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A battery pack is produced by connecting the cells in series and/or in parallel to provide the necessary power for electric vehicles (EVs). Those parameters affecting cost and reliability of the EVs, including cycle life, capacity, durability and warranty are highly dependent on the thermal management system. In this work, computational fluid dynamic analysis is performed to investigate the air cooling system for a 38,120 cell battery pack. The battery pack contained 24 pieces of 38,120 cells, copper bus bars, intake and exhaust plenum and holding plates with venting holes. Heat generated by the cell during charging is measured using an accelerating rate calorimeter. Thermal performances of the battery pack were analyzed with various mass flow rates of cooling air using steady state simulation. The correlation between Nu number and Re number were deduced from the numerical modeling results and compared with literature. Additionally, an experimental testing of the battery pack at different charging rates is conducted to validate the correlation. This method provides a simple way to estimate thermal performance of the battery pack when the battery pack is large and full transient simulation is not viable. [ABSTRACT FROM AUTHOR]

Due to the importance of examining the temperature of battery packs (BYP), a study on the temperature of a lithium-ion BYP with 9 cylindrical cells is performed in this article. The BYP is filled with phase change material (PCM) to better temperature uniformity on the battery cells. The batteries and the PCM pack are placed in an air channel with two inlets. At the inlets, 4 arc blades are supposed to guide the airflow to enhance the uniformity of cooling in the BYP. By changing the horizontal and vertical distance (VD) of the batteries inside the pack, this study is carried out in 2500 s for the charging and discharging times of the batteries (1.5C rate). The thermal analysis is done on the batteries using COMSOL software. The results show that an increment in the horizontal distance (HD) of batteries has less effect on battery temperature (T-BT) and PCM phase change compared to their VD. By enhancing the horizontal and VDs of the batteries, the value of the PCM phase change during the maximum T-BT is higher. The heat transfer coefficient (HTCT) between the PCM and the air is also decreased by increasing the distance between the batteries. The T-BTs is not significantly impacted by changing the distance between them. • Study thermal management of a lithium-ion BYP with 9 cylindrical cells is performed. • BYP is filled with PCM to better temperature uniformity on the battery cells. • T-BTs is not significantly impacted by changing the distance between them. • HTCT between the PCM and air is also decreased by increasing the distance. [ABSTRACT FROM AUTHOR]

In this paper, a 3D battery pack (B-PK) containing 16 battery cells (BCL) with aligned and non-aligned arrangements is simulated. The batteries are 18,650 lithium-ion cylindrical ones. The B-PK is placed in a square air duct. Air enters from the top of the B-PK and exits from the bottom of the batteries. This study is performed by changing the inlet air velocity (V-AR) to the B-PK from 0.03 to 0.09 m/s for three charging and discharging cycles within 2000 s. The findings revealed that extending the duration and charging and discharging of the B-PK up to the third cycle increased the temperature of B-PK. The effect of V-AR changes is more pronounced in the second and especially the third cycles of battery charging process. The maximum (T-MX) and average (T-AV) temperatures of the B-PK as well as the temperature of air leaving the B-PK are all reduced when the V-AR is increased. The central batteries of the B-PK have a high temperature, whereas the batteries at the B-PK corners have a low temperature, according to an analysis of BCLs. Using an aligned arrangement of batteries in the pack reduces the T-AV of B-PK compared to the non-aligned arrangement of batteries. • A 3D battery pack containing 16 lithium-ion cylindrical battery cells is simulated. • Effect of inlet air velocity for three charging and discharging cycles are assessed. • Temperature of B-PK rises by extending its charging/discharging up to third cycle. • The maximum temperature of battery pack reduces by boosting the inlet air velocity. • Aligned batteries entails a lower battery temperature than non-aligned arrangement. [ABSTRACT FROM AUTHOR]

The numerical and transient behavior of a battery pack (BA-PK) consisting of three battery cells positioned within an air duct is investigated in this work. The BA-PK was connected to a solar system. The inside of the BA-PK is filled with phase change material. The air within the duct moved at a speed of 0.001–0.003 m/s around the BA-PK. The investigation was carried out by altering the dimensions of the BA-PK using COMSOL software. The finite element approach is used to solve the equations. The results of this research indicated that the battery temperature (Tbatt) drops gradually until the surrounding area is filled with molten PCM, but that once the PCM around the battery is entirely frozen, the Tbatt drops abruptly. The use of a larger BA-PK increases the temperature of the exhaust air out of the duct, but reduces the percentage of solid PCM. The Tbatt, as well as the maximum Tbatt and average TPCM within the compartment, are reduced by using a smaller BA-PK. In addition to increasing the quantity of solid PCM, increasing the speed lowers the temperatures of the batteries and PCM, as well as the temperature of the exhaust air. • Numerical and transient behavior of a battery pack positioned within an air. • Battery pack is filled with phase change material and was connected to solar system. • The use of a larger battery pack increases the temperature of the exhaust air. • Increasing the speed lowers the temperatures of batteries, PCM and exhaust air. [ABSTRACT FROM AUTHOR]

