Battery Management for Monitoring up to

Six LeadLead-Acid Batteries at the Individual

Battery and System Levels
Dr. David Liu, PhD
PHM Society
BMS Workshop
September 26, 2011

Overview

Why Do We Need a Battery Fuel Gauge?

Capabilities and Benefits of HDM BFG Technology
BFG Application Examples
BFG Configurations
HDMs BFG Dual Tracking Methodology
BFG Highlights Effects of Unhealthy Batteries on
the Bank
Re-Cap
2

Information is Power

You would not drive a car

without a gas gauge
Why would you execute a mission-critical
operation, such as silent watch,
without a Battery Fuel Gauge?
3

Capabilities of HDM BFG Technology

Battery Power Usage Information: Diagnostics and Prognostics

State of Charge (SOC) at 95% Accuracy

State of Health (SOH) at 95% Accuracy
Hours Remaining (HR) at 90% Accuracy
Battery Voltage (V)
Battery Temperature (T)
Current (I)
State of Life (SOL)

Functionality

System Interface: CANBUS, RS232, Control Panel-Mounted Display

Real-Time Data and Estimations
Self-Calibration
Lightweight Packaging
4

Benefits of HDM BFG Technology

Operations
Alerts crew when re-charging is necessary
Provides Hours Remaining for silent watch
Ensures mission capacity and success

Maintenance
Identifies unhealthy batteries for replacement
Facilitates Condition-Based Maintenance (CBM)

Cost-Efficiency
Single BFG per system vs. multiple BFGs per system
Simple configuration reduces install, operation, and maintenance
Powerful tool for intelligent power management systems
5

BFG Implementation
Mobile Application
Customer
Navistar Defense
UK MOD/NATO

Vehicle
Husky Tactical Support Vehicle

Application
Monitors Battery SOC and SOH
Over 1500 HDM BFGs have
been installed in Husky
TSVs in Afghanistan
supporting the NATO troops
6

BFG Implementation
Stationary Application
Customer
Raytheon Company

System
R-Series Regenerator Hybrid
Power System

Application
USMC Experimental
Forward Operating Base
Phase IV Demonstration in
2010 at 29 Palms, CA
HDM BFG is critical component
of intelligent Hybrid Power
System
7

Battery Fuel Gauge Configurations

Configuration 1
System Level Monitoring Only
Inline Fuse
Battery Positive Sense Wire

12VDC
Battery
#1

12VDC
Battery
#3

12VDC
Battery
#5

DC Load

(Alte
ernator)

Cha
arger

Interface Connection
(Display, RS232, CAN-Bus)

Fuel Gauge Sensor Module

12VDC
Battery
#2

12VDC
Battery
#4

12VDC
Battery
#6

Load
Neg

Batt
Neg

Load Negative Connection

Battery Negative Connection

Advantage: SIMPLICITY
9

Configuration 2
Cell Level Monitoring Only

12VDC
Battery
#1

Load
Neg

Batt
Neg

12VDC
Battery
#3

Load
Neg

Batt
Neg

12VDC
Battery
#5

Load
Neg

DATA

R E A D IN G S

SOH

C e ll

SOC

C e ll

Batt
Neg

Inline Fuse

DC Load

(Alte
ernator)

Cha
arger

Battery Positive Sense Wire

12VDC
Battery
#2

Load
Neg

Batt
Neg

12VDC
Battery
#4

Load
Neg

Batt
Neg

12VDC
Battery
#6

Load
Neg

Batt
Neg

olta ge)
Interface(V
Connection
(Display, RS232, CAN-Bus)

C e ll

HFuel
R Gauge
(H r R em ain )
Sensor Module

C e ll

Load Negative Connection

I (C u rre nt)

C e ll

Battery Negative Connection

Tem p

C e ll

Advantage: PRECISION
10

Configuration 3
System/String/Cell Level Monitoring

12VDC
Battery
#1

12VDC
Battery
#3

12VDC
Battery
#5

DATA

READINGS

SOH

Cell/String/System

SOC

Cell/String/System

Inline Fuse

DC
C Load

(Altternator)

Ch
harger

Battery Positive Sense Wire

Cell/System

Interface(Voltage)
Connection
(Display, RS232, CAN-Bus)

HR
(Hr Remain)
Fuel Gauge
Sensor Module
12VDC
Battery
#2

12VDC
Battery
#4

12VDC
Battery
#6

Load
Neg

Batt
Neg

Load Negative Connection

System

I (Current)

Cell/String/System

Temp

System

Battery Negative Connection

Advantage: SIMPLE, PRECISE & COST-EFFECTIVE

11

HDMs Battery Fuel Gauge Technology:

Dual Tracking Methodology

12

SOC Measurement
Using Dual Tracking Method
100
Fuel Gauge SOC
Theoretical SOC
Fuel Gauge SOH:82%
(at discharging time = 0 min.)

