Professional Documents
Culture Documents
1. EV Drive Systems
TODAY >>
2. EV Batteries
3. EV Charging Systems
4. EV Donor Vehicles
Agenda
What is a Battery? Battery History EV Battery Requirements Types of EV Batteries EV Battery Temperature Control
EV Battery Charging
EV Battery Management EV Battery Comparison EV Record Holders Future EV Batteries EV Drive System Testimonials, Show and Tells and Test Drives
What is a Battery?
During Charge
voltage and energy increases heat anode + electrolyte chemical reaction cathode -
heat
current
charger energy
What is a Battery?
During Discharge
voltage and energy decreases heat anode + electrolyte chemical reaction cathode -
heat
current
load work
Battery History
Rechargeable batteries highlighted in bold.
First battery, Voltaic Pile, Zn-Cu with NaCl electrolyte, nonrechargeable, but short shelf life 1800 Volta
First battery with long shelf life, Daniel Cell, Zn-Cu with H2SO4 and CuSO4 electrolytes, non-rechargeable
First electric carriage, 4 MPH with non-rechargeable batteries
1836
1839
England
Scotland
John Fedine
Robert Anderson
1859
1896
France
Gaston Plante
Carl Gassner
1910 1914
Sweden US
1955
US
1970s 1989
US US
1991
1997
US
US
EV Battery Requirements
High Capacity
Small and Light Large Format
Long Life
Low Overall Cost
external or internal
under normal circumstances or caused by a crash immediate or latent Damage liquid electrolyte acid leakage
Battery voltage changes with current level and direction, and state of charge
1 Horsepower = 746 Watts Charger efficiency = ~90% Battery charge and discharge efficiency = ~95% Drive system efficiency = ~85% AC, 75% DC heat heat heat heat
charger
batteries
motor controller
motor
shaft
100% in
Accelerating or driving up a steep hill Motor Shaft Power = ~50 HP or ~37,000 W Battery Power = ~50,000 W DC, ~44,000 W AC Battery Current ~400A for 144V nominal pack with DC drive ~170A for 288V nominal pack with AC drive Driving steady state on flat ground Motor Shaft Power = ~20 HP or ~15,000 W Battery Power = ~20,000 W DC, ~18,000 AC Battery Current ~150A for 144V nominal pack with DC drive ~70A for 288V nominal pack with AC drive Charging Depends on battery type, charger power and AC outlet rating Example: for 3,300 W, 160V, 20A DC for 3,800 W, 240V, 16A AC
Example: 48 3.2V 100 Amp-Hour cells with negligible Peukert Effect and 95% efficiencies
EV Battery Requirements
Large Format Minimize the need for too many interconnects; example 100 Ah
Long Life Minimize the need for battery replacement effort and cost Example: 2000 cycles at 100% Depth-of-Discharge to reach 80% capacity charging at C/2; 5 years to 80% capacity on 13.8V float at 73C
Low Overall Cost Minimize the purchase and replacement cost of the batteries Example: $10K pack replacement cost every 5 years driven 40 miles per day down to 80% DOD = 1825 days, 73,000 miles, 14 cents per mile
EV Battery Comparison
Max temp ~ ~ ~
Power Energy + + ~ + + ~ ~
Stability + ~ ~
Life ~ +
Toxicity + + + -
Cost ~ +
PbA AGM
PbA gel PbA flooded
+
~ ~
+
+ -
~
~ ~
+
+ +
Available large format only considered; NiMH, small format lithium and large format nano lithium not included.
90%
80%
70%
60%
50%
40%
30%
20%
10%
Data Source: MPS 12-75 Valve Regulated Lead Acid Battery Datasheet, http://www.cdstandbypower.com/product/battery/vrla/pdf/mps1275.pdf.
Note: do not use Dynasty MPS batteries in EVs they are not designed for frequent deep cycling required in EVs
Lead Acid AGM Batteries are Better for High Current Discharge Rates
Gels have higher internal resistance.
Higher discharge rates are typical in heavier vehicles driven harder in higher gears with smaller packs and less efficient, higher current, lower voltage DC drive systems.
Source: Dynasty VRLA Batteries and Their Application, http://www.cdtechno.com/custserv/pdf/7327.pdf.
In addition to securing all batteries so they do not move during a collision or rollover, flooded lead acid batteries need their acid contained so it does not burn any passengers.