Variations in cell properties are unavoidable and can be caused by manufacturing tolerances and usage conditions. As a result of this, cells connected in series may have different voltages and states of charge that limit the energy and power capability of the complete battery pack. Methods of removing this energy imbalance have been extensively reported within literature. However, there has been little discussion around the effect that such variation has when cells are connected electrically in parallel. This work aims to explore the impact of connecting cells, with varied properties, in parallel and the issues regarding energy imbalance and battery management that may arise. This has been achieved through analysing experimental data and a validated model. The main results from this study highlight that significant differences in current flow can occur between cells within a parallel stack that will affect how the cells age and the temperature distribution within the battery assembly. [ABSTRACT FROM AUTHOR]

Battery cell capacity loss is extensively studied so as to extend battery life in varied applications from portable consumer electronics to energy storage devices. Battery packs are constructed especially in energy storage devices to provide sufficient voltage and capacity. However, engineering practice indicates that battery packs always fade more critically than cells. We investigate the evolution of battery pack capacity loss by analyzing cell aging mechanisms using the “Electric quantity – Capacity Scatter Diagram (ECSD)” from a system point of view. The results show that cell capacity loss is not the sole contributor to pack capacity loss. The loss of lithium inventory variation at anodes between cells plays a significant role in pack capacity evolution. Therefore, we suggest more attention could be paid to the loss of lithium inventory at anodes in order to mitigate pack capacity degradation. [ABSTRACT FROM AUTHOR]

This paper describes a cooling strategy development method for an air cooled battery pack with lithium-ion pouch cells used in a hybrid electric vehicle (HEV). The challenges associated with the temperature uniformity across the battery pack, the temperature uniformity within each individual lithium-ion pouch cell, and the cooling efficiency of the battery pack are addressed. Initially, a three-dimensional battery pack thermal model developed based on simplified electrode theory is correlated to physical test data. An analytical design of experiments (DOE) approach using Optimal Latin-hypercube technique is then developed by incorporating a DOE design model, the correlated battery pack thermal model, and a morphing model. Analytical DOE studies are performed to examine the effects of cooling strategies including geometries of the cooling duct, cooling channel, cooling plate, and corrugation on battery pack thermal behavior and to identify the design concept of an air cooled battery pack to maximize its durability and its driving range. [ABSTRACT FROM AUTHOR]

Thermal management is a routine but crucial strategy to ensure thermal stability and long-term durability of the lithium-ion batteries. An air-flow-integrated thermal management system is designed in the present study to dissipate heat generation and uniformize the distribution of temperature in the lithium-ion batteries. The system contains of two types of air ducts with independent intake channels and fans. One is to cool the batteries through the regular channel, and the other minimizes the heat accumulations in the middle pack of batteries through jet cooling. A three-dimensional anisotropic heat transfer model is developed to describe the thermal behavior of the lithium-ion batteries with the integration of heat generation theory, and validated through both simulations and experiments. Moreover, the simulations and experiments show that the maximum temperature can be decreased to 33.1 °C through the new thermal management system in comparison with 42.3 °C through the traditional ones, and temperature uniformity of the lithium-ion battery packs is enhanced, significantly. [ABSTRACT FROM AUTHOR]

The present paper documents a comprehensive study on the ground impact of lithium-ion battery packs in electric vehicles. With the purpose of developing generic methodology, a hypothetic global finite element model is adopted. The force–displacement response of indentation process simulated by the global FE model is cross-validated with the earlier analytical solutions. The punching process after the armor plate perforation, the ensuing crack propagation of the armor plate as well as the local deformation modes of individual battery cells are clearly predicted by the global modeling. A parametric study is carried out, and a few underlying rules are revealed, providing important clues on the design of protective structure of battery packs against ground impact. In the next step, detailed FE models at the level of a single battery cell and shell casing are developed and simulations are performed using boundaries and loading conditions taken from the global solution. In the detailed modeling the failure of individual components is taken into account, which is an important indicator of electric short circuit of a battery cell and possible thermal runaway. The damage modes and the deformation tolerances of components in the battery cell under various loading conditions are observed and compared. [ABSTRACT FROM AUTHOR]

In this work, a novel acausal and reconfigurable battery pack model is presented. The model structure adopted for the battery cell is based on an equivalent circuit representation. The circuit elements are modified to take account of both hysteresis and diffusion limitation. The latter is known to be a nonlinear function of large operating currents or long operating times. It is shown that the integration of a current dependent time constant within the cell model better emulates the solid diffusional dynamics of lithium intercalation into the active material under large electrical loads. The advantages of an acausal modeling approach, when scaling-up individual cell models into a complete battery system are also presented. Particular consideration is given to emulating the impact of cell to cell variations on pack performance. Using statistical analysis of battery tests, cell model parameter variations are characterized and quantified. The cell and scaled-up pack model are parameterized for a number of commercially available cell formats, energy capacities and chemistries. The new models are validated using transient, real-world, electrical data measured from an electric vehicle (EV) operating within an urban environment. [ABSTRACT FROM AUTHOR]