80

SOC (%)

60

40

20

0
0

10

20

30

40

50

60

70

80

90

100

Discharging Time (min)

SOC Accuracy at 95%

13

What is Dual Tracking Methodology?

14

Template for Initial

I-SOC and VocVoc-SOC Estimation
Segments

Voc

AH

SOC (%)

> 12.8

100-98

12.80-12.74

98-96

12.74-12.69

96-94

12.69-12.66

94-92

.
.
.

.
.
.

.
.
.

.
.
.

48

11.14-11.08

6-4

49

11.08-10.88

4-2

50

10.88-10.64

2-0

Total Segments: 1-50

Voc: >12.8 to 10.64

Total AH: 100

SOC: 100%-0%

I-SOC = AHremaining AHdischarge

Total Initial AH

15

Template for SelfSelf-Calibrated

I-SOC and VocVoc-SOC Estimation
Segments

Voc

AH

SOC (%)

> 12.8

1.8

100-98

12.80-12.74

1.8

98-96

12.74-12.69

2.1

96-93

12.69-12.66

2.1

93-90

.
.
.

.
.
.

.
.
.

.
.
.

48

11.14-11.08

1.6

6-4

49

11.08-10.88

1.6

4-2

50

10.88-10.64

1.8

2-0

Total Segments:
1-50

Voc:
>12.8 10.64

Self-Calibrated
Total AH: 90

SOC:
100%-0%

I-SOC = AHremaining AHdischarge

Total Self-Calibrated AH

16

Error from CurrentCurrent-Based Tracking

Charge/Discharge Cycling

Fuel Gauge SOC

Overestimated

100

Accurate
Underestimated

SOC (%)

80

60

40

20

0
0

50

100

150

200

250

300

350

400

450

500

Discharging Time (min)

Lack of precise charge and discharge efficiency information results

in accumulation of SOC estimation errors
17

Error from VoltageVoltage-Based Tracking

27

B (78%SOC)

26

V
o
c(V
o
lta
g
e
)

Voc (Volts)

25

A (100%SOC)

24

23
Voc 12Hrs Rest after Full Charge
Voc No Rest after Full Charge
22

21
0

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

time(mins)

Time (min)

Lack of voltage relaxation results in SOC errors

18

Dual Tracking Methodology

Voltage-Based Tracking SOC

100

Combined SOC
Voltage-based SOC

SOC
(%)
SOC
(%)

80

60

40

Dual Tracking SOC

20

0
0

50

100

150

200

250

Discharging Time (min)

Discharging
Time (min)

Dual Tracking Method is optimal for all loading conditions

19

Configuration 3
System/String/Cell Level Monitoring
12VDC
Battery
#1

12VDC
Battery
#3

12VDC
Battery
#5

DATA

READINGS

SOH

Cell/String/System

SOC

Cell/String/System

Inline Fuse

DC Load
L

(Altern
nator)

Charrger

Battery Positive Sense Wire

Cell/System

Interface(Voltage)
Connection
(Display, RS232, CAN-Bus)

HR
(Hr Remain)
Fuel Gauge
Sensor Module
12VDC
Battery
#2

12VDC
Battery
#4

12VDC
Battery
#6

Load
Neg

Batt
Neg

Load Negative Connection

System

I (Current)

Cell/String/System

Temp

System

Battery Negative Connection

Advantage: SIMPLE, PRECISE & COST-EFFECTIVE

20

BFG Detection of Unhealthy Battery: Cycle 1

Theoretical - 5%

Battery 1

10

15

20

25

30

Battery Monitor SOC

35

Theoretical SOC

Theoretical - 5%

Battery 4

10

15

20

25

30

Theoretical + 5%
Theoretical - 5%

Battery 2

100 0
90
80
70
60
50
40
30
20
10
0

SOC (%)

