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Review Article
Furkan Ahmad1 , Mohammad Saad Alam1, Ibrahim Saad Alsaidan2, Samir M. Shariff3
1Department of Electrical Engineering, Aligarh Muslim University, Aligarh, India
2Department of Electrical Engineering, Qassim University, Buraydah, Kingdom of Saudi Arabia
3Department of Electrical Engineering, Taibah University, Al-Medina, Kingdom of Saudi Arabia
E-mail: furkanahmad@zhcet.ac.in
Abstract: In contemporary days, the research and development enterprises have been focusing to design intelligently the
battery swap station (BSS) architecture having the prospects of providing a consistent platform for the successful installation of
the large-scale fleet of hybrid and electric vehicles (i.e. xEVs). The BSS may calibrate its subsystem for the electric vehicle (EV)
deployment by accomplishing similar idea as in existing gasoline refuelling stations, in which the discharged batteries are being
replaced or swapped by partially or fully charged ones by spending a few minutes. The BSS approach has arisen as a
promising technology to the traditional EV recharging station approach as it provides a broader experience of business
prospects for the specific stakeholders. This work deals with the introduction to BSS including infrastructure, techniques,
benefits over charging station and key challenges associated with BSS. Furthermore, an S34X-smart swapping station for xEVs
is proposed and finally, the key thrust is research for BSS is discussed. To the authors’ knowledge, this is the first kind of review
work on BSS.
underlying power system caused by a massive xEV fleet. Several in the manner such that the car is placed on an elevated platform
works have been focused on multidimensional aspects of an ideal and the batteries are swapped from the bottom using a robotic
BSS deployment, considering both customers, the BSS owner and arm and other accessories generally, placed below the ground
the smart grids. The configuration of a BSS such as number of level.
batteries, chargers, employees and other entities is to be decided in • Top swapping: This is most commonly used for the electric
advance and dependent on the nature of the fleet that the BSS has buses wherein the batteries are placed at the top and upon the
to manage. Since the resource at each end is limited, whether it is arrival of the bus, the rooftop opens and the swapping is
the investment cost of the BSS owner or running cost of a xEV/bus completed by means of the robotic arm.
driver or it may be the burden on the grid system, there should be a
multi-objective optimisation model that assures all these met [30, 3 Functioning of the swapping station
42–45].
Furthermore, Section 2 deals with the different battery To establish and successfully implement the swapping technique
swapping techniques. Section 3 explains the functioning of the for buses, vans, and other cars, extensive planning needs to be done
BSS. In Section 4, BSSs have been explained for public transport, covering all the necessary requirements ranging from the
Sections 5 and 6 give the detail of associated benefits and availability of the batteries, chargers to data storage and
challenges. A BSS model has been proposed in Section 7, and management through cloud and communication between the
further, Section 8 concluded the key finding of the study and components to ensure interoperability. The BSS for the vehicles
suggested some future research interest. will operate successfully provided there is continuous
communication between the different components of the system
2 Different battery swapping techniques viz. the smart vehicle, swapping station, and information system.
The information system will be used to communicate with the
The steps involve for swapping of the battery at BSS is replacing vehicle as well as with the station. The vehicle will communicate
the used battery that has been depleted below its predetermined with the information system through the WAVE communication
state-of-charge (SoC) level from a new and fully charged one to while the station will utilise the local internet for communication.
sustain the electrified transportation. The early 19th century backs When the vehicle's battery is depleted, the information system will
the history of swapping when the interchangeable battery services receive the notification from the vehicle, requesting a battery
were first suggested to overcome the limited range of electric cars, swapping service. The information system will inform the station
trucks etc. [46], in which the exchange process was done by about the location of the vehicle, its expected arrival time and
utilising the manpower. Better Place [47] was the first identifications so that it prepares the battery by the time the vehicle
commercially deployed battery switching service that employed the reaches the station. Once the vehicle reaches the station, the driver
swapping strategy for electric cars. The swapping technique was swipes his membership card and the information system locates all
not implemented for heavy-duty vehicles (buses and trucks) and the relevant data correlated with this card. This data includes
was limited to electric cars only. However, due to high capital information concerning the vehicle, battery, vehicle's swapping
investment for developing charging and swapping infrastructure history, transactions completed and other pertinent information.