When a cell becomes full, it gives off explosive hydrogen gas. Thus vehicles and their garages need fail safe active ventilation systems, especially during regular higher equalization charge cycles that proceed watering.
High Power, High Capacity Deep Cycle Large Format Batteries Used in EVs:
LiFePO4 Hi Power Thunder Sky LMP Valence Technologies U-Charge XP, Epoch AGM
PbA
Flooded Trojan Golf & Utility Vehicle US Battery BB Series NiCd NiZn Li Poly Flooded Saft STM SBS Evercel Kokam SLPB
Note: LiFePO4 are recommended, having the lowest weight but highest initial purchase price. But they have similar overall cost, and the rest have safety, toxicity or power issues.
EV Battery Charging
Source: Thermal Runaway in VRLA Batteries Its Cause and Prevention, http://www.cdtechno.com/custserv/pdf/7944.pdf.
EV Battery Management
All batteries need to be kept within their required voltage and temperature ranges for performance, long life and safety. This is particularly important for nickel and thermally unstable lithium ion batteries which can be dangerous if abused. Ideally each cell is monitored, the charge current is controlled, and the driver is alerted when discharge limits are being approached and then again when exceeded.
For high quality multi-cell modules without cell access, module level voltage monitoring is better than no monitoring.
For chargers without a real time level control interface, a driven disable pin or external contactor will suffice for battery protection, but may result in uncharged batteries in time of need. Dashboard gages and displays are good, but combining them with warning and error lamps is better.
Amp-Hour Counters are More Accurate Fuel Gages Than Volt Meters
To predict when your batteries will drop below the minimum voltage, Depth of Discharge should be monitored. Open circuit voltage drops only 0.9V between 0 and 80% depth of discharge.
Open Circuit Rest Voltage vs. Depth of Discharge
13.0 13.0
Voltage drops up to 2.7V at 600 amps discharge, and can take a good part of a minute to recover.
Internal Resistance Effect
12.5
12.5
12.0
12.0
11.5
AGM Gel
battery voltage
11.5
11.0
11.0
10.5
10.5
10.0 0% 10% 20% 30% 40% 50% Depth of Discharge 60% 70% 80% 90% 100%
10.0 0 100 200 300 discharge rate, amps 400 500 600
Ideally your fuel gage looks at all of the above plus temperature and then estimates depth of discharge.
Data Source: Integrity Testing, http://www.cdtechno.com/custserv/pdf/7264.pdf.
Data Source: MPS 12-75 Valve Regulated Lead Acid Battery Datasheet, http://www.cdstandbypower.com/product/battery/vrl a/pdf/mps1275.pdf.
Note: do not use Dynasty MPS batteries in EVs they are not designed for frequent deep cycling required in EVs
All batteries will drift apart in state of charge level over time. This is due to differences in Peukert effect and internal leak rates. This will be detected during monitoring as early low voltages during discharge, and early high voltages and not high enough voltages during charge. Sealed batteries need to be individually balanced, whereas flooded batteries can be overcharged as a string, then watered.
Individual balancing can be done manually on a regular basis with a starter battery charger, or with a programmable power supply with voltage and current limits, but the latter can be expensive. And it can be a hassle, and it can be difficult if the battery terminals are hard to get to. Automatic balancing maximizes life and performance. Ideally balancing is low loss, switching current from higher voltage cells to lower voltage cells at all times. Bypass resistors that switch on during finish charging only is less desirable but better than no automatic balancing.
EV Battery Pictures
Optima Blue Top AGM Sealed Lead Acid Batteries with PCHC-12V2A Power Cheqs Installed in Don McGraths Corbin Sparrow
Valence Module
Valence BMU
Valence Cycler 2.4 battery monitoring screen capture (idle mode; 2.8 now available)
EV Record Holders
AC Propulsion tZero: drove 302 miles on a single charge at 60 MPH in 2003, Lithium Ion batteries
Phoenix Motorcars SUT: charged 50 times in 10 minutes with no degradation in 2007; 130 mile range
Solectria Sunrise: drove 375 miles on a single charge in 1996, NiMH batteries
DIT Nuna: drove 1877 miles averaging 55.97 MPH on solar power in 2007, LiPo batteries
Future EV Batteries
Stanford University Silicon Nanowire electrodes have 3X capacity improvement expected for Lithium batteries
Not technically a battery, but MIT Nanotube ultracapacitors have very high power, 1M+ cycle energy storage approaching Lithium battery capacity