To address the problem of DC bus voltage surge caused by load demand fluctuation in an off-grid microgrid, here, an adaptive energy optimization method based on a hybrid energy-storage system to maintain the stability of DC bus voltage is presented. The adaptive energy optimization method consists of three parts: the average filtering algorithm, extracting fluctuating power in demand load; the supercapacitor terminal voltage control, keeping the terminal voltage of the supercapacitor near reference; and the battery pack balance control, adjusting the charge/discharge to balance the state of charge for battery packs. In this proposed method, after extracting the fluctuating power by the low-pass filter when the demand load fluctuates, the battery packs release the power to offset the low-frequency fluctuation load and the supercapacitor to instantaneously compensate the high-frequency fluctuation power, to prolong the service life of batteries and maintain the stability of DC bus voltage. The effectiveness of the proposed adaptive energy optimization method is validated and is confirmed to maintain the stable operation of the off-grid microgrid, extend the cycle life of batteries in off-grid microgrid simulations and experiments. [ABSTRACT FROM AUTHOR]

Abstract: Because of the inevitable inconsistency during manufacture and use of battery cells, cell variations in battery packs have significant impacts on battery pack capacities, durability and safety for electric vehicles (EVs). To reduce cell variations and increase pack capacity, cell equalization is essentially required. In the series of two papers, we discover that dissipative cell equalization (DCE) using dissipative resistances is a feasible on-line equalization method for battery packs in EVs. We subsequently propose on-line equalization algorithms for lithium-ion battery packs based on charging cell voltage curves (CCVCs). The objective of these algorithms is to maximize pack capacities by conditioning CCVCs. As the first paper of the series, we first briefly review equalization topologies and algorithms. We discover cell remaining charging capacity (RCC) can be on-line estimated and further propose DCE algorithm based on remaining charging capacity estimation (RCCE). We establish a pack model with 8 cells in series and simulate 4 scenes with different cell variations. RCCE–DCE algorithm is proved to be effective by comparing pack capacities with/without RCCE–DCE algorithm. The equalization capability and over-equalization prevention are further examined, and the result shows that RCCE–DCE algorithm is suitable for on-line equalization in EVs. [Copyright &y& Elsevier]

Abstract: In the first part of this work, we propose dissipative cell equalization (DCE) algorithm based on remaining charging capacity estimation (RCCE) and establish a pack model with 8 cells in series. The results show that RCCE-DCE algorithm is suitable for on-line equalization in electric vehicles (EVs) and no over-equalization happens. However, 1% pack capacity difference from the DCE theoretical pack capacity is observed with RCCE-DCE algorithm. Therefore, as the second part of the series, we propose fuzzy logic (FL) DCE algorithm based on charging cell voltage curves (CCVCs). Cell capacities and SOCs are fuzzily identified in FL-DCE algorithm by comparing cell voltages at the beginning and end of charging. Adaptive FL-DCE is further improved to prevent over-equalization and maintain the equalization capability. The simulation results show that pack capacity difference from the DCE theoretical pack capacity with the adaptive FL-DCE is smaller than that with RCCE-DCE algorithm, and the duration of the infant stage is also shorter. The proposed adaptive FL-DCE is suitable for on-line equalization in EVs and well prevents over-equalization. [Copyright &y& Elsevier]

Abstract: In battery packs with cells in parallel, the inter-cell connection resistances can cause unequal loads due to non-uniform interconnect overpotentials and consequentially lead to non-uniform heating. This article explores how load imbalances are generated in automotive applications, by describing a battery pack with finite interconnect resistances. Each cell inside the pack is represented by a pseudo 2D electrochemical model coupled with a lumped thermal model. Increasing the number of cells in parallel results in a linear increase in load non-uniformity, whilst increasing the ratio of interconnect to battery impedance results in a logarithmic increase in load non-uniformity, with cells closest to the load points experiencing the largest currents. Therefore, interconnect resistances of the order of mΩ can have a significant detrimental impact. Under steady state discharge the cell impedance changes until the loads balance. This process, however, can take hundreds of seconds and therefore may never happen under dynamic load cycles. Cycling within a narrow state-of-charge range and pulse loading are shown to be the most detrimental situations. Upon load removal, re-balancing can occur causing further heating. Simulation of a 12P7S pack under a real world load cycle shows that these effects could cause localised thermal runaway. [Copyright &y& Elsevier]