and lower market penetration, the company incurred severe Operating personnel will verify this data and direct the customer
financial losses and was eventually liquidated. The battery towards the swapping area where the required battery switching
swapping technique for electric buses was first used commercially will take place by means of a robotic arm. All the data is being
by China in 2008 during the summer Olympics when they switched backed up on cloud storage from where it will be accessible to the
batteries of ∼50 buses operating over different routes [48]. Since authorities as well as customers to ensure complete transparency
then the swapping technique for the buses has been widely within the procedures. Once the swapping is done, the vehicle's
implemented in China, Japan, South Korea, and other countries as battery will be monitored immediately for its state of charge, state
well. The different swapping techniques are discriminated based on of health (SOH), remaining charge, battery age, battery life,
the position of the battery in the vehicle and the point of number of charging and discharging cycles undergone and
application of the robotic arm and are given as follows: accordingly the owner will be informed about the charges incurred
and the estimated time by which he can receive his fully charged
• Sideways swapping: This is mostly employed in case of vans battery. The robotic arms will sequentially place the battery within
and other vehicles where the sideways position is the most the charging racks in which each slot has the capability to charge
convenient. the battery. The electric bus battery pack has a battery management
• Rear swapping: This is utilised for the vehicles in which the system that monitors safety, voltage, and temperature of the
battery is placed from backwards. Usually in the case of cars individual cells for charge safety and balancing. The high voltage
with large boot space. battery connector will be attached manually and only when the
• Bottom swapping: This is used for the vehicles whose battery is connector and the inlet have been sealed the charging begins. The
placed at the bottom of the vehicle. The swapping station is built closed contact between the connector and the inlet will be
safeguarded by means of a latch which will allow the current to power to all the chargers. In the second configuration, we have
flow once the contact is complete. Also, the swapping station has AC–DC converters placed locally at each of the chargers providing
the ability to perform bi-directional power flow with the grid. DC power. Both the configurations are feasible but generally, the
Load curve is improved by the process of charging in off-peak latter one is preferred because it provides the advantage of
hours and injection of power into the grid during peak hours by the operability even if any one of the converters is not in operation
stored batteries. This process eventually increases the overall state. Also, the centralised AC–DC converter will be a very large
efficiency of power systems. To generate revenue from its one in terms of size, weight, and cost which might raise issues
charging/supplying patterns, the swapping station will supply when during installation.
the demand is high (high price) and borrow when the demand is As shown in Fig. 2, any power distribution substation (1) can
low (low price), this scheduling of power will also be a substantial also be monitored by said BSS control room (2). The said control
factor when considering the economic feasibility of the swapping room (2) can control and/or regulate and/or monitor the overall
stations. functioning of the said BSS. The said charging racks (3) equipped
Distribution transformer, AC–DC converters, battery chargers, with any slow and/or fast charging methods capable EVSEs
vehicle batteries, robotic arms, charging racks, maintenance coupled with the said battery racks (4). The said swapping track (5)
systems, and control systems are the chief components of a BSS can facilitate any logistics and/or safety check and/or manual
along with other equipment necessary for swapping and charging and/or automatic unscrewing and/or screwing the battery of any
of batteries. There exist two possible locations for the converters in xEV. The said swapping lane (6) can be any stationary and/or
the BSS. In the first one, we have a central AC–DC converter moving lane from the entry point to the exit point of the said BSS.
connected directly to the distribution transformer, providing DC The said swapping robot (7) can facilitate any xEV discharged
6.2 Feasibility
The battery design is currently posing as the highest hurdle of
battery swapping technology. The design of the battery should
incorporate robustness in removing and re-installing it from the
vehicle. In India, only a few vehicles are presently offering such
battery pack designs. For example, Hero Maxi allows discharged
Fig. 3 Challenges of BSS battery to be swapped easily with a charged battery and the
discharged battery can be put to charging separately [54, 57, 58].
6.3 Infrastructure
The infrastructure required for the battery packs is immense and
much more complex and expensive than charging. BSSs in
comparison with charging stations exert the same magnitude of
demand with the prime requirement of charging the battery packs.
