Battery Performance and Design Aida Rahim, PhD Senior Applications - - PowerPoint PPT Presentation
Monitoring Cell Temperature to Optimize Battery Performance and Design Aida Rahim, PhD Senior Applications Engineer Presenter Aida Rahim, PhD Senior Applications Engineering PhD Mechanical Engineering from MIT Part of the Luna team
Aida Rahim, PhD Senior Applications Engineer
Presenter
Aida Rahim, PhD
testing
Luna Corporate Overview
Corporate HQ Division HQ Commercial only
Luna Labs Charlottesville, VA Headquarters - Roanoke, VA Lightwave Division
TeraMetrix Division Ann Arbor, MI Edinburgh, United Kingdom Shanghai, China Stuttgart, Germany
Founded 1990 NASDAQ: LUNA (2006) Corporate HQ in Roanoke, VA 260+ employees Worldwide presence and support Strong, consistent growth Recent expansion
▪ Micron Optics – 2018 ▪ General Photonics – 2019
Lausanne, Switzerland Guangzhou, China Beijing, China
Luna Lightwave Division Focus
Sensing and gauging solutions that deliver data and insight not available with conventional data acquisition and monitoring systems
FIBER OPTIC SENSING Developing advanced optical technology that enable our customers to deliver better products and processes faster and more efficiently
Innovative measurement technologies for testing
and data-communications markets
Automotive | Aerospace |Structures | Security
OPTICAL MEASUREMENT & CONTROL Communications Test and Measurement
Motivation
Sources: https://www.survivalkit.com/blog/how-to-deal-with-lithium-ion-battery-fires/ https://www.bestattorney.com/orange-county/hoverboard-injury-lawyers.html http://allaboutwindowsphone.com/flow/item/18407_Replaceable_batteries_again_ba.php https://www.scientificamerican.com/article/how-lithium-ion-batteries-grounded-the- dreamliner/ https://www.bensound.com/
A safer, more powerful, and cost-effective solution to detect and provide warning of battery faults well in advance of failure is necessary
Types of Fiber Optic Sensing
Standard, Electrical Approach
Multiple Copper Wires Per Sensor
DAQ System
Sensors
Foil strain gages, thermocouples, RTDs, etc.
Susceptible to Electromagnetic Interference Bulky Sensors and Cabling
Selected Sensor Locations
Limited Data (Low Sensor Count)
Types of Fiber Optic Sensing
FOS/FBG Interrogator Multiple Sensor Points Per Fiber Distributed ‘Continuous’ Measurements
measurements
High-Speed Distributed Sensing High-Definition Distributed Sensing
HD-FOS Interrogator
▪ Very small, low profile (easy to embed) ▪ Lightweight ▪ Flexible ▪ Distributed ▪ Passive ▪ Immune to EMI ▪ Chemically inert ▪ Intrinsically safe
Works in harshest environments Can measure where you need data Provides more data, more insight
▪ High-definition mapping
▪ Distributed sensing
Optical Sensing can be applied at each level of battery design for all styles of cells
Distributed Sensors Single-Point Sensor
Single sensing element Multiple sensing points Continuous sensing along fiber Multiplexed/Quasi-Distributed Fully Distributed
Optical fiber Optical fiber Optical fiber
Fiber Bragg Grating (FBG) Sensing – How Does It Work?
Transmitted Signal λ1
λ
λ2 λ3
λ
Fiber Bragg Gratings (FBGs)
fiber core
Reflected Signal λ1
λ
λ2 λ3 λ1 λ2 λ3 Transmitted Signal
λ
Reflected Bragg wavelengths ( n) change with strain and temperature
Reflected Signal
Surface Strain Embedded Strain Temperature Acceleration
(multiplexed Fabry-Perot)
ENLIGHT Measurement Software HYPERION Interrogator
HYPERION
Sensors
Hundreds of sensors per system Strain, temperature, acceleration, displacement, etc. Acquisition rates up to 5 kHz Long fiber range (km’s)
Up to 16 parallel channels
Distributed Sensing: How it Works
Optical Fiber
Rayleigh backscatter, due to natural minute variations in index of refraction in fiber core Tunable Laser Source
temperature
Rayleigh backscatter signal
Strain or Temperature vs. Length
40 20
Temperature (°C) 40 20
Temperature (°C) 40 20
Temperature (°C)
ODiSI (Optical Distributed Sensor Interrogator)
ODiSI
HD Sensors – Strain and Temperature
Up to 8 parallel channels
Measures strain or temperature continuously along fiber (resolution down to 0.65 mm) Sensor length up to 50 m (per channel) Acquisition rates up to 250 Hz
High-Definition (Rayleigh) Fiber Optic Sensing High-Speed (FBG/FP) Fiber Optic Sensing
Ultra-high spatial resolution High-speed measurements Measure continuously along standard
FBGs or FBG/FP-based transducers distributed on optical fiber Strain, Temperature Strain, Temperature, Acceleration, Displacement, Pressure
ODiSI HYPERION
High-Definition Fiber Optic Sensing with Luna ODiSI 6100
Effective and Efficient Design Tool
Cell ▪ Evaluate effects different charge/discharge rates have on cell chemistry ▪ Qualify cells being cycled in different environmental conditions Module ▪ Evaluate cooling effectiveness ▪ Find hot-spots among clusters of neighboring cells Pack ▪ Ensure cell connections are robust ▪ Evaluate thermal profile inside enclosures
Optical Sensing can be applied at each level of battery design for all cell types.
https://www.electricvehiclesresearch.com/articles/2822 /the-growing-ev-market-will-fail-without-battery-size- standards-support
Enclosure Cells
Monitor the temperature
Integrating fiber sensing into a battery
Directly on the terminals ▪ Sensor can be placed across each terminal ▪ Held in place with a putty, tape, or
Using a pre-made “pad” design ▪ Sensor is fabricated into electrically non-conductive sheet ▪ Pattern ensures proper placement ▪ Simplifies installation
Fiber Path
Fiber Sensor path covering every terminal on a module
Pre-fabricated sheet integrated into a simulated battery module
Battery Fault Monitoring: Temperature
Cell 1
Battery Fault Monitoring: Strain
Design and Evaluation of a 1000V Li-Ion Battery
High voltage energy storage Understand the safety and reliability challenges 1000 VDC lithium-ion cell battery at University of Texas Arlington, instrumented with a single fiber sensor During installation, the location of each terminal throughout the 280S/1P battery was saved as a location of interest Monitor the controlled cycling of the battery to characterize its performance
A single 10S/1P LI module 1000 VDC LFP-LI battery
Dodson, David A.; Wetz, David A.; Sanchez, Jacob L.; Gnegy-Davidson, Clint; Martin, Matthew J.; Adams, Blake; Johnston, Alexander; Heinzel, John; Cummings, Steve; Frank, Nick; Rahim, Nur Aida Abdul; Davis, Matthew, Design and Evaluation of a 1000 V Lithium-Ion Battery. Naval Engineers Journal, Volume 131, Number 3, 1 September 2019, pp. 107-119(13)
Fiber Sensor path covering every terminal on a module
Design and Evaluation of a 1000v Li-Ion Battery
Dodson, David A.; Wetz, David A.; Sanchez, Jacob L.; Gnegy-Davidson, Clint; Martin, Matthew J.; Adams, Blake; Johnston, Alexander; Heinzel, John; Cummings, Steve; Frank, Nick; Rahim, Nur Aida Abdul; Davis, Matthew, Design and Evaluation of a 1000 V Lithium-Ion
Surface plots of Module 8 and 13
Individual cell temperatures
250kW discharge, 5s ON/1s OFF pulsed profile Temperature increase of each cell is similar Module 13 cell temperatures vary widely: 45ºC to 75ºC Possible reasons: ▪ Higher ohmic contact resistance between the cell terminal and the bus bar interconnecting series cells ▪ Poor thermal contact at the cell terminals If higher ohmic loss, this location needs to be assessed more carefully prior to use When this type of thermal resolution is not captured, these potential issues of concern are never identified
“What if?” Application
Could the time to full charge be reduced if every cell temperature was monitored? Would battery life be increased if the control method took into account cell temperature when charging?
https://hawaiienergy.com/for-businesses/incentives/electric-vehicle-charging-stationsEnvision an electric vehicle which has a sensor integrated into its battery and that sensor is used to monitor battery temperature during charging. Data is provided to the charging station enabling active control of the charge rate.
Summary
Introduced two ways of using optical fiber to make strain and temperature measurements ▪ Fiber Bragg Gratings ▪ OFDR Demonstrated the benefits of using this technology for battery development and in- service monitoring ▪ High spatial density ▪ Safe and non-intrusive ▪ Enables a measurement from every cell Showed how to integrate the sensors into a battery system
Bye Aerospace Volvo XC40 SUV
HD-FOS Addresses Key Challenges in Aerospace & Automotive
FEA Model Verification
geometries
test data
data Additive Manufacturing & Molds
printed parts
printing process
performance
Structural Testing
detection
monitoring
life cycle mgt. Manufacturing Processes
strain mapping
Material Joining & Welding
performance
strain
Acknowledgements
Director, Pulsed Power & Energy Lab Electrical Engineering Department University of Texas Arlington Contact: ▪ Aida Rahim, rahima@lunainc.com ▪ David Potter, potterd@lunainc.com, Marketing Director