Abstract: A fuzzy logic-based energy management strategy for a hybrid power system used in electric vehicles was developed and verified in this paper. First, the topology structure of a hybrid power system was put forward that the ultracapacitors connected with the battery pack in parallel after a bidirectional DC/DC converter. To improve the systematic efficiency, a fuzzy logic-based energy management strategy was designed and the control model was built. We proposed an active electricity management module for the ultracapacitors on the basis of the real-time vehicle velocity. Then, the vehicle model, the interface model of the electrical load and the xPC Target were built with the Simulink/State flow soft. Finally, the hybrid power/energy system-in-loop simulation experiment was carried out to verify the energy management strategy under the Urban Dynamometer Driving Schedule (UDDS) dynamic driving cycle. The results show the proposed fuzzy logic-based energy management strategy can ensure the battery pack working in high efficiency range and show better performance than the traditional logic threshold-based control strategy. The hybrid power system’s electricity economy was improved by 4.1% and the bad influences of the high-current discharging and charging on battery pack were avoided successfully. [Copyright &y& Elsevier]

Abstract: Due to cell-to-cell variations in battery pack, it is hard to model the behavior of the battery pack accurately; as a result, accurate State of Charge (SoC) estimation of battery pack remains very challenging and problematic. This paper tries to put effort on estimating the SoC of cells series lithium-ion battery pack for electric vehicles with adaptive data-driven based SoC estimator. First, a lumped parameter equivalent circuit model is developed. Second, to avoid the drawbacks of cell-to-cell variations in battery pack, a filtering approach for ensuring the performance of capacity/resistance conformity in battery pack has been proposed. The multi-cells “pack model” can be simplified by the unit model. Third, the adaptive extended Kalman filter algorithm has been used to achieve accurate SoC estimates for battery packs. Last, to analyze the robustness and the reliability of the proposed approach for cells and battery pack, the federal urban driving schedule and dynamic stress test have been conducted respectively. The results indicate that the proposed approach not only ensures higher voltage and SoC estimation accuracy for cells, but also achieves desirable prediction precision for battery pack, both the pack's voltage and SoC estimation error are less than 2%. [Copyright &y& Elsevier]

Highlights: [•] Characterized two novel high capacity electrode materials for Li-ion batteries. [•] A numerical discharge model was run to characterize Li-ion cell behavior. [•] Engineering model of Li-ion battery pack developed from cell fundamentals. [•] ESP-r model integrated micro-cogeneration and high capacity Li-ion storage. [•] Higher capacity batteries shown to improve micro-cogeneration systems. [Copyright &y& Elsevier]

Highlights: [•] We propose a Mean-plus-Difference Model (M+D Model) for battery pack. [•] Mean model represents the whole pack and difference model investigates inconsistency. [•] OCV differences are estimated using cell difference model for LiFePO4 pack. [•] SOC strategy is proposed to identify SOC inconsistency by lowering pack SOC in HEV. [•] SOC differences are determined using SOC-difference/OCV-difference curve. [Copyright &y& Elsevier]

Abstract: Electric vehicle cooling modes are divided into air cooling, liquid cooling and phase change material cooling, the air cooling is divided into natural air cooling and forced air cooling. This paper selects the forced air cooling as the study object, and researches the heat dissipation performance of different airflow duct modes, the results indicated that: as considering that changing the longitudinal battery pack into horizontal battery pack, it could improve the heat dissipation performance by shorting airflow path; it increases the contact area for thermal conduction by adding bottom duct, and the area of battery pack top exists natural convection, so the heat dissipation performance of bottom duct mode is more superior; for battery pack with bottom duct mode, it uses the double “U” type duct instead of double “1” type duct in order to improve the heat dissipation performance; when the heat dissipation condition is poor, it could reduce the SOC state or charge & discharge rate to satisfy the heat dissipation performance requirements; as considering the practical operation condition of battery pack with double “U” type duct, it has a large margin of high charge and discharge rate to meet the needs of electric vehicle acceleration or deceleration operation. [Copyright &y& Elsevier]

Abstract: Systems integration issues, such as electrical and thermal design and management of full battery packs – often containing hundreds of cells – have been rarely explored in the academic literature. In this paper we discuss the design and construction of a 9kWh battery pack for a motorsports application. The pack contained 504 lithium cells arranged into 2 sidepods, each containing 3 modules, with each module in a 12P7S configuration. This paper focuses particularly on testing the full battery pack and diagnosing subsequent problems related to cells being connected in parallel. We demonstrate how a full vehicle test can be used to identify malfunctioning strings of cells for further investigation. After individual cell testing it was concluded that a single high inter-cell contact resistance was causing currents to flow unevenly within the pack, leading to cells being unequally worked. This is supported by a Matlab/Simulink model of one battery module, including contact resistances. Over time the unequal current flowing through cells can lead to significant differences in cells’ state of charge and open circuit voltages, large currents flowing between cells even when the load is disconnected, cells discharging and aging more quickly than others, and jeopardise capacity and lifetime of the pack. [Copyright &y& Elsevier]

