computing systems, temperature management, etc. improving efficiency, lowering emissions and having greater
fuel economy than the conventional type of vehicles.
As such, this report highlights and discusses on the topic of “Battery management in HEVs.” where, we shall
discuss different types of batteries, transmission systems and thermal management systems for HEVs.

5
Introduction-
At beginning of 20th century, new forms of road transportation were being adopted as new technology sprung up
allowing for more efficient and reliable power sources, among these was the invention of car, a four wheeled
transport that could carry goods and personnel. The advent of gasoline powered vehicles sparked an automobile
revolution that would change the modern world, along with gasoline, much consideration was given for
electrically powered vehicles further, this gave rise to new class of vehicles that would utilize both, conventional
IC engines and electric batteries for propulsion known as HEVs (Hybrid Electric Vehicles), first made in 1901.[1]
Due to cheap gasoline prices and primitive battery technology, there was no need for such complex vehicles.
However, as technology improved and fuel crisis caused companies to look further into this class of cars. Modern
HEVs have numerous features and systems that increases efficiency of the vehicle, one of these consist of Battery
Management System (BMS) that takes care of the electrical power source that monitors the health of battery such
as State of Charge (SoC), discharge rate, depth of discharge, etc. overall forming a protective battery management
to increase longevity, reliability and check the State of Health (SoH) of batteries in use.[1,2]

I. Batteries-
The first consideration made for any electric power source has always been Lithium-ion batteries due to low
maintenance, rechargeability and long life. It has become an industry standard for many; however, it still presents
an expensive option and have their own issues such as negatively affecting the environment and difficulty in
recyclability.[3]
In consideration of this, many alternatives have been considered as given in table below-
S. No. Material Chemical Prop. Mechanical Thermal Prop. Cost Life
Prop. (years)
1. Lithium- Usage of lithium ions due Reactions are Lithium-ion $7,000 to 6-12
ion[3,4,7] to its high electrode minute batteries are $20,000
potential and easy resulting in temperature
rechargeability. small changes sensitive and ($145
in compounds their /kWh to
hence high performance $200
mechanical degrade faster /kWh)
stability. when they are
Can handle overcharged.
minute The failure of
deformations a lithium-ion
but is pack results
vulnerable to into burning of
extreme the battery.
stresses and This can also
cause severe lead to thermal
breakdowns runaway and
and short combustion.
circuiting.
2. Ni- Positive electrodes of Reactions are Nickel $21,000 3-4
MH(Nickel nickel compound and the minute electrode (+ve)
Metal negative electrodes uses a resulting in tends to ($150
Hydrate)[5,6,8] hydrogen absorbing alloy, small changes unwanted /kWh)

6
 easily recyclable but lower in compounds oxygen
power density. hence high evolution
mechanical above 60–
stability. 70°C. Self-
discharge. The
initial self-
discharge of
20% per week
at 40°C.
3. Lead PbO2 is used as the Slow reactions An increase in $50,000 2-3
Acid[9,10] positive electrode and the allow longer temperature to to
aqueous sulfuric acid is storage of 45°C increases $80,000
used as the electrolyte. charge and the
Degradation accelerates extremely low performance
due to shedding of active discharge rate, of the battery,
materials and acidic though its capacity ($430
reactions. efficiency and decreases /kWh to
decreases over the life time of $549
time. the system. /kWh)
Quite Underperforms
lightweight in higher or
too. lower
temperatures.
4. Lithium- A lithium–air battery Extremely Lithium N/A N/A
air[11,12] contains a lithium high energy becomes
electrode and porous air density ineffective
electrode separated by a compared to below 10°C
membrane and an other batteries. and higher
electrolyte. Flat discharge temperatures
2Li → 2Li+ + 2e− voltage causes warm
2Li + O2 + 2e− → Li2 O2
+ profile, air to degrade
Lithium–air batteries environmental battery life.
comprise three major friendliness
components, namely an Li and relatively
anode, an electrolyte, and long storage
an air cathode. life.
5. Graphene[13, Used co-doped with Sheet of Ineffective to N/A 1-2
14, 15]
nitrogen and sulphur in carbon atoms extremely hot
potassium batteries, can bounds temperatures
increase existing together in a but discharges
capacities of conventional lattice. High under colder
batteries by 45%. stability, temperatures
But pure graphene rechargeability (20°C and
batteries possess being lighter below)
extremely low charge for in weight and
same size and bulk. flexibility.
Longer service
life with lower
charge
density.

