Module 2 - 20210223 v3.7 Battery

INTRODUCTION - ROBIN FOSTER
• Battery Solutions Lead at HSSMI
• Meng Chemical Engineering at Heriot

Watt University
• 5 Years in Lithium Ion Cell

Manufacturing
• 3 Years with HSSMI supporting Cell

and Battery manufacturing and circular
economy approaches to electrification
2
HSSMI – Our work across the battery value chain
Lithium Ion Battery Pack Fundamentals
ROBIN FOSTER
How Big Is Battery Pack Life after
Testing
My Pack? Construction Vehicle
How Big Is My Battery Pack Life after
Testing
Pack? Construction Vehicle
How Big is Does My Pack Have to Be?
400V 36V 1000V

25kW Sustained 200W Sustained 200kW Sustained
5 Hours 8 Hours
http://www.evwest.com/catalog/index.php?cPath=8
/https://www.e-bikeshop.co.uk/Gepida-Miliare-Folding-Bosch-Electric-Bike
https://www.citiesdigest.com/2017/03/02/50-mw-grid-energy-storage-facilities-build-uk/
Some Maths…
Power
Some Maths…
Power
𝐸𝑛𝑒𝑟𝑔𝑦 (J)
𝑃𝑜𝑤𝑒𝑟 (𝑊) = 𝑃𝑜𝑤𝑒𝑟 (𝑊) = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡(𝐴)
𝑇𝑖𝑚𝑒 (𝑠)
Some Maths…
Power
𝑃𝑜𝑤𝑒𝑟 (𝑊) = 𝑃𝑜𝑤𝑒𝑟 (𝑊) = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡(𝐴)
So what is watt hours and kWh??

𝐸𝑛𝑒𝑟𝑔𝑦 (J) 𝐸𝑛𝑒𝑟𝑔𝑦 (J)
𝑃𝑜𝑤𝑒𝑟 𝑊 = → × 𝑇𝑖𝑚𝑒 ℎ𝑜𝑢𝑟 = 𝐸𝑛𝑒𝑟𝑔𝑦
𝑇𝑖𝑚𝑒 𝑠 𝑇𝑖𝑚𝑒 ℎ𝑜𝑢𝑟
Some Maths…
3.7V
3400mAh ()
Ampere Hour is measure of “Electric Charge”
3.4A for 60 mins → 3.4A x 1 Hour = 3.4Ah = 3400mAh
C Rate of 1C
6.8A for 30 mins → 6.8A x 0.5 Hours = 3.4Ah = 3400mAh
C Rate of 2C
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 = 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶ℎ𝑎𝑟𝑔𝑒 × 𝐶 − 𝑅𝑎𝑡𝑒
https://www.batteryjunction.com/panasonic-ncr18650b-3400.html /
Some Maths…
3.7V
3400mAh (milli-Ampere-Hour)
𝑃𝑜𝑤𝑒𝑟 𝑊 = = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡(𝐴)
𝑇𝑖𝑚𝑒 𝑠
𝐸𝑛𝑒𝑟𝑔𝑦 (𝐽)
→ 𝐸𝑛𝑒𝑟𝑔𝑦 𝑊ℎ = × 𝑇𝑖𝑚𝑒 (𝑠)
𝑃𝑜𝑤𝑒𝑟 (𝑊) = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡(𝐴)
→ 𝐸𝑛𝑒𝑟𝑔𝑦 𝑊ℎ = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 × 𝑇𝑖𝑚𝑒 ℎ = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶ℎ𝑎𝑟𝑔𝑒 (𝐴ℎ)
https://www.batteryjunction.com/panasonic-ncr18650b-3400.html /
Specifying a Battery Pack - Voltage
3.5V
0.9V
3.5V
0.9V 0.9V 0.9V

0.9V
0.9V+0.9V+0.9V+0.9V = 3.6V
SERIES – SUM VOLTAGES
0.9V 0.9V 0.9V 0.9V

Capacity (AH)
Voltage (V)
Capacity (Ah)
Voltage (V)
Bigger ”Engine” same ”Fuel Tank”

Specifying a Battery Pack - Capacity
PARALLEL – SUM CAPACITIES

4AH
Capacity
3AH
2AH
1AH
0AH
0V 0.9V 1.8V 2.7V 3.6V
Voltage
How Big Does My Pack Have to Be?
400V 36V 1000V

25kW Sustained 200W Sustained 200kW Sustained
5 Hours 8 Hours
http://www.evwest.com/catalog/index.php?cPath=8
/https://www.e-bikeshop.co.uk/Gepida-Miliare-Folding-Bosch-Electric-Bike
https://www.citiesdigest.com/2017/03/02/50-mw-grid-energy-storage-facilities-build-uk/
36V 1000V
400V 200W Sustained 200kW Sustained
25kW Sustained 8 Hours ?
5 Hours
Question 2 Question 3
Question 1
Cell B Cell C
Cell A
Voltage: 4.1V Voltage: 3.9V

Voltage: 3.7V
Weight: 138g Weight 380G
Weight: 150g
”Capacity”: 2.6Ah ”Capacity”: 20Ah
”Capacity”: 2.9Ah
What configuration do I If the a battery pack contains 5 parallel

What configuration do I
need? And what current modules of 257 cells, how long will the
need? And what current
do I run at? battery last?
do I run at?
400V Look at Voltage First
25kW Sustained
5 Hours 400𝑉 ÷ 3.7𝑉 = 109 𝐶𝑒𝑙𝑙𝑠
Question 1
Cell A
Voltage: 3.7V
Weight: 150g
do I run at?
25kW Sustained
5 Hours 400𝑉 ÷ 3.7𝑉 = 109 𝐶𝑒𝑙𝑙𝑠
Question 1
Cell A
Now consider Capacity
Voltage: 3.7V
Weight: 150g
”Capacity”: 2.9Ah 5 𝐻𝑜𝑢𝑟𝑠 × 25𝑘𝑊 = 125𝑘𝑊ℎ For Pack
What configuration do I 2.9 𝐴ℎ × 403𝑉 = 1168 𝑊ℎ For Series Module

do I run at?
125 𝑘𝑊ℎ
= 107 𝑃𝑎𝑟𝑎𝑙𝑙𝑒𝑙 𝑆𝑒𝑟𝑖𝑒𝑠 𝑀𝑜𝑑𝑢𝑙𝑒𝑠
1168 𝑊ℎ
400V Finally the Current is Calculated
25kW Sustained
5 Hours
Question 1
Cell A
Voltage: 3.7V 𝑃𝑜𝑤𝑒𝑟 (𝑊)

Weight: 150g → 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 =
𝑉𝑜𝑙𝑡𝑎𝑔𝑒 (𝑉)
do I run at?
25𝑘𝑊
→ 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 62.5𝐴
400𝑉
36V 1000V
5 Hours
Question 1
Cell B Cell C
Cell A

Voltage: 3.7V
Weight: 150g

do I run at?
200W Sustained
8 Hours 36𝑉 ÷ 4.1𝑉 = 8.8 ~ 9 𝐶𝑒𝑙𝑙𝑠
Question 2
Cell B
Voltage: 4.1V
Weight: 138g
do I run at?
200W Sustained
8 Hours 36𝑉 ÷ 4.1𝑉 = 8.8 ~ 9 𝐶𝑒𝑙𝑙𝑠
Question 2
Cell B
Voltage: 4.1V
Weight: 138g
”Capacity”: 2.6Ah 8 𝐻𝑜𝑢𝑟𝑠 × 200𝑊 = 1.6𝑘𝑊ℎ For Pack
What configuration do I 2.6 𝐴ℎ × 36.9𝑉 = 95.94 𝑊ℎ For Series Module

do I run at?
1.6 𝑘𝑊ℎ
0.0959 𝑊ℎ
36V Finally the Current is Calculated
200W Sustained
8 Hours
Question 2
Cell B

Weight: 138g → 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 =
do I run at?
200𝑊
→ 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 5.6𝐴
36𝑉
36V 1000V
5 Hours
Question 1
Cell B Cell C
Cell A

Voltage: 3.7V
Weight: 150g

do I run at?
200kW Sustained
? 1000𝑉 ÷ 3.9𝑉 = 257 𝐶𝑒𝑙𝑙𝑠
Question 3
Cell C
Voltage: 3.9V
Weight 380G
”Capacity”: 20Ah
If the a battery pack

contains 5 parallel
modules of 257 cells, how
long will the battery last?
200kW Sustained
? 1000𝑉 ÷ 3.9𝑉 = 257 𝐶𝑒𝑙𝑙𝑠
Question 3
Cell C
Voltage: 3.9V
Weight 380G
”Capacity”: 20Ah X 𝐻𝑜𝑢𝑟𝑠 × 200𝑘𝑊 = 200𝑋 𝑘𝑊ℎ For Pack
If the a battery pack 20 𝐴ℎ × 1002.3𝑉 = 20 𝑘𝑊ℎ For Series Module

contains 5 parallel
long will the battery last? 200𝑋 𝑘𝑊ℎ
20 𝑘𝑊ℎ
𝑋 = 0.5 𝐻𝑜𝑢𝑟𝑠
1000V Can the Cells Handle it??
200kW Sustained
?
Question 3
Cell C
Voltage: 3.9V
Weight 380G

contains 5 parallel
1000V Can the Cells Handle it?? Assume cell can handle 1C
200kW Sustained
?
Question 3
Cell C