Theoretical + 5%

SOC (%)

100
90
80
70
60
50
40
30
20
10
0

Theoretical SOC

SOC (%)

SOC (%)

Theoretical + 5%

35

100
90
80
70
60
50
40
30
20
10
0

Battery Monitor SOC

10

15

20

25

30

100
90
80
70
60
50
40
30
20
10
0

35

Battery Monitor SOC

Theoretical SOC
Theoretical + 5%
Theoretical - 5%

Battery 5

Battery5
5

AH Discharged

HDM BFG identifies

weak battery during
discharge cycle 1

10

15

20

25

30

Battery Monitor SOC

Theoretical SOC
Theoretical + 5%

SOC (%)

Theoretical SOC

100
90
80
70
60
50
40
30
20
10
0

Theoretical - 5%

Battery 3

10

15

20

25

30

Battery Monitor SOC

35

Theoretical + 5%
Theoretical - 5%

Battery 6

35

Theoretical SOC

SOC (%)

Battery Monitor SOC

10

AH Discharged

15

20

25

30

35

AH Discharged

100
90
80
70
60
50
40
30
20
10
0

Battery Monitor SOC

Theoretical SOC
Theoretical + 5%

SOC (%)

100
90
80
70
60
50
40
30
20
10
0

Theoretical - 5%

Battery System
6 Batteries Combined
0

20

40

60

AH Discharged

80

100

21

BFG Accuracy Established: Cycle 3

100

Battery Monitor SOC

Theoretical SOC

SOC (%)

SOC (%)

Theoretical + 5%
Theoretical - 5%

Battery 1

90

Battery Monitor SOC

80

Theoretical SOC

70

Theoretical + 5%

60

Theoretical - 5%

50
40

Battery 2

30
20
10
0

100
90
80
70
60
50
40
30
20
10
0

10

15

20

25

30

35

10

15

20

25

30

Battery Monitor SOC

Theoretical SOC

80

Theoretical SOC

70

Theoretical + 5%

SOC (%)

Battery 4

60

Theoretical - 5%

50
40
30
20

Battery 5

10
0

10

15

20

25

30

35

10

AH Discharged

HDM BFG achieves

95% accuracy by
discharge cycle 3
(i.e. no adjustments needed)

15

20

AH Discharged

25

30

Theoretical + 5%
Theoretical - 5%

Battery 3

100
90
80
70
60
50
40
30
20
10
0

35

10

15

20

25

30

35

40

Battery Monitor SOC

Theoretical SOC
Theoretical + 5%
Theoretical - 5%

Battery 6

10

15

20

25

30

35

40

AH Discharged

100
90
80
70
60
50
40
30
20
10
0

Battery Monitor SOC

Theoretical SOC

SOC (%)

Theoretical SOC

SOC (%)

90

SOC (%)

Battery Monitor

Theoretical - 5%

Battery Monitor SOC

35

100

Theoretical + 5%

100
90
80
70
60
50
40
30
20
10
0

SOC (%)

100
90
80
70
60
50
40
30
20
10
0

Theoretical + 5%
Theoretical - 5%

Battery System
6 Batteries Combined
0

20

40

60

80

100

AH Discharged
22

Effects of Unhealthy Battery on Bank 1*

String #

Battery #

Individual Battery Voltage @

End Point

11.3V

11.5V

11.4V

11.4V

10.8V

12.0V

Sum
1-3

Sum
1-6

System Battery End Voltage:

22.8V

1
2

Discharge Current
From
To
12A
10A
18A

19A
18A
4A

System Discharge Current:

~41A
~41A

SOC
%

SOH
%

10

73

16

78

12

71

12

73

50

36

78

0%

68%

* Battery Bank 1: Optima Batteries

String 3: Divergence of voltage and reduction in discharge current

cause over-current stress on Strings 1 and 2
Premature termination of discharge cycle, resulting in 19% loss in
usable capacity
23

Effects of Unhealthy Battery on Bank 2*

String #

Battery #

Individual Battery Voltage @

End Point

11.3V

11.4V

10.6V

12.1V

11.2V

11.5V

Sum
1-3

Sum
1-6

System Battery End Voltage:

22.7V

1
2

Discharge Current From

To
33A
33A
34A

49A
6A
45A

System Discharge Current:

100A
100A

SOC
%

SOH
%

14

77

19

80

55

51

93

12

75

22

87

0%

62%

* Battery Bank 2: Hawker Batteries

String 2: Divergence of voltage and reduction in discharge current

cause over-current stress on Strings 1 and 3
Premature termination of discharge cycle, resulting in 17% loss in
usable capacity
24

Weakest Battery Threshold

vs. Conventional Threshold at 21V
String Battery
#
#

Battery Voltage
@ End Point 1
(Bat 3 SOC=0%)

@ End Point 2 (Bat

Voltage=21V)

11.3V

9.9V

11.4V

11.1V

10.6V

9.6V

12.1V

11.5V

11.2V

9.7V

11.5V

Sum
1-3

Sum
1-6

22.7V

1
2

Discharge Current

Charge Current

@ 100%
SOC

@ End
Point 1

@ End
Point 2

@ Low SOC

36A

51A

20A

20A

30A

6A

65A

3A

11.3V

36A

45A

17A

19A

21.0V

102A

102A

102A

Set @ 42A

By extending the system run-time (e.g. by 30 minutes), would be at

the expense of the weakest battery
25

System-Level Monitoring During Complete

Charge-Discharge Cycles
Battery System

Battery Monitor SOC

Theoretical SOC
Theoretical + 5%

100

Theoretical - 5%

90
80

SOC (%)

70
60
50
40
30
20
10
0
0

200

400

600

800

1000

1200

1400

1600

1800

2000

AH Discharged/Charged

SOC accuracy reaches 90-95% during the charge portion of the cycle
within 3 cycles
26

Single BFG at 95% Accuracy

for up to 6 Individual Batteries
Provides breadth and depth necessary for Cost-Effective
Battery Management Systems and CBM
User Level
Ensures power system reliability and performance

Maintenance Level
Enables precision pinpoint of unhealthy batteries for CBM

Incorporates theoretically scalable algorithm, for banks

greater than 6 batteries (i.e. important for larger, stationary
energy storage systems)
27

Thank You!
Contact Information:
Dr. David Liu, VP of R&D: davidliu@hdm-sys.com
HDM Systems, Inc.
226 Lincoln Street
Allston, MA 02134
Tel: 617.562.4054
Fax: 617.562.4013
Web: www.HDM-Sys.com

28

Appendix

29

SOC Measured by DualDual-Tracking Method:

Partial Discharge Cycle 1 to Cycle 4
2nd Discharge Cycle (100% to 50% SOC) (2x55AH 12V
Batteries, 24V in Series, 10A/40A Alternating Loads)

Initial Discharge Cycle (100% to 50% SOC) (2x55AH 12V

Batteries, 24V in Series, 10A/40A Alternating Loads)

100

100

Fuel Gauge SOC

Theoretical SOC

Fuel Gauge SOC

Theoretical SOC

80

80
60
Fuel Gauge SOH: 89%
at Discharge Time = 0 min.
40

SOC (%)

SOC (%)

Fuel Gauge SOH: 95%

at Discharge Time = 0
60

40

20

20

0
0

20

40

60

80

100

Discharging Time (min)

20

40
60
Discharging Time (min)

100

4th Discharge Cycle (100% to 0% SOC) (2x55AH 12V Batteries,

24V in Series, 5A/40A Alternating Loads)

3rd Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries,

24V in Series, 10A/40A Alternating Loads)

100

100

Fuel Gauge SOC

Fuel Gauge SOC

Theoretical SOC

80

Theoretical SOC

80

Fuel Gauge SOH: 83%

at Discharge Time = 0

Fuel Gauge SOH: 86%

at Discharge Time = 0
60

SOC (%)

SOC (%)

80

40

60

40

20

20

0
0

20

40

60

Discharging Time (min)

80

100

20

40

60

80

100

Discharging Time (min)

SOC accuracy reaches 90-95% after four partial discharge cycles

30

Partial Charge and Discharge Cycles

of Battery Bank
Battery System

100
90
80
70
60
50
40
30
20
10
0

SOC (%)

SOC (%)

Battery H2

50

100
AH Discharged/Charged

150

200

100
90
80
70
60
50
40
30
20
10
0
0

100

200

300

400

500

600

AH Discharged/Charged

SOC accuracy reaches 90-95% after four partial charge and

discharge cycles
31

BFG: Water Submersion Test

BFG was submersed in water at 25C for three

hours, and was tested for operational performance
32