7
Many vehicles have been using different types of batteries to much success with new technology being developed
which prevents the degradation of anodes and cathodes of the batteries by using non-parasitic catalysts and better
charge carriers.

II. Vehicle Configuration-

One must consider the overall architecture of the vehicle after selecting an optimal battery, modern HEVs use the
concept of bang-bang principle that instantly alternates to either of the power sources when required, this will be
handled by the computer systems onboard resulting in a very responsive unit.
However, the conventional engine and battery generators must share a drive train to allow propulsion, which is
why a planetary gear system (PGS) is utilized with a Continuous Variable Transmission (CVT) to allow smooth
switching with both power sources.[16]
There is a set of objectives that should be considered to maintain the best results for a HEV-[17]
1. Fuel economy
2. Emissions
3. System costs
4. Driving performance
These objectives can be achieved by a specialised EV-ECU (Electric Vehicle-Engine Control Unit) that monitors
the health of the battery and decides the ideal circumstances to switch to electric engine or gasoline engine.
Emphasis on model predictive control (MPC) based strategies would help in achieving highlighted objectives
through stochastic modelling while utilizing deterministic rule-based strategies in order for the system to take
“decisions” based on favourable outcomes. [17,18]

• MPC-
A smart strategy for energy optimization can be built up as Model Predictive Control (MPC) for HEVs.
A MPC system calculates the on basis of creating a virtual model which considers SOCs, state of battery, distance
of travel, speed, etc. It requires constant calculation and selecting the appropriate plan for energy expenditure,
thus increasing the range and efficiency while also protecting battery from fluctuating charges.[17]
MPCs can be built upon different strategies and decision-making programs. Among many, one could build the
system to follow stochastic model, a prediction-based types through usage of GPS and cluster analysis.
Alternatively, a frozen type MPCs would depend on the drive cycle of the vehicle, which would result in less
efficient system and strategic planning, such strategies would often be given “future” information accurately i.e.,
what path is being taken? What is the fuel economy? Etc.[18]

8
III. Thermal Control of batteries-
Under the Battery Management System (BMS) comes a very important topic of thermal management of batteries,
as extrapolated from above details, difference in temperatures can cause multitude of issues in the electrical
power sources.[19]
As such, it forms one of the most important bases for designing an electric vehicle.
One must aim for the following as given below-[19]
1. The battery must be protected against outside factors.
2. The battery’s temperature must be regulated and kept at optimal temperatures.
3. To dissipate heat or cold in efficient manner.
The above three objectives must be achieved for healthy functioning of the vehicle.
At present, there are two main ways for temperature maintenance in HEVs, air-cooled and liquid-cooled,
depending upon the type of application, the MPC system can be designed around such constraints.
Air cooling offers a simpler architecture that may prove beneficial for simplicity of system along with low energy
consumption and low cost.[20, 22] Whereas, liquid cooling may utilize specialized solutions for purpose of cooling
by having intricate flow paths in thin fins and plates and consists of radiators to carry the heat from the liquid
away from the equipment, further, evaporators are also used to cool down the liquid itself and repeat this process,
while there is complexity in this system, the advantage being more efficient and more controllable cooling
system.[21, 23]
Further under liquid cooling, mini channels that circulate around entirety of system or copper foam stuffed in
cooling plates soaked with special liquid could be used.[21]
Discussing about forced air cooling suggest to allow radiator fins in contact with battery and a powered fan-
ventilation system would cool down those fins made of high thermal conductivity, such system could be
lightweight but less efficient as compared to liquid cooling.[22]