Abstract: A three-dimensional thermal model has been developed to gain better understanding of thermal behavior of battery cells in a pack under simulated driving cycles. The numerical approach incorporates a three-dimensional CFD pack-level sub-model, a one-dimensional battery pack network sub-model, and a three-dimensional thermal and electrochemical coupled cell/module level sub-model so that the battery non-uniform heat generation rate, the battery temperature distribution as well as battery temperature variation across a pack can be quickly predicted. In particular, the flow profiles of each individual battery cooling channel are calculated using the three-dimensional CFD sub-model. Using the predicted flow profiles of the cooling channel as flow boundary conditions the thermal behavior of battery cells is predicted using the one-dimensional battery pack network sub-model and the cell/module level thermal sub-model, in which both electrochemical reaction and double layer effect of battery cells are considered. The thermal behavior of battery cells is correlated through physical tests. Finally, the effects of the cooling flow of battery pack and the design of battery pack cooling system on non-uniformity of individual battery cell temperature and battery cell temperature variation across the pack under simulated US06 driving cycles are studied and discussed. [Copyright &y& Elsevier]

Lithium-ion (Li-ion) batteries are nowadays the best tradeoff between performance, cost, and lifetime to store electric power and energy effectively. The reliable determination of the batteries’ instantaneous power capability and energy content is mandatory for many mobile high-energy and power-consuming applications. Herein, the battery impedance and state of charge (\SOC) are the relevant values. In energy storage systems, these values are to be considered for each battery cell individually, due to arising limitations caused by cell-specific variations. Simple algorithms to determine the battery system’s impedance and \SOC are presented including parameter and state-estimation techniques. Furthermore, methods are derived making the impedance and \SOC determination possible for a large number of particular cells in a battery system. The applicability of the demonstrated algorithms for battery control unit implementation is proved incorporating data achieved from load scenarios applied to a cell stack Li-ion battery module. Cell impedance and \SOC variations could be detected precisely. Moreover, a combination of impedance and \SOC spread was identified during typical battery operation. [ABSTRACT FROM PUBLISHER]

Depending on the level of electrification ([PH]EV, [M]HEV) and cell format (pouch, prismatic, cylindrical), the number of individual cells in a vehicle's battery pack can span several orders of magnitude (from tens to thousands). In this paper, we develop a novel analytical framework to investigate the impact of cell-level manufacturing variability on pack performance. Statistical distributions of pack energy and pack power are derived for any NsMp pack configurations and any level of cell-to-cell variability. These distributions are used to develop vehicle-dependent cell-level manufacturing requirements. The degree to which the series direction negatively affects pack statistics, and the degree to which the parallel direction improves pack statistics, is first quantified under a random sampling scenario. PHEV packs (96s1p) are found to have the highest pack-level statistical penalty, while EV packs made of small-format cylindrical cells (96s74p) incur virtually no statistical penalty. Pack-level statistics for Ns1p packs are shown to greatly benefit from the clustering of low-performing cells. Cell binning strategies for NsMp packs present both advantages and disadvantages. The impacts of cell aging and pack-level voltage limits are further discussed. The results of this study apply even in the presence of cell balancing and under partial SOC usage. [Display omitted] • A novel analytical model is developed to relate cell variability and pack statistics. • The model is valid for any level of cell variability and any pack configuration. • Pack distribution of energy and power is derived for different vehicle segments. • Cell binning strategies to optimize pack-level statistics are presented. • The effect of cell balancing, cell aging and pack-level voltage limits are discussed. [ABSTRACT FROM AUTHOR]

State-of-health (SOH) monitoring of lithium-ion batteries plays a key role in the reliable and safe operation of battery systems. Influenced by multiple factors, SOH is an aging path-dependent parameter, which challenges its accurate estimation and prediction. Numerous methods have been proposed for lithium-ion batteries SOH diagnostics and prognostics, but there is little discussion on how to characterize SOH. In this paper, we first review the existing characteristic parameters in defining battery SOH at cell-level and pack-level, and then propose some suggestions for SOH definitions. The impact of external influencing factors on battery degradation is introduced to lay a foundation for SOH estimation. SOH estimation methods are categorized by the parameters used to define SOH, i.e. capacity, impedance and aging-mechanism parameters. We discuss the goals of SOH monitoring and summarize its applications from short- and long-term perspectives accordingly. Finally, the challenges and future trends of battery SOH diagnostics and prognostics are thoroughly analyzed and discussed, in order to provide a comprehensive understanding for researchers and technologists. • Discuss how to comprehensively characterize battery SOH at cell-level and pack-level. • Analyze the strengths and weaknesses of the SOH estimation methods from the perspective of data acquisition sources. • Present the gaps between existing research on SOH estimations and SOH applications. • Summarize the challenges and prospects for SOH characterizations, estimations and applications. [ABSTRACT FROM AUTHOR]

The cooling structure of a battery pack and coupled liquid cooling and phase change material (PCM) were designed in a thermal management system to enhance the cooling performance and extend the service life of lithium-ion battery packs. Numerical simulations were conducted based on the finite volume method. This study focuses on factors such as the layout of the terminal, flow rate of the coolant, different sections of the cooling pipe, position of the cooling pipe, and coupled liquid cooling, and investigates their influences on the operating temperature. The results show that a reasonable terminal layout can reduce heat generation inside the batteries. The appropriate flow rate and position of the cooling pipe effectively reduced the maximum temperature and minimized energy consumption. Then, the PCM was placed between the adjacent batteries near the outlet to enhance the uniformity of the battery pack. The temperature difference was reduced to near 5 K. This study provides a clear direction for improving the cooling performance and extending the service life of battery packs. [ABSTRACT FROM AUTHOR]

Abstract: A simple approach for using accelerating rate calorimetry data to simulate the thermal abuse resistance of battery packs is described. The thermal abuse tolerance of battery packs is estimated based on the exothermic behavior of a single cell and an energy balance than accounts for radiative, conductive, and convective heat transfer modes of the pack. For the specific example of a notebook computer pack containing eight 18650-size cells, the effects of cell position, heat of reaction, and heat-transfer coefficient are explored. Thermal runaway of the pack is more likely to be induced by thermal runaway of a single cell when that cell is in good contact with other cells and is close to the pack wall. [Copyright &y& Elsevier]

We discuss a rapid testing of capacity in Li-ion battery packs with impedance-measuring technology to evaluate their capability in mobile phones. Our measurements of the capacity and impedance at 1 kHz for various kinds of battery packs conclusively proved that there is a strong correlation between capacity and impedance. It can be applied even when the pack consists of not only a Li-ion battery but also a Positive Temperature Coefficient (PTC) device and a protection circuit in-series, and this correlation is largely unaffected by the degree of charge. The results we obtained from measuring impedance revealed the possibility of quickly assessing degradation in Li-ion battery packs. [Copyright &y& Elsevier]

A serious issue relative to the construction of electronic devices is proper power source selection. This problem is of particular importance when we are dealing with portable devices operating in varying environmental conditions, such as military equipment. A serious problem in the construction of electronic devices is the correct selection of the power source. In these types of devices, lithium-ion batteries are commonly used nowadays, and in particular their variety—lithium iron phosphate battery—LiFePO4. Apart from the many advantages of this type of battery offers, such as high power and energy density, a high number of charge and discharge cycles, and low self-discharge. They also have a major drawback—a risk of damage due to excessive discharge or overcharge. This article studies the process of charging and discharging a battery pack composed of cells with different initial charge levels. An attempt was made to determine the risk of damage to the cells relative to the differences in the initial charge level of the battery pack cells. It was verified, whether the successive charging and discharging cycles reduce or increase the differences in the amount of energy stored in individual cells of the pack. [ABSTRACT FROM AUTHOR]

Reliability optimization has always been an important topic in the application of lithium-ion batteries in electric vehicles. To optimize the redundancy and layout design of battery packs accurately and efficiently, a novel reliability optimization method based on a multiphysics coupling simulation and a response surface methodology is proposed. An electrochemical-thermal-fluid dynamics model, a temperature-dependent stochastic degradation model and a multistate performance reliability model are developed. A response surface method with the Box-Behnken design method is applied to reduce the number of simulation trials. Then, the redundancy scheme and two layouts of a battery pack are optimized, followed by a sensitivity analysis of the design parameters. The results show that a large spacing in the direction of air flow contributes to improving system reliability. In this case, for the layout of a cross arrangement with equal spacing, the optimal reliability design scheme of a 5 × 5 parallel series with optimal design parameters can improve the cycle life from approximately 1989 to 2933 when taking 90% system reliability as the criterion. The collaborative optimization of redundancy and layout is of great importance to extend the service life and improve the system reliability of battery packs. • A novel reliability optimization method for lithium-ion battery pack is proposed. • This method combines multiphysics simulation and response surface methodology. • Collaborative optimization of redundancy and layout is implemented efficiently. • A optimal redundancy scheme with optimal layout of a battery pack is determined. [ABSTRACT FROM AUTHOR]

