Thermal & Electr Thermal & Electrochemical Simulation of - - PowerPoint PPT Presentation

Thermal & Electr Thermal & Electrochemical Simulation of

• chemical Simulation of

Batt Batter ery Pack Syst y Pack Systems ems

St Steve Har e Hartridge ridge Direct Director

• r, Electric &

, Electric & Hybrid V Hybrid Vehicles hicles

Micr Micro-structure Electr

• -structure Electrochemistr
• chemistry
• Vir

Virtually t ually test SEM pr st SEM produced

• duced electr

electrod

• de geome

e geometry

• Conduct design studies on

Conduct design studies on ne new conce w concepts ts

Pro Provid ides pr es previously un iously unseen spat seen spatia ial ef l effects w within elec thin electrod trodes es “De “Design” n” ne next gene xt generation elec electrodes

CD-adapco Batt CD-adapco Batter ery Modeling T y Modeling Technology chnology

Cell Design Cell Design Tool

• ol
• Build ph

Build physics based models ysics based models o

• f el

elect ectrode pair

• de pairs and

and couple couple them t them to the the cells cells ph physical constru ysical constructio tion

• Use the pr

Use the provid ided ed database of mat database of materials t rials to constru construct vir t virtua ual cells and t l cells and test st their per their performa mance nce

Ov Overall Syst erall System Design em Design

• Int

Interface Module & ace Module & Pack analyses with Pack analyses with com comple lex po x power train train syst system mode em models ls

• Embed ph

Embed physics ysics based or based or em empirical pirical models in models in to po power r train syst train systems s mod models ls

Module Module & P & Pack Analysis ck Analysis

• Flo

Flow, therma , thermal & l & Ele Electr troche hemistr stry analys analysis of is of com comple lex po x power syst r systems ems

• Study detailed spatial

Study detailed spatial ef effects at cts at cell, module & cell, module & pack le pack level

Pouch

Battery

A A genuinely uniq genuinely unique ue tool which predicts the spatial distribution of ions

• ol which predicts the spatial distribution of ions

and and po potential within an ntial within an arbitrar arbitrary, multi-phase micr multi-phase microstructure region

• structure region

– Electric Potential in solid and electrolyte regions – Salt concentration in electrolyte – Concentration of Li in active parts of electrode Uses the arbitrary geometry handling power and massively parallel architecture

• f STAR-CCM+

Easy set up of the initial states of the electrode based on OCV and state of charge “Primary use is the design of next generation battery electrodes”

Micr Micro-structure Electr

• -structure Electrochemistr
• chemistry

A A VARTA LIC 1 A LIC 18650 8650 WC LiCO2 batt LiCO2 batter ery w y was segment s segmented b ed by FIB-SEM and FIB-SEM and reconstruct reconstructed**. A ed**. A 21 million cell f million cell finit nite v volume mesh w lume mesh was creat s created d including activ including active mat e material, secondar rial, secondary conductiv y conductive phase and e phase and electr electrolyt

• lyte

e fluid phase*. fluid phase*.

“Primary use is the design of next generation battery electrodes”

Micr Micro-structure Electr

• -structure Electrochemistr
• chemistry –

– Case Study ase Study

*Presen *Presented at ed at Solid Stat Solid State Electr e Electrochemi

• chemist

stry W Workshop 20 rkshop 2013 held at held at Heide Heidelberg berg **Hutz utzenlau nlaub et al. 2 2012 T 12 Three-Dimens Dimensional m ional model d l development lopment f for l lithium ium intercalat alation e ion electr trodes es, J , J. P Power S Sour urces 185(2) 185(2) Thr Three-dimens ee-dimensional electr ional electrochemical L

• chemical Li-ion ba
• ion batter

ery m y modelling lling featuring a uring a focus cused i d ion- beam scannin beam scanning electr electron micr

• n microscop
• scopy based

based three-phas e-phase r e reco cons nstr truct uction o ion of a LiCoO2 O2 cathod cathode, e, Hutze Hutzenlaub et.al .al. Electr Electrochimica ca Acta ta - 2014

A A design study using DEM design study using DEM

“Primary use is the design of next generation battery electrodes”

Micr Micro-structure Electr

• -structure Electrochemistr
• chemistry –

– Case Study ase Study

Binders Active Material

3 Phases Problem

Use STAR-CCM+ CAD tool to improve binder’s network realism

A A com comprehensiv rehensive design en design envir vironment which links a nment which links a ph physics based ysics based electr electrochemistr

• chemistry model with a

model with a sizing pr sizing program,

• gram, enabling

enabling the the electr electrochemical and ph

• chemical and physical design of a

ysical design of a cell t cell to be studied be studied

– Electrochemistry model – numerous derivatives with increasing fidelity – Sizing program – Numerically ‘build’ the cell and understand important metrics

Co Covers all Batt rs all Batter ery f y form f rm fact ctor

• rs –

s – Stack tack, w , wound prismatic & und prismatic & wound und cylindrical cylindrical Parame rameterization of a rization of a batt batter ery cell – y cell – creating either an reating either an cont contem emporar porary electr electrochemistr

• chemistry model or eq

model or equiv uivalent cir lent circuit uit model model Exam Example Model ple Model

Cell Design T Cell Design Tool

• ol

Sizing Sizing Exam Example – ple – Cylindrical Cell ylindrical Cell

– Default High Power NCA/Graphite 18650 cell, 1.04 Ahr, – Increased Energy NCA/Graphite 18650 cell, 1.28 Ahr(23% up)

Cell Design T Cell Design Tool

• ol

Discharge R Discharge Response sponse

– Sanyo LiNi0.33Mn0.33Co0.33O2 18650 cell (2.05Ahr) – Cells disassembled and physically characterized – C/5 to 2C discharge rate – Errors within 6.5% over total discharge – Errors within 2.8% over 60% SOC window

Cell Design T Cell Design Tool –

• ol – Validation R

alidation Result sult

Sakt Sakti, et.

• et. Al,

Al, A A val validation stud study of

• f lith

lithium-ion cel cell cons constant c- c-rate te dis discharge sim simulation with with Battery D ry Design S gn Studio io, Internat International Journa Journal of

• f Energ

Energy Researc Research 2012 2012

Cell Design T Cell Design Tool -

• ol - Validation R

alidation Result sult

Figure re shows shows the pred the predicti tion

• n of cel
• f cell vol

voltage usi using a a deta detailed d electro electroche hemi mica cal model model, ov

• ver

er a a comp complete te drive drive cycl

• cycle. T

. The lowe he lower r grap graph compa h compares es simu simulati tion

• n (red

(red lin line) with with experi experimen enta tal (gree (green poin points) s) resu result.

• t. The upper

he upper graph graph is the instan is the instanta taneous error error betwe between the two lin the two lines es . . Average age pred predicti tion

• n erro

error over

• ver the 30

the 30 minu minute te driv drive cycl cycle is 8mV is 8mV Thanks hanks to Dav Dave Howell Howell, DoE , DoE f for t their c eir co-funding unding of

• f the CD-

he CD-ad adapco CA apco CAEBAT BAT pr project and

• ject and NRE

NREL L for t their pr eir project involvement

• ject involvement

Cell Description Cell Description

– Geometric Description of cell – Material properties of coatings – Voltage vs. Stoichiometry for active – Electrolyte selection

Cell Design T Cell Design Tool –

• ol – Process

cess

Cell Calibration Data Cell Calibration Data

– OCV curve – HPPC tests at differing rates/differing temperatures – Constant current at low C rate/differing temperatures

Cell P Cell Parame rameter Estimation r Estimation

– Stoichiometry at formation to match capacity – Temperature dependent diffusion co-eff – Kinetic rate constant – SEI resistance to match voltage drop in HPPC test

Cell V Cell Validation lidation

• Creat

Created a d a 20Ah cell with LiF 20Ah cell with LiFePo cathode/Graphit cathode/Graphite anode anode

• Run a 1 y

n a 1 year ar aging simulation aging simulation

• Com

Compare “Initial” with “aged” cell per are “Initial” with “aged” cell performance

• rmance

Cell Design T Cell Design Tool –

• ol – Aging Prediction

ging Prediction

Solvent Solvent Diffusion Model for Diffusion Model for agin aging g of

• f lith

lithium-ion batter ium-ion battery cells, H. cells, H. P P loehn, P. loehn, P. Ramadass, R. Ramadass, R. White

• White. J

J Elect Electrochemistr emistry y

• Soc. 151
• Soc. 151 (3)

(3) A456-A462 A456-A462 (2004) (2004)

Cell Design T Cell Design Tool > Module & Pack Analysis

• ol > Module & Pack Analysis

Cell Design Cell Design Tool

• ol
• Buil

Build ph d physics based mode ysics based models of

• f elec

electr trode pair

• de pairs and couple

s and couple them t them to the cells ph the cells phys ysical construc constructi tion

• Use the pr

Use the provided database database of

• f mat

materials t s to constru construct t vir virtual ual cell cells and t s and test their per st their performance

Module & Module & Pack ck Analysis Analysis

• Flo

Flow, therma , thermal & l & Ele Electr troche hemistr stry analys analysis of is of com comple lex po x power syst r systems ems

• Study detailed spatial

Study detailed spatial ef effects at cts at cell, module & cell, module & pack le pack level

Electrochemist/Cell Electrochemist/Cell Designer Designer Thermal Thermal Analyst/application expert Analyst/application expert