9
Literature Review-
S.No. Author’s Name Title of paper Methodology Results
1. Fenfang Chena, Rui Air and PCM cooling for Research. Analysis of batteries under
Huanga, battery thermal ambient temperatures and
Chongming Wangc, management considering studying the performance of
Xiaoli Yua, Huijun battery cycle life. entire system.
Liua,b, Qichao
Wua, Keyu Qiana,
Rohit Bhagat
2. Lívia Salles Electric car battery: An Research/Survey Historical and social impact of
Martins, Lucas overview on global electric vehicles and its
Fonseca demand, recycling and subsets on modern world.
Guimaraes, future approaches towards
Amilton Barbosa sustainability.
Botelho Junior,
Jorge Alberto
Soares Tenorio,
Denise Crocce
Romano Espinosa
3. Sebastian Ibarra- Assessing the potential of Research/Survey Research on lithium reserves
Guti´errez, Jocelyn quebec lithium industry: used in making of batteries
Bouchard, Marcel Mineral reserves, lithium- and effects on nature.
Laflamme, ion batteries production and
Konstantinos Fytas greenhouse gas emissions.
4. Golriz Kermani and Review: Characterization Research Properties of lithium-ion
Elham Sahraei and Modeling of the batteries.
Mechanical Properties of
Lithium-Ion Batteries.
5. F. Zhan , L.J. Jiang, Characteristics of Ni/MH Research Applications of NiMH battery
B.R. Wu, Z.H. Xia, power batteries and its in vehicles
X.Y. Wei, G.R. Qin application to electric
vehicles.
6. Noboru Sato, Thermal behavior analysis Research Thermal properties of NiMH
Kazuhiko Yagi of nickel metal hydride as a battery.
batteries for electric
vehicles
7. Fabio Orecchini, EVs and HEVs Using Research/Reading Lithium-ion batteries in
Adriano Lithium-Ion Batteries. HEVs.
Santiangeli,
Alessandro
Dell’Era
8. M.Fetcenko, Nickel–metal hydride and Research NiMH batteries in HEVs and
J.Koch, M.Zelinsky nickel–zinc batteries for EVs.
hybrid electric vehicles and
battery electric vehicles.
9. J. Garche, P.T. Lead–acid batteries for Research/Survey Usage of lead acid batteries in
Moseley, E. Karden hybrid electric vehicles and HEVs and EVs.
battery electric vehicle.

10
10. C. Chumchal, D. Lead–acid battery operation Research Lead acid batteries in HEVs.
Kurzweil in micro-hybrid and
electrified vehicles.
11. Oi Lun Li, Development, Challenges, Research Lithium-air batteries research.
Takahiro Ishizaki and Prospects of Carbon-
Based Electrode for
Lithium-Air Batteries.
12. MIT LITHIUM AIR Research/Review Lithium-air batteries in HEVs
BATTERIES and EVs.
New catalysts push up
lagging efficiency in
lightweight batteries for
electric cars.
13. A. H. Castro Neto The electronic properties of Research Graphene’s electric properties.
graphene.
14. Gints Kucinskis, Graphene in lithium-ion Review Graphene’s effects on lithium-
Gunars Bajars, battery cathode materials: A ion battery.
Janis Kleperis review.
15. Juhyung Choi, Nitrogen and sulfur co- Research Doped graphene used in
Aihua Jin, Hyun doped graphene potassium ion anodes.
Dong Jung, nanoribbons with well-
Dongjin Ko, Ji ordered stepped edges for
Hyun Um, Yoon high-performance
Jeong Choi, So potassium-ion battery
Hee, Kim, Seoin anodes.
Back, Seung-
HoYub, Yuanzhe
Piaoae
16. Zicong Zhao, Jing MPC Based Hybrid Electric Research Usage of different
Xun, Xin Wan, Vehicles Energy transmission systems in
Ruochuan Yu Management Strategy. HEVs.
17. K.T. Chau, Y.S. Overview of power Review Power management strategies
Wong management in hybrid in HEVs.
electric vehicles.
18. Jim Douglass Battery management Review Battery monitoring system
architectures for HEVs. requirements,
19. Jimmy Neutron The Importance of Thermal Review Guidelines for thermal
Management System in systems in HEVs.
electric vehicles.
20. Yan Ma, Hao Ding, Battery thermal Research Air cooled thermal
Hongyuan Mou, management strategy for management system tested.
Jinwu Gao electric vehicles based on
nonlinear model predictive
control.
21. Bengt Sundén Thermal management of Research. Liquid cooled thermal
batteries. management system tested.
22. Heesung Park A design of air flow Research Forced air cooled system for
configuration for cooling HEVs
lithium-ion battery in
hybrid electric vehicles.