Weight 380G → 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 =

contains 5 parallel
200 𝑘𝑊
long will the battery last? → 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 200𝐴
1000𝑉
200kW Sustained
200 𝑘𝑊
? 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 200𝐴
1000𝑉
Question 3
Current in each series string
Cell C
200 𝐴
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 40𝐴
Voltage: 3.9V 5
Weight 380G

contains 5 parallel
200kW Sustained
200 𝑘𝑊
? 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 200𝐴
1000𝑉
Question 3
Current in each series string
Cell C
200 𝐴
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 = = 40𝐴
Voltage: 3.9V 5
Weight 380G
”Capacity”: 20Ah Now calculate C-Rate
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 = 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶ℎ𝑎𝑟𝑔𝑒 × 𝐶 − 𝑅𝑎𝑡𝑒
contains 5 parallel
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 40𝐴
→ 𝐶 − 𝑅𝑎𝑡𝑒 = = = 2𝐶
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶ℎ𝑎𝑟𝑔𝑒 20𝐴ℎ
A Few Notes on Modules
Parallel
Series
Parallel
Series
9s
Module
Parallel
Series
5s 2p
Module
Parallel
Series
5s 2p
Module
Module Handling
- Voltage
- Weight
How Big Is My Battery Pack Life after
Testing
Pack? Construction Vehicle
Testing
Where does the battery sit within the
powertrain? Battery Battery
Monitoring Management
CHARGING POINT
DC/AC
Electric Inverter DC/DC High Voltage AC/DC Converter
Motor (Motor Converter Battery Pack (Charger)
Control)
DC/DC
Converter
12V Electronics
Components
• Cell Stack/Modules
• BMS/CMUs
• Monitoring and Control System
• Fuses
• Limits current of pack under a short circuit
• Service Disconnect
• Electrically Isolates High Voltage Terminals Once Removed
• Relays and Contactors
• Control Output power to External Connections
• Normally “open”
• Typically 2 between Cell Stack and Outputs

Building a Battery Pack – Cell and Welding
Building a Battery Pack – Cooling
Building a Battery Pack - Cooling
Building a Battery Pack – Temperature Sensor
Building a Battery Pack – End Plate
Building a Battery Pack – CMU Housing
Building a Battery Pack – CMU
Building a Battery Pack – Module to Pack Housing
Building a Battery Pack – Introduction of BMS
Building a Battery Pack – Module Interconnects
Building a Battery Pack – Module Connected
Building a Battery Pack – Parallel Strings
Connected
Building a Battery Pack – Battery Pack Sealed
Roles of the Battery Management System
● 3 Objectives
• Protect Cells/Battery from damaging itself
• Prolong the life of the battery
• Meet function requirements of application
● Functions
• Cell Protection – out of tolerance conditions
• Charge Control
• Determine State of Charge/ Depth of Discharge
• Determine State of Health
• Cell Balancing
• Data Log
• Communications
Testing
Testing
Battery Pack Testing
• Specific to Product
• Level of testing – Money Dependant
• No Faults Forward
Cell Level Assembly Load/Cycle

