BATTERY MANAGEMENT THE HEART OF EFFICIENT BATTERIES BATTERY TECHNOLOGIES FOR ELECTRO 28 TH NOVEMBER 2013 MOBILITY AND SMART GRID PURPOSES

Transcription

1 BATTERY MANAGEMENT THE HEART OF EFFICIENT BATTERIES BATTERY TECHNOLOGIES FOR ELECTRO MOBILITY AND SMART GRID PURPOSES 28 TH NOVEMBER 2013

2 Presentation Agenda 1. Introduction to LiTHIUM BALANCE 2. Battery Management Basic issues and aspects of battery management 4. Project examples Pb-Acid NiCad NiMH Li-Ion 2

3 A leading, European supplier of Li-ion battery management solutions LiTHIUM BALANCE have: Over 170 separate projects completed Several hundred vehicles driving Our BMS in the world s first manned electric helicopter RED HERRING Top 100 winner 2012 Runner up in the Eurecan venture contest

4 LiTHIUM BALANCE Battery Management Systems Founded in 2006 LiTHIUM BALANCE is owned by: Management A group of private investors DONG Energy LiTHIUM BALANCE offers: Battery Management systems Accessories Design and engineering services Battery packs Chargers 4

5 Battery management, explained The collection of features and functions that enable the safe and reliable operation of battery cells or packs All battery types require some degree of management to optimise performance. The larger the pack, the greater the need for management Lithium Ion batteries are relatively expensive and do not tolerate abuse management is essential Lithium Ion batteries are inherently unsafe unless properly managed 5

6 BMS function overview Cell Management Overcharging Deep discharge Overloading Short-circuit High/low Temperature Balancing Charging control Discharge rate Pack Management SoC calculation SoH calculation Pack level parameters Collection and summary of cell data Communication with external devices Contactor control Warranty management High level logic and special algorithms 6

7 Generic BMS Elements Pack Current & Voltage Communications interface Micro Processor I/O Switching Controller Cell voltage monitoring and balancing Temperature monitoring Charger Controller % SoC 80% SoC 80% SoC 80% SoC 80% SoC 80% SoC 80% SoC 80% SoC 80% SoC

8 Resistor Charger IO 8 RELAY + 12 Volt supply - HV- Load IO 2 IO 4 RELAY Current shunt HV+ RELAY LMUs IO6 or7 IO1 RELAY BMCU Serial Comm. bus

9 Charger BMS Installation Transmission Inverter or motor contoller VCU 9

10 When the battery management fails Stranded vehicle Damaged cells Dead cells Damaged HV bus Venting cells Burning cells Burning device (vehicle) Burning house (where the vehicle is parked)

11 Basic issues and aspects Cell measurement engine Temperature measurment Architecture and communications Functional safety

12 Cell voltage measurement Trade off between performance and cost Common mode is the cheapest and slowest Differential is the fastest and potentially most expensive A/D Common mode A/D A/D Multiplexed Differential A/D Differential

13 Terminal voltage Vt Cell model and OCV OCV open circuit voltage SoC indicator Measure when the cell is relaxed under no load Estimate during discharge using Vt = OCV (I x DCR) Vcpv You can measure DCR during charging (I x DCR)+ Vcpv can be measured during discharge Ohmic resistance (DCR) Cell polarisation voltage (Vcpv) OCV Not to scale! 13

14 Cell temperature measurement Lowest temperature is just as important as the highest Temperature measurements for safety as well as parameter correction More temperature measurements is not always better Simulation or actual measurements needed to place temperature sensors correctly

15 Architecture and communications Master Master Monolithic Serial thin client Master IU Multi drop thin client Networked distributed intelligence

16 Functional Safety and hazard analysis BMS Fuses HVIL Electrical hazards containment Vents Chemical hazards Fire hazards BMS Vents Safety handle Mechanical hazards ABS Dual circuit brakes Collition hazards

17 Standards for functional safety IEC 61508: Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems ISO 26262: Road vehicles -- Functional safety ISO is an adaptation of the IEC61508 for the automotive segment. The two standards were largely developed in paralell, thus a significant overlap and certain inconsistencies exists between the two. IEC 61511: Functional safety - Safety IEC 61511: Functional safety - Safety instrumented IEC 61511: systems Functional for safety the process - Safety instrumented systems for the process industry instrumented sector systems for the process industry sector industry sector

18 FMEA and risk classification Failure mode and effect analysis How it might fail and would would be the consequences Risk classification R= f x c [Risk= freq x conseq] Catastrophic Critical Marginal Negligible Frequent Probable Occasional Remote Improbable Incredible

19 Counter measures EMC Noise source Radiated noise affecting board directly Radiated noise on communication wires Immunity 6 layer print with ground planes isolating all routing Fully differential, optically isolated communications bus. Passive noise filtering on communications bus Conducted noise on cell monitoring wires Passive noise filtering on all inputs Noise on 12V power supply Passive noise filtering on input and output from all power supplies Electrostatic shock Capacitive filtering to ground on all inputs 19

20 Project examples Li Ion technology presents a range of opportunities The next few slides will show some of the ones that LiTHIUM BALANCE has been involved with on land sea and air

21 World s first all electric road sweeper Tennant EZ 500 Electric street sweeper LiTHIUM BALANