Smart Factory: Prospect of Future

Automotive Technology

Battery Technology

Marojahan Tampubolon, Ph.D.

Marojahan.Tampubolon@umn.ac.id
Electrical Engineering Department
Universitas Multimedia Nusantara
 Outline
• Background of Battery Developments
• Batteries Working Principle
• Type of Batteries
• Battery Parameters
• Battery Modeling
• Battery Packaging
• Battery Management System
• Charging Technology
• Electric Vehicle EV Battery Infrastructure

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BATTERY MODELING

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 Battery Modeling
• Battery models have become an indispensable tool for the
design of battery-powered systems. Their uses include battery
characterization, state-of-charge (SOC) and state-of-health
(SOH) estimation, algorithm development, system-level
optimization, and real-time simulation for battery
management system design.
• There are many strategies for battery modeling such as
electrochemical model, mathematical models, circuit-oriented
models, black box modelling, and grey box modeling.

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 Battery Modeling
• Why do we need battery modeling
1. Development of efficient BMS.
2. Key in the improvement of charging/discharging techniques and the
enhancement of battery capacity.
3. Need to capture the influence of power consumption on the battery.
4. To prevent serious damage to batteries from overcharging or over-
discharging.
5. Faster and safer way to study battery behaviour under different
operating conditions.
6. Identifying the operating limits that achieve best lifetime for specific
applications.

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 Battery Modeling
• Electrochemical Modelling of a Battery
– Based on electrochemical reactions that take place in the electrodes
and the electrolyte deployed
– The effect of the various electrochemical reactions taking place in
the cell on the cell potential are written in the form of a set of partial
differential equations.
– Advantages: Very Accurate
– Disadvantage: without any simplification, models of this complexity
can only be solved using powerful computational tools and methods
such as Computational Fluid Dynamics (CFD) frameworks

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 Battery Modeling
• Some well-known Electrochemical Modelling
𝐾1
– Shepherd model: 𝑦𝑘 = 𝐸0 − 𝑅. 𝑖𝑘 −
𝑥𝑘
– Unnewehr universal model: 𝑦𝑘 = 𝐸0 − 𝑅. 𝑖𝑘 − 𝐾2 𝑥𝑘
– Nernst model: 𝑦𝑘 = 𝐸0 − 𝑅. 𝑖𝑘 + 𝐾3 . ln(𝑥𝑘 ) + 𝐾4 . ln(1 − 𝑥𝑘 )
𝑲𝟏
𝒙𝒌
𝐚𝐧𝐝 𝑲𝟐 𝒙𝒌 Reflect the polarization
𝑦𝑘 : Battery output voltage resistance of the battery
𝐸0 : Cell Potential 𝑲𝟑 . 𝒍𝒏(𝒙𝒌 ) and 𝑲𝟒 . 𝒍𝒏(𝟏 − 𝒙𝒌 ) reflect the
𝑅 : Internal Resistance influence of the internal temperature and
𝑥𝑘 : Number of the state vector present in the system material activity during the electrochemical
reaction of the
Battery.
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 Battery Modeling
• Mathematical Modelling of a Battery
– This model based on Shepherd discharge model
– Mainly develop to predict system-level behavior by using the
Empirical equations or math-based stochastic models
– Only evaluate the charge recovery effect and ignores all other
factors
– The use of mathematical model is very low because the relation with
the parameters of the model and I-V characteristics is not sufficient

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 Battery Modeling
• Circuit-Oriented Modelling of a Battery
– Circuit-Oriented Models (COM) are electrical equivalent models
– COM are most suitable to represent the features of the battery
– COM subclass: Simple models, Thevenin-based models, impedance-
based models, runtime-based models and combined models
• Simple models are resistance models that use an ideal voltage source and an
internal resistance to represent the battery and they do not take into account
charging/discharging rates, SoC and nonlinear effects.

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 Battery Modeling
– Impedance-based models: parameters are determined using a
complicated Electrochemical Impedance Spectroscopy (EIS)
method. It provides a good description of its internal behaviour.
– The runtime-based models use coupled electrical networks and
look-up tables to determine SoC, battery runtime, cell voltage and
thermal characteristics. This method simulate the battery lifetime
and voltage during the continuous current discharge process with
reasonable accuracy, but they could not present good results when
simulating variable current discharges due to their low precision
modelling of transient battery characteristics.
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 Battery Modeling
• Thevenin models provide the transient responses of the battery
using resistor capacitor (RC) networks and these models are
usually able to capture two time dependent effects, depletion and
recovery
– This model mimic the transient and steady-state behaviour of the battery.
– SoC is determined using the coulomb counting procedure or extended
Kalman filter (EKF)
– Circuit parameters are obtained by either (a) the battery’s time response
using pulse discharge test, (b) by looking at the instantaneous voltage
drop, the time constants of the charge depletion and recovery regions and
the current, (c) the least square method, etc.
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Battery Modeling using RC network
OCV-SOC characteristic for LiFePO4 battery cell

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 Thevenin-based modelling
•

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 Thevenin-based modelling

PNGV: partnership new generation of vehicles

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 Thevenin-based modelling

GNL: General non linear

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BATTERY PACKAGING

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 Battery Packaging
Things to consider for battery packaging:

• Mechanical : Integrated to existing vehicle crash structure

• Electronic control: Integrated with the vehicle control module
• Thermal: Safety consideration

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 Battery Packaging
• Mechanical
– Should be safe in the even of crashes and during the normal vehicle
use and vibration
– Location of battery should consider the existing design. Make a new
design will add more cost and might add more weigh, volume, and
burden to the package.
– Example: Placing battery outside the passenger zone require
structural reinforcement this also will effect the package design of
battery.