Materials Database Pouch Prismatic

Input Program: Drive Cylce, Discharge (Current, Power,etc) Model Parameters: Properties + Experiments Output SOC (%) Voltage (V) Heat Generation (W) Concentration Solid Diffusion Coefficient (m2/s) Etc…

Module & Pack Analysis Module & Pack Analysis

Coup Coupled led Physics Physics

Pouch Cylindrical Prismatic

Thermal/ ermal/Fluidic uidic Solv Solver er Equivalent Cir Equivalent Circuit uit Or Physi Or Physics Based s Based

ElectroChemical Solver

Battery Heat Battery Temperature

Cooling Plates Pouch LCO cells Compression Pads Tab Connector

21 Ahr LCO – 3.8V Nominal Voltage Opposite Tab Design Liquid Cooling Performance Prediction:RCR Model

Module & Pack Analysis Module & Pack Analysis

Periodicity Applied

US06 Charge Depleting Drive Cycle

Current (A) Flow rate (kg/s)

120

• 80

0.002

Cooling Channels Flow Rate

Time (s) Time (s)

600 600

Conditions

Current Density in Tab Connectors (A/m2)

Module & Pack Analysis Module & Pack Analysis

German German Autos OEM s OEM Pr Project (Daimler

• ject (Daimler, P

, Porsche & che & GM GM Eur Europe) managed pe) managed by by A ASCS, S Stuttgart

– 84 cell off-road hybrid pack – Liquid cooled cold plate thermal control – Equivalent circuit cell model – Transient electrical/thermal boundary conditions

Li- Li-ion

• n b

battery s simula lation s tion strategies rategies and valid lidate ted d im implementations f tions for r the virt rtua ual l develo developmen ent pro process of electrified

• f electrified vehicles

vehicles

• S. Fell, E. Schneider, M. Lindner, R. Immel, J. Kremser

SIMVEC – Berechnung, Simulation und Erprobung im Fahrzeugbau 2012, VDI-Berichte 2169, p.241-254; ISSN 0083-5560, ISBN 978-3-18-092169-3; VDI Verlag GmbH, Düsseldorf 2012

Pac Pack V Voltage age Cell T Temperat eratures ures

Left Side – with weak cell Right side – all strong cells

Current shows <20 Amps provided by “weak” side “Weak” cell runs hotter

Module & Pack Analysis – Module & Pack Analysis – Weak Cell eak Cell

Ov Overall Syst erall System Design em Design

Link t Link to syst system design sof em design software re

– Matlab Simulink

• Link available at cell or module/pack level
• Embed certain cell models in to Simulink directly

– AMESim

• Link available at cell or module/pack level

Equivalent Cir Equivalent Circuit uit Or Physi Or Physics Based s Based

ElectroChemical Solver

Inputs Outputs

Nissan – Nissan – Star Global Conf tar Global Conference 20 erence 2012 12 FMC FMC – Star Global Conf tar Global Conference 20 erence 2012 12 GM GM Eur Europe – pe – Star Global Conf tar Global Conference 20 erence 2012 12 Hitachi Max Hitachi Maxell – ll – Japanese Conf apanese Conference 20 erence 2012 12 Hyundai Mobis Hyundai Mobis – Korean Conf rean Conference 20 erence 2012 12 Carnegie Mellon - Carnegie Mellon - INTERNATIONAL JOURNAL OF ENERGY RESEARCH + man + many user users w s worldwide rldwide that that are no are not named t named Depar Department of Energy ment of Energy

– Co-funded project with JCI & A123 – $3M project – Software now available

Wide spread adoption of CD-adapco batt Wide spread adoption of CD-adapco batter ery modeling me y modeling methods thods

Batt Batter ery Simulation Industr y Simulation Industry Present Presenters rs

Conclusions Conclusions

CD-adapco’s CD-adapco’s Batt attery Solution is Solution is a a Multi-ph Multi-physics ysics and nd Multi-scales Multi-scales solution solution

• f
• ffering per

ring performance simulation of coupled syst

• rmance simulation of coupled systems

ems involving Li-ion

• lving Li-ion

batt batteries. eries. Predicts the per Predicts the performance of a

• rmance of a ne

new cell and w cell and an an aged aged or aging

• r aging cell

ell Current de Current development f lopment focuses on cuses on abuse conditions such as abuse conditions such as thermal thermal runa runaway caused b y caused by nail nail pene penetration, tration, int internal or rnal or external shor rnal short cir t circuits uits De Development also f lopment also focuses on cuses on other aging her aging mechanisms mechanisms Visit the com Visit the compan any’s w y’s websit bsite: e: http://www

http://www.cd-adapco co.com/ind /industrie ustries/batt tterie ies

Current Temperature