11
23. Seokkan Ki, A bio-inspired, low Research Liquid cooling mechanics
Jooyoung Lee, pressure drop liquid cooling being utilized.
Seunggeol Ryu, system for high-power
Soosik Bang, IGBT modules for EV/HEV
Kichong Kim, applications.
Youngsuk Nam

12
Conclusion-
The results indicate the possibilities of new battery technology and systems that can be incorporated in new
generation of hybrid vehicles that would increase fuel economy, better range, longer overall life and lesser impact
on the overall environment. With the fluctuating fuel prices and dangers of pollution caused by conventional
vehicles, HEVs present an alternative, transitional form of transportation next to purely electric vehicles while
also reaping benefits from both types of vehicles.
As such, the great advancements made in the field has allowed design, production and ownership of such vehicles
much easier now than ever, hence, such technology must be exploited for further use.

13
Bibliography-
1. Fenfang Chena, Rui Huanga, Chongming Wangc, Xiaoli Yua, Huijun Liua,b, Qichao Wua, Keyu Qiana,
Rohit Bhagat, et al. Air and PCM cooling for battery thermal management considering battery cycle
life.
2. Lívia Salles Martins, Lucas Fonseca Guimaraes, Amilton Barbosa Botelho Junior, Jorge Alberto Soares
Tenorio, Denise Crocce Romano Espinosa, Electric car battery: An overview on global demand,
recycling and future approaches towards sustainability.
3. Sebastian Ibarra-Guti´errez, Jocelyn Bouchard, Marcel Laflamme, Konstantinos Fytas, Assessing the
potential of quebec lithium industry: Mineral reserves, lithium-ion batteries production and
greenhouse gas emissions.
4. Golriz Kermani and Elham Sahraei, Review: Characterization and Modeling of the Mechanical
Properties of Lithium-Ion Batteries.
5. F. Zhan , L.J. Jiang, B.R. Wu, Z.H. Xia, X.Y. Wei, G.R. Qin, Characteristics of Ni/MH power batteries
and its application to electric vehicles.
6. Noboru Sato, Kazuhiko Yagi, Thermal behavior analysis of nickel metal hydride batteries for electric
vehicles.
7. Fabio Orecchini, Adriano Santiangeli, Alessandro Dell’Era, EVs and HEVs Using Lithium-Ion
Batteries.
8. M.Fetcenko, J.Koch, M.Zelinsky, Nickel–metal hydride and nickel–zinc batteries for hybrid electric
vehicles and battery electric vehicles.
9. J. Garche, P.T. Moseley, E. Karden, Lead–acid batteries for hybrid electric vehicles and battery
electric vehicle.
10. C. Chumchal, D. Kurzweil, Lead–acid battery operation in micro-hybrid and electrified vehicles.
11. Oi Lun Li, Takahiro Ishizaki, Development, Challenges, and Prospects of Carbon-Based Electrode for
Lithium-Air Batteries.
12. MIT, LITHIUM AIR BATTERIES New catalysts push up lagging efficiency in lightweight batteries
for electric cars.
13. A. H. Castro Neto, The electronic properties of graphene.
14. Gints Kucinskis, Gunars Bajars, Janis Kleperis, Graphene in lithium-ion battery cathode materials: A
review.
15. Juhyung Choi, Aihua Jin, Hyun Dong Jung, Dongjin Ko, Ji Hyun Um, Yoon Jeong Choi, So Hee, Kim,
Seoin Back, Seung-HoYub, Yuanzhe Piaoae, Nitrogen and sulfur co-doped graphene nanoribbons
with well-ordered stepped edges for high-performance potassium-ion battery anodes.
16. Zicong Zhao, Jing Xun, Xin Wan, Ruochuan Yu, MPC Based Hybrid Electric Vehicles Energy
Management Strategy.
17. K.T. Chau, Y.S. Wong, Overview of power management in hybrid electric vehicles.
18. Jim Douglass, Battery management architectures for HEVs.
19. Jimmy Neutron, The Importance of Thermal Management System in electric vehicles.
20. Yan Ma, Hao Ding, Hongyuan Mou, Jinwu Gao, Battery thermal management strategy for electric
vehicles based on nonlinear model predictive control.
21. Bengt Sundén, Thermal management of batteries.
22. Heesung Park, A design of air flow configuration for cooling lithium-ion battery in hybrid electric
vehicles.
23. Seokkan Ki, Jooyoung Lee, Seunggeol Ryu, Soosik Bang, Kichong Kim, Youngsuk Nam, A bio-inspired,
low pressure drop liquid cooling system for high-power IGBT modules for EV/HEV applications.

14
15