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 Nissan leaf structural design

Hyundai Ionic 5 EV structure

https://www.greencarcongress.com/2021/05/20210525-ioniq5.html

Source:Allan Miller, uploaded to researchgate.net Prospect of Future Automotive Technology

 Battery Packaging
• Electrical
– Electronic control assists the battery pack in providing the required propulsion
power while maintaining the battery within the normal operating condition
– Commonly, a battery pack consists of cells string. The voltage can be vary
depend on the design.
– Lead acid battery traditionally set at 12V, power auxiliary load such as lights,
alarm system, and radio.
– Packs typically also contain manual service disconnects (MSDs) to electronically
disable a pack in the event of a malfunction or maintenance.
– Low voltage battery packs (≤ 50𝑉) are typically grounded to the vehicle
chassis, whereas high voltage battery packs (≥ 50𝑉) requires electrical isolation
– Pack/module/cell voltages and current are measured and controlled by the
battery management system (BMS)

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 Battery Packaging
• Thermal
– To keep the temperature within a normal operating range.
– Most of the chemical matter achieve desirable balance of available
energy and power in the range of 10-40 oC.
– Existing cooling system can be used to share the airflow to the
battery pack. But it is difficult to communize it because of the
temperature difference between the set temperature and the
battery pack.
– Type of cooling system: Passive air, active air, liquid temperature
control.

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 Battery Packaging
• Battery Sizing
– To determine the size a battery some parameters should be
considered first.
• Drive Cycles: Regulated by government.
• Power: Need to consider cold cranking (the ability of the battery to start the
motor at low temperature) and also all the total electric load in a normal
condition.
• Electric Range
• Voltage/Capacity

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• International Drive Cycle

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Lithium-ion containing PHEVs

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Lithium-ion containing PHEVs

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Lithium-ion containing HEVs

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 Activities
1. Battery Management System
– Purpose, features, example available in the market

2. EV Charging Technology
– Charging components /parts
– Charging method (explain the advantages and disadvantages)
+
3. Electric Vehicle EV Battery Infrastructure
– Standard (type of connector), Infrastructure for EV charging and in the
future.
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BATTERY MANAGEMENT SYSTEM

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 Typical Battery Management System

Source:
https://www.cyient.com/bl
og/battery-management-
system-in-electric-vehicles

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 Battery Management System
• Function:
– Monitors the state of a cell as represented by parameters such as:
• Voltage—indicates a cell’s total voltage, the battery’s combined voltage, maximum and
minimum cell voltages, and so on.
• Temperature—displays the average cell temperature, coolant intake and output
temperatures, and the overall battery temperature.
• The state of charge of the cell to show the battery’s charge level.
• The cell’s state of health—shows the remaining battery capacity as a percentage of the
original capacity.
• The cell’s state of power——shows the amount of power available for a certain duration
given the current usage, temperature, and other factors.
• The cell’s state of safety——determined by keeping a collective eye on all the parameters
and determining if using the cell poses any danger.
• The flow of coolant and its speed.
• The flow of current into and out of the cell.

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 Battery Management System
• Managing thermal temperatures
– The battery’s thermal management system keeps an eye on and
controls the temperature of the battery.
– These systems can either be passive or active, and the cooling
medium can either be a non-corrosive liquid, air, or some form of
phase change.
– Using air as a coolant is the simplest way to control battery
temperatures.

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 Battery Management System
• Making key calculation
– A BMS calculates various battery values based on parameters such as
maximum charge and discharge current to determine the cell’s charge
and the discharge current limits. These include:
• The energy in kilowatt-hour(s) (kWh) delivered since the last charge cycle
• The internal impedance of a battery to measure the cell’s open-circuit voltage
• Charge in Ampere per hour (Ah) delivered or contained in a cell (called the Coulomb
counter), to determine the cell’s efficiency
• Total energy delivered and operating time since the battery started being used
• Total number of charging-discharging cycles the battery has gone through

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 Battery Management System
• Facilitating internal and external communication
– A BMS has controllers that communicate internally with the
hardware at a cellular level and externally with connected devices
• Different types of serial communications
• CAN bus communicators, often used in vehicles
• DC-BUS communications, which are serial communications over power lines
• Various types of wireless communication including radio, pagers, cellphones,
and so on

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Battery Management System

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 EV Charging Technology
• Plugin Charging
– Use a charging cord from the
charging station to vehicle.
• Wireless charging
– Use either inductive power
transfer or capacitive power
transfer to transfer the power

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Charging Profile of a Lithium Battery

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 Electric Vehicle EV Battery Infrastructure
• Static Battery Charging
• Battery Swap
• Dynamic Battery Charging

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 References
1. Albert N. Link; Alan C. O’ Cornnor; Troy J. Scott., Battery Technology for Electric
Vehicles,London & New York: Routledge, Taylor & Francis Group, 2015
2. Marc A. Rosen; Aida Farsi, Battery Technology: From Fundamentals to Thermal Behavior
and Management, first edition, USA & UK: Academic Press, 2023.
3. Shunli Wang, Battery State Estimation: Methods and models, UK: IET, 2021
4. Tamilselvi, S.;Gunasundari, S.; Karuppiah, N.;Razak RK, A.; Madhusudan, S.;Nagarajan, V.M.; Sathish, T.;
Shamim,M.Z.M.; Saleel, C.A.; Afzal, A. A Review on Battery Modelling Techniques. Sustainability 2021, 13,
10042. https://doi.org/10.3390/su131810042

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