Testing Testing Testing
BATTERY TESTS – AVAILABLE METHODS
Inline Testing Methods

Test Type Description Application
Cycle Testing Charge and Discharge of cell/module/pack.
Cell (after formtion), Module and Pack
(Load Testing) Determines capacity and confirms basic operation.
Utilises out put from cycle test. Difference between
Coulomic
charge and discharge curves. Determines Cell Testing (after formation)
Efficiency Test
efficiency of cell.
Standardized test. ~100mA and 1kHz signal on cell
AC - Internal
to determine "power response". Monitors phase Cell Testing (after formation), incoming
Resisitance
shift in voltage response. EIS is a more AC cells to module line, can test batteries
(Impedance)
impedance test.
Voltage change measured while (negative or
DC - Internal
positive) current pulse applied to cell. Impedance Cell Testing (after formation), incoming
Resisitance
calculate (dV/I). Large current needed for sufficient cells to module line, can test batteries
(Pulse Testing)
voltage change.
Measures the unloaded voltage of a cell or pack.
Open Circuit
Check expected voltage. Monitor over time to Cell (after formation), Module and Pack
Voltage (OCV)
determine self discharge.
Used to check for shorts in cell - foreign objects,
Insulation Test -
damaged separator, damaged electrode, etc. Also Cell (after formation), Module and Pack
Hi Pot
used on HV systems.
Checks for current leak after cell sealing (tag to
Insulation Test -
bag). Also used to check module busbar Cell (after formation), Module and Pack
Resistance Test 62
connections.
Cell Testing
• Determine if Cells meet
Manufacturers specification
sheet
• Grading
• Eliminate Faulty Cells
• Costly if fitted in to module
• Time Consuming Process
• Cycle Testing
• EIS Testing
• Expensive Test Equipment
• Important Supplier Relationship

BATTERY TESTING – OUTGOING/ INCOMING CELLS
https://www.youtube.com/watch?v=FHAJRouE2Hg 64
•
Assembly Testing Types of Joining Methods
•
Assembly Testing Types of Joining Methods
• Mechanical Compression
• Laser Welding
• Ultrasonic Welding
• Mechanical Threaded
• Resistance Welding
• Qualifying Joining Methods

• Physical
• Pull Tests
• Vibration
• Electrical
• Continuity Tests
• Current/Voltage/Temp LV
• HV if required
• Inline and Offline Testing

• Automated End of Line Test
Assembly Testing • Quick charge, Quick discharge
• BMS Functioning, allows
charge
• Short circuit
• System recognises short and
reacts rapidly
• Quick charge, Quick discharge
• Checks short circuit test hasn’t
damaged pack
• Data interrogation
• Additional Testing
• Waterproofing
• Thermal Imaging
Cycle Testing
• Most Important
Qualification Test
• Generally a Catch All
• Gives best indication

of performance
• Cycle life – Number of

charge/discharge
cycles before capacity
drops below 80%
• Time Consuming
http://batteryblog.ca/2013/07/lithium-ion-life-cycle-test//
Load Testing
• Verify Operational
Requirements are
met
• Constant or Pulsed
Loads
• Simulated Drive
Cycles
https://www.mpoweruk.com/testing.htm
How Big Is Battery Pack Life After
Testing
Testing
Batteries put in the market by application
Source: Hans Eric Mellin, Baseline report commissioned by GBA,

2018
Batteries reaching EoL vs available for recycling
In 2025
40,000 London buses every year
”
”
”
Source: Hans Eric Mellin, Baseline report commissioned by GBA,

2018
Directives and Regulations
EU Directives Regulations
• Most common form of EU legal act • Binding legislative acts
• Do not apply directly at the national level • Self-executing, do not require any
• Set out an objective to be achieved, then implementing measures
left to the individual countries to achieve • Automatically come into force on a set
this objective however they best see fit date
• Have a deadline by which all countries
must transpose it into their national
legislation
Transposition
• Translates an EU directive into national legislation
(normally regulations in the UK)
● EU Directives are transposed into UK Law by Regulations

75
Key Legislation
Extended Producer Responsibility
Packaging ELV
Directive Directive
Waste
Battery
Framework
Transport
Directive
Batteries WEEE
Directive Directive
76
Key Legislation
Packaging ELV
Directive Directive
Waste
Battery
Framework
Transport
Directive
Batteries WEEE
Directive Directive
77
Key Legislation
Packaging ELV
Directive Directive
Waste
Battery
Framework
Transport
Directive
Batteries WEEE
Directive Directive
78
Current state: Remanufacturing in the automotive sector
Before After
Courtesy of MCT Reman

Current state: Remanufacturing in the automotive sector
Repair Refurbish/Recondition Remanufacture

• Acceptable state • Good functional state • As good as new (or better)
• Isolated fix • Module level • Complete overhaul of all parts
2 different models
Current - Linear Future - Circular
Cell and Pack

2nd life facilities
Material processor
Car Assembly
ATFs
How do we do it?
● Enablers
● Competitive manufacturing
● Design for Disassembly
● Efficient recycling methods
● Rapid battery performance

testing
● Design for second life

Current Linear Battery Value Chain
CHEMICAL BATTERY VEHICLE AUTHORISED BATTERY

MINING PROCESSING MANUFACTURE MANUFACTURE TREATMENT RECYCLING
FACILTY
CHEMICAL BATTERY VEHICLE
MINING PROCESSING MANUFACTURE MANUFACTURE
Circular Battery AUTHORISED

TREATMENT
Value Chain FACILTY
REPAIR
BATTERY REPURPOSE
/REMANUFACTURE
RECYCLING
So what else?
● Enablers ● Future investment

● Automated High Voltage
● Vehicle/Battery data to ATFs component disassembly robots
● Design for Disassembly – at ● National Qualification for High

vehicle level Voltage handling
● Transportation solutions ● Encourage consistent

throughput to recyclers
● Training for ATF/ rework staff
● Standards for battery design
● Informed insurance companies
○ Lifting points
○ labelling
Current state: processing EV batteries in the UK
(HSSMI, 2019)
Second life opportunities by automakers
Testing
QUESTIONS
89
GET IN TOUCH
robin.foster@hssmi.org
Follow us
www.hssmi.org hssmi @hssmi

Module 2 - 20210223 v3.7 Battery

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Module 2 - 20210223 v3.7 Battery

Uploaded by

Copyright:

Available Formats

INTRODUCTION - ROBIN FOSTER

• Battery Solutions Lead at HSSMI

• Meng Chemical Engineering at Heriot

• 5 Years in Lithium Ion Cell

• 3 Years with HSSMI supporting Cell

400V 36V 1000V

So what is watt hours and kWh??

Ampere Hour is measure of “Electric Charge”

3.4A for 60 mins → 3.4A x 1 Hour = 3.4Ah = 3400mAh

6.8A for 30 mins → 6.8A x 0.5 Hours = 3.4Ah = 3400mAh

𝐶𝑢𝑟𝑟𝑒𝑛𝑡 = 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶ℎ𝑎𝑟𝑔𝑒 × 𝐶 − 𝑅𝑎𝑡𝑒

𝑃𝑜𝑤𝑒𝑟 (𝑊) = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡(𝐴)

→ 𝐸𝑛𝑒𝑟𝑔𝑦 𝑊ℎ = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐴 × 𝑇𝑖𝑚𝑒 ℎ = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉 × 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐶ℎ𝑎𝑟𝑔𝑒 (𝐴ℎ)

0.9V 0.9V 0.9V

SERIES – SUM VOLTAGES

0.9V 0.9V 0.9V 0.9V

Bigger ”Engine” same ”Fuel Tank”

PARALLEL – SUM CAPACITIES

400V 36V 1000V

Voltage: 4.1V Voltage: 3.9V

What configuration do I If the a battery pack contains 5 parallel

What configuration do I 2.9 𝐴ℎ × 403𝑉 = 1168 𝑊ℎ For Series Module

Voltage: 3.7V 𝑃𝑜𝑤𝑒𝑟 (𝑊)

Voltage: 4.1V Voltage: 3.9V

What configuration do I If the a battery pack contains 5 parallel

What configuration do I 2.6 𝐴ℎ × 36.9𝑉 = 95.94 𝑊ℎ For Series Module

Voltage: 4.1V 𝑃𝑜𝑤𝑒𝑟 (𝑊)

Voltage: 4.1V Voltage: 3.9V

What configuration do I If the a battery pack contains 5 parallel

If the a battery pack

If the a battery pack 20 𝐴ℎ × 1002.3𝑉 = 20 𝑘𝑊ℎ For Series Module

If the a battery pack

Voltage: 3.9V 𝑃𝑜𝑤𝑒𝑟 (𝑊)

If the a battery pack

If the a battery pack

• Typically 2 between Cell Stack and Outputs

• Level of testing – Money Dependant

Cell Level Assembly Load/Cycle

Inline Testing Methods

• Eliminate Faulty Cells

• Costly if fitted in to module

• Time Consuming Process

• Expensive Test Equipment

• Important Supplier Relationship

• Qualifying Joining Methods

• Inline and Offline Testing

• Gives best indication

• Cycle life – Number of

Source: Hans Eric Mellin, Baseline report commissioned by GBA,

Source: Hans Eric Mellin, Baseline report commissioned by GBA,

● EU Directives are transposed into UK Law by Regulations

Extended Producer Responsibility

Extended Producer Responsibility

Extended Producer Responsibility

Courtesy of MCT Reman

Repair Refurbish/Recondition Remanufacture

Cell and Pack

● Design for Disassembly

● Efficient recycling methods

● Rapid battery performance

● Design for second life

CHEMICAL BATTERY VEHICLE AUTHORISED BATTERY

Circular Battery AUTHORISED

● Enablers ● Future investment