In this article, analysis of average Nusselt number (Nu avg), which indicates the heat removal from the battery pack cooled by flowing fluid is carried out considering coupled heat transfer condition at the pack and coolant interface. Five categories of coolant, mainly gases, common oils, thermal oils, nanofluids, and liquid metals, are selected. In each coolant category, five fluids (having different Prandtl number Pr) are selected and passed over the Li-ion battery pack. The analysis is made for different conductivity ratio (Cr), heat generation term (Q gen), Reynolds number (Re), and Pr. Pr varying in the range 0.0208–511.5 (25 coolants) and Cr for each category of coolant having its own upper and lower limit are used to analyze the heat removed from the battery pack. Using single feed-forward network and integrating two feed-forward networks having multi-layers with back-propagation is employed for artificial neural network (ANN) modelling. In this modelling, the concept of the main network and space network is devised for multiple back propagation (MBP). The numerical analysis revealed that the temperature distribution in battery and fluid is greatly affected by increasing Cr. The maximum temperature located close to the upper edge of battery is found to get reduced significantly with the increase of Cr , but upto a certain limit above which reduction is marginal. The analysis carried out reveals that Cr and Q gen have no role in improving Nu avg while Pr and Re vary it significantly in each step. Moreover, Nu avg is found to increase with Re continuously irrespective of any Cr and Q gen. While, for oils with an increase in Pr and Re , Nu avg was found to reduce significantly. Nanofluids are found to be more effective in improving heat transfer from the battery pack when cooled by flowing nano-coolants over it. The MBP networks proposed are successfully trained, and hence they can be used for prediction of Nu avg. • Conjugate numerical analysis of battery cells is carried for several coolants. • Multiple back propagation modelling of Nusselt number is carried. • Nanofluids provide maximum heat transfer. • Multiple feed forward with back propagation predicts Nusselt number properly. [ABSTRACT FROM AUTHOR]

Lithium-ion battery packs are widely deployed as power sources in transportation electrification solutions. To ensure safe and reliable operation of battery packs, it is of critical importance to monitor operation status and diagnose the running faults in a timely manner. This study investigates a novel fault diagnosis and abnormality detection method for battery packs of electric scooters based on statistical distribution of operation data that are stored in the cloud monitoring platform. According to the battery current and scooter speed, the operation states of electric scooters are clarified, and the diagnosis coefficient is determined based on the Gaussian distribution to highlight the parameter variation in each state. On this basis, the K-means clustering algorithm, the Z-score method and 3σ screening approach are exploited to detect and locate the abnormal cells. By analyzing the abnormalities hidden beneath the external measurement and calculating the fault frequency of each cell in pack, the proposed algorithm can identify the faulty type and locate the faulty cell in a timely manner. Experimental results validate that the proposed method can accurately diagnose faults and monitor the status of battery packs. This theoretical study with practical implications shows the promising research direction of combining data mining technologies with machine learning methods for fault diagnosis and safety management of complex dynamical systems. • The operation state of electric scooter is classified by current and speed. • A faults diagnosis and state monitoring scheme is proposed for lithium-ion battery. • The outlier screening algorithm is employed to detect and locate abnormal cell. • Fault frequency is imported to quantitatively evaluate healthy status of battery. [ABSTRACT FROM AUTHOR]

• A pack comprising the electro-thermal coupling of individual cells was developed. • Z shape module shows a significant advantage over a ladder configuration. • The correlation between system inhomogeneity and design parameters was quantified. • Contact resistance has the highest impact on the inhomogeneity of a system. • There is not a strong correlation between system inhomogeneity and C-rate. Cell-to-cell variations can originate from manufacturing inconsistency or poor design of the battery pack/thermal management system. The potential impact of such variations may limit the energy capacity of the pack, which for electric vehicle applications leads to reduced range, increased degradation along with state of health dispersion within a pack. The latter is known to reduce the accessible energy and the overcharging/discharging of some of the cells within a system, which may cause safety concerns. This study investigates the short-term impact of such effects, which is highly important for designing of an energy storage system. A generic pack model comprising individual cell models is developed in Simscape and validated for a 1s-15p module architecture. The results highlight that a number of cells and interconnection resistance values between the cells are the dominant factors for cell-to-cell variation. A Z shape module architecture show a significant advantage over a ladder configuration due to the reduced impact of interconnection resistance on differential current flow within the module. Current imbalance is significantly higher for a ladder system and its magnitude is not dependent on the module current. Capacity variation does not have a significant impact on the system. By increasing the capacity variation from 9% to 40% the current inhomogeneity increases from 4% to 13%, whilst 25% resistance variation leads to 22% current dispersion. Further, a linear relationship is observed between the current inhomogeneity and thermal gradient (Δ T). A 30 °C Δ T leads to 24% current variation within the module. [ABSTRACT FROM AUTHOR]

Heat transfer and phase change flow inside a Li-ion battery enclosure filled with a copper metal foam embedded in paraffin wax phase change material (PCM) are studied numerically. For simplicity and due to the axisymmetric of the enclosure geometry, half of the battery cell is considered as the heat source on the right wall. The vertical walls are considered symmetric, while the bottom wall is insulated, and the top wall is subjected to the convective heat transfer. The governing equations of the flow and heat transfer are presented as partial differential equations and then transformed into non-dimensional forms and solved by employing the finite element method. The local thermal equilibrium model was used, which limits the model to metal foams with high pore densities. For validation, results are compared with some of the well-known studies in the literature. The isotherms and streamlines are presented for three levels of heat pulse intensity. Both melting and solidification occur as a result of the unsteady heat pulses induced by the thermal source. The vertical location of the battery inside the enclosure can affect the streamlines and isotherm contours. Results show that for higher heat pulse powers, the melt volume fraction (MVF) increases, and heatsink will have higher efficiency. For a comparatively strong heat pulse, the efficiency was increased about seven times. [ABSTRACT FROM AUTHOR]

CubeSats and small satellite solutions are increasing in popularity as they enable a fast, cheap, and agile way for satellite applications. An essential component of nearly every satellite is the energy storage device, which is practically equal to a battery. Consequently, an overview of past, present, and future battery technologies for CubeSats is presented. CubeSats use typically commercial off-the-shelf (COTS) batteries. They are not primarily dedicated to space, so their suitability to the space environment needs to be evaluated. Batteries are also considered as potentially dangerous goods. Thus, there are guidelines and standards that specify safety criteria and tests for the batteries in order to be allowed for transportation and launch. Furthermore, the character of satellites' missions determines their demand on batteries in terms of current rates, depth-of-discharge, and lifetime. Thus, these expectations are discussed. A market survey was also carried out to identify currently available commercial battery solutions and their parameters. This work summarizes the status, requirements, and the market situation of batteries for CubeSats. [ABSTRACT FROM AUTHOR]

Large-scale introduction of electric vehicles (EVs) to the market sets outstanding requirements for battery performance to extend vehicle driving range, prolong battery service life, and reduce battery costs. There is a growing need to accurately and robustly model the performance of both individual cells and their aggregated behavior when integrated into battery packs. This paper presents a novel methodology for Lithium-ion (Li-ion) battery pack simulations under actual operating conditions of an electric mining vehicle. The validated electrochemical-thermal models of Li-ion battery cells are scaled up into battery modules to emulate cell-to-cell variations within the battery pack while considering the random variability of battery cells, as well as electrical topology and thermal management of the pack. The performance of the battery pack model is evaluated using transient experimental data for the pack operating conditions within the mining environment. The simulation results show that the relative root mean square error for the voltage prediction is 0.7–1.7% and for the battery pack temperature 2–12%. The proposed methodology is general and it can be applied to other battery chemistries and electric vehicle types to perform multi-objective optimization to predict the performance of large battery packs. [ABSTRACT FROM AUTHOR]

• Adaptive federated Kalman filter is used for enhanced battery pack SOC estimation. • A fuzzy system is used to adapt to various cell SOC inconsistency distributions. • Accuracy is evaluated under SOC inconsistencies against conventional methods. • Fault tolerance is evaluated under the influence of measurement errors. Inconsistencies among battery cells and measurement errors have significant impacts on the accuracy and reliability of state of charge (SOC) estimations for series-connected battery packs. The aim of this paper is to propose a novel SOC estimation method for series-connected battery packs based on the fuzzy adaptive federated filtering. The mean-plus-difference model is employed to characterize the inconsistencies among battery cells. The fuzzy system is designed to improve the accuracy and adaptability of SOC estimation under cell inconsistencies. The SOC estimation value from a cell mean model and the standard deviation of SOC estimation are combined with a fuzzy system to determine their fusion weights. The master filter adaptively adjusts the information distribution coefficient according to the local filter estimation accuracy to improve reliability. Through simulation and experimentation on series-connected battery packs with different SOC distributions, the estimation accuracy of the proposed method is compared between the proposed method and the conventional methods. The SOC estimation accuracy of each battery cell is evaluated. The results show that, over the full SOC range, the root-mean-square error (RMSE) of the battery pack SOC estimation is less than 0.6% and 1.5% using online and offline parameters, respectively. The SOC estimation RMSEs of the battery cells using online and offline parameters are less than 0.4% and 1%, respectively. The fault tolerance is verified by artificially adding measurement errors. These accurate and reliable results show a strong prospect for the design and optimization of future clean and sustainable mobility. [ABSTRACT FROM AUTHOR]

The utility of a single-point impedance-based technique to monitor the state-of-health of a pack of four 18650 lithium-ion cells wired in series (4S) was demonstrated in a previous publication. This work broadens the applicability of the single-point monitoring technique to identify temperature induced faults within 4S packs at 0 °C by two distinct discharge cut-off thresholds: individual cell cut-off and pack voltage cut-off. The results show how the single-point technique applied to a 4S pack can identify cell faults induced by low temperature degradation when plotted on a unique state-of-health map. Cell degradation is validated through an extensive incremental capacity technique to quantify capacity loss due to low temperature cycling and investigate the underpinnings of cell failure. [ABSTRACT FROM AUTHOR]