The sole difference is that the demand of the former can be
controlled (even in a practical scenario, the battery packs should
always be available for consecutive incoming customers and hence
should offer charging time accordingly). Furthermore, to fulfil the
daily requirement of any station, the stacked quantum of charged
battery packs should always exceed by a certain percentage of
daily demand. So, the feasible strategy is to keep one battery pack
Fig. 4 S34X-smart swapping station for xEVs
within the vehicle and another at swapping station, i.e. two battery
packs for every car. Even after sorting all this out it still seems a
5.2 Power system benefits distant future, as the economics of a nationwide battery swapping
system is not speaking in favour when compared with a nationwide
With a rapidly growing EV market the need for fast chargers can car charging system [1, 59].
become the prime concern of consumers. To keep with the
advancements in technology they will be required to upgrade to the 6.4 Battery degradation
latest available charger to satisfy their daily energy needs. In this
aspect, BSSs are obviously superior to the traditional charging The maximum battery charge range is negatively affected by the
infrastructures as the upgrade is only needed at the BSS site degradation of its performance over time. Hence the new battery
whereas in the traditional framework the upgrade is to be made on packs will be more favoured by customers over the option of other
both sides, i.e. at the household level and also at the charging relatively old battery packs as they will offer low energy storage
station. Furthermore, as the system is a pack of batteries, it can due to degradation over time and this will reflect in the mileage of
inject power back into the grid, smoothing the net daily demand EVs. Hence the content of customers will lie only in new battery
curve and can provide services to the system as a whole. This very packs, which considerably, will reduce the operating cycle of any
feature of the proposed BSS apart from being a storage device battery pack [59].
offers additional benefits such as frequency regulation, load
following, and voluntary reserve provisions [56]. 6.5 Battery ownership
The vehicle owner owns the battery: in this case, the owner will
6 BSS challenges have to purchase an additional battery pack that can be used as a
Let us talk about battery swapping; the main benefit associated replacement battery when the battery in the vehicle gets
with the swapping model is speed. The whole operation could take discharged, which is very less likely to happen!
less than five minutes, pretty much the same amount of time many The ownership over a battery pack will always be null for a
people spend filling their gas tanks at stations today. Another plus vehicle owner. This offers several advantages. Since the vehicle
point is that people need not have to leave their vehicle or deal with owner does not own it he does not have to pay for it, which makes
potentially tangled or dirty cords. You could sit in your vehicle EV cheaper. On the contrary, he is never getting the swapped
while the operation takes place. However, the picture is more battery back and has to pay an additional lease amount besides the
complex than this, and below the challenges associated with BSS cost of energy. This can be charged on each swapping or any other
have been shown in Fig. 3. Furthermore, it has been explained in mutually agreed frequency, say one month. The later method of
detail in [57]. lease amount is costly considering the least amount is inclusive of
minimum two battery packs and service charge of swapping station
6.1 Interchangeability (whereas only one battery is bought if the vehicle is charged and
has one owned battery). The lease-on-each-swap option is, even
Brand compatibility and cross-platform features promise the more, costlier (as swapping stations will be at an elevated level of
success of technology and make it a dominant trend of the market. investment risks) and will bend customers for less usage of
The availability of similar interchangeable battery packs of swapping stations to avoid these excessive charges, especially
different manufacturers is the only hope of a battery swapping when a charging option is available [60].
system to stand firm as a primary option. This simple solution is
dependent on the manufacturer's consent. However, this might limit 7 Proposed BSS architecture (S34X)
the innovation, uniqueness, and flexibility of products designed
exclusively by any manufacturer. Moreover, it will also limit The S34X (smart swapping station for xEVs) architecture proposed
product development as cell manufacturers, residing at the top of in this work (Fig. 4) is a cloud-integrated big-data driven model
the product chain, will have to design standardised cells to provide battery swapping. The whole architecture can be broadly delineated
similar cells to next level manufacturing entity, only through which into three modules, each having a number of sub-modules having
further standardisation can be produced. One can argue that there distinctive functionalities. The three major actors in the S34X