Title

Battery Packs

1.2 V 1.2 V
1000 mA 1000 mA

- +
1.2 V 1.2 V
1000 mA 1000 mA

In this presentation you will:

 recognise the design requirements for a battery pack

Next >
Battery Pack Function

The main function of the battery pack is to power the

electric traction motor.

On a hybrid vehicle, the HV battery

battery pack is charged Electronic pack
circuits
by the electric motor in
generator mode, or by a
secondary generator.

Generator
Electric traction
motor/generator Next >
Battery Pack Function

On an electric vehicle, the battery pack is charged

by the electric motor in generator mode, or by a
plug-in connection.
Electronic
modules
Plug-in Note: Some
connection
of the latest
hybrid vehicles
also have a
plug-in
connection.
HV battery
Electric traction pack
motor/generator

Next >
Increasing Battery Voltage

A single NiMH cell produces a nominal voltage of 1.2V.

- 1.2V
1000 mA
1.2V
1000 mA
1.2V
1000 mA
1.2V
1000 mA +

1.2V 2.4V 3.6V 4.8V

1000 mA

To produce a higher voltage, connect additional cells in

series with the first cell.

The same current flows through all cells. Therefore, the

capacity (amps  hours) of the ‘battery pack’ is the same
as the capacity of the individual cells. Next >
Increasing Battery Capacity

The capacity of a battery

pack can be increased by

1000 mA

1000 mA
1000 mA

1000 mA
1.2V

1.2V
1.2V

1.2V
connecting cells in parallel.
-
1.2V
1000 mA 2000 mA 3000 mA 4000 mA

Connecting cells in series 1.2V 1.2V

1000 mA 1000 mA
and parallel increases - +
battery pack voltage and 1.2V 1.2V
capacity. 1000 mA 1000 mA

1.2V 2.4V
2000 mA 2000 mA Next >
Increasing Battery Capacity

Extra cells increase the size and weight of the battery

pack, which is not good for hybrid and electric vehicles.

Many battery pack manufacturers prefer to use cells that

have a capacity big enough to ‘do the job’, and connect
them in series.

Next >
Question 1

If a battery pack has an output voltage of 266.4V, how

many 1.2V NiMH batteries does it contain if they are all
connected in series?
A) 2

B) 22

C) 222

D) 2222

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Question 1

If a battery pack has an output voltage of 266.4V, how

many 1.2V NiMH batteries does it contain if they are all
connected in series?
A) 2

B) 22

C) 222

D) 2222

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Battery Energy and Power

The design of battery cells can

be optimised for either power
or energy use.

NiMH batteries typically

Hybrid vehicles require batteries provide higher power
and lower energy.
that can provide high power for
short periods of time.

Electric vehicles require batteries

that can provide high energy for
a long time period. Li-ion batteries typically
provide higher energy
and lower power.

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Specific Energy and Power

A battery pack is
manufactured using Ragone Plot of Different Energy Storage Systems
many batteries that add 100,000

weight to a vehicle.

Specific Power, W/kg at Cell Level

Super capacitors
10,000
Li-ion very high power

NiCd
Hybrid and electric 1,000
Li-ion high
power
vehicle designers 100

often need to know Li-ion high

10 NiMH
which batteries give energy
Lead acid
the best power or 1
0 20 40 60 80 100 120 140 160 180 200
energy output for the Specific Energy, Wh/kg at Cell Level
least weight.

Next >
Specific Energy and Power

The specific power of

a battery is the Ragone Plot of Different Energy Storage Systems
amount of current that 100,000

it can provide,

Specific Power, W/kg at Cell Level

Super capacitors
10,000
Li-ion very high power
measured in watts per
NiCd
kilogram (W/kg). 1,000
Li-ion high
power
100

The specific energy of 10 NiMH Li-ion high

energy
a battery is the amount Lead acid
1
of energy that it can 0 20 40 60 80 100 120 140 160 180 200

provide, measured in Specific Energy, Wh/kg at Cell Level

watt hours per

kilogram (Wh/kg).
Next >
Question 2

How is the specific energy of a battery measured?

A) Amperes

B) Kilowatt hours

C) Watts per kilogram

D) Watt hours per kilogram

Next >
Question 2

How is the specific energy of a battery measured?

A) Amperes

B) Kilowatt hours

C) Watts per kilogram

D) Watt hours per kilogram

Next >
Battery Pack Design Requirements

A typical battery pack Graph showing energy per kilogram for

different battery types

design should provide the 180

160
following: 140
120
 As much energy as 100

Wh/kg
80
possible for the least 60
weight. 40
20
 A compact housing that 0

Lead acid

NiCd

NiMH

Li- phosphate

Li- manganese

NMC

Li-Cobalt
has high resistance to
impact, vibration, and
cell failure.
 Maximum power delivery.
 Adequate cooling to  Charging and
keep cell temperatures discharging for the
within specified limits. life of the cells. Next >
Other Design Considerations

Here are some other design considerations:

 Internal cell
connections must be
low resistance; they
are usually welded
rather than soldered,
to limit possible heat
damage.

Next >
Other Design Considerations

Here are some other

design considerations:

 External battery pack

connections are
usually threaded metal
studs covered with
shrouds for reliable
contact and safety.

 Mounting frames, especially those for lithium-ion

pouches, must allow for the expansion of the
working cell.
Next >
Battery Pack Concerns

Some typical concerns are shown here:

 The cost of a battery

pack may account for
up to one third of the
total cost of a vehicle.

 Battery packs have Cost of battery pack Total cost of vehicle

= £10,000 = £30,000
limited life and are
expensive to replace.

 The safe disposal of large

numbers of ‘end of usable life’
battery packs. Next >
Battery Pack Example – Toyota

The second generation

Toyota Prius uses 28
Panasonic prismatic NiMH
modules in its battery pack.

Each module contains six

Cells
1.2V cells, producing a
voltage of 7.2V.

Therefore, 28 of these
modules are connected in
series to produce a battery
pack voltage of 201.6V.
Next >
Battery Pack Example – Ford

The Ford Escape Hybrid

uses Sanyo cylindrical NiMH
cells in its battery pack.

Five 1.32V cells are

connected together to
form a 6.6V module.

Module
Therefore, 50 of these
modules are connected in
series to produce a battery
pack voltage of 330V.
Next >
Battery Pack Example – Honda

The Honda Insight uses 120 Panasonic

cylindrical NiMH cells in its battery pack.

Each cell produces 1.2V.

Therefore, 120 cells

produce a battery pack
voltage of 144V.

Next >
Question 3

How many NiMH cells does a Ford Escape battery pack

contain?

A) 120

B) 168

C) 250

D) 50

Next >
Question 3

How many NiMH cells does a Ford Escape battery pack

contain?

A) 120

B) 168

C) 250

D) 50

Next >
Battery Pack Management

To ensure efficient and safe operation, a battery pack

must be managed by a computer.

Functions of a typical ‘battery pack’ computer (ECU):

 Uses a cooling fan to control the

temperature of the battery pack
during charging and recharging.

Next >
Battery Pack Management

Functions of a typical ‘battery pack’ computer (ECU):

 Monitors battery
voltage, current, and
temperature, and
restricts or stops
charging if a fault is
detected.
Chevrolet Volt battery pack electronics

 Monitors and maintains battery

state of charge (SOC) within
specified limits.
Next >
Summary

In this presentation you have seen:

 the design requirements for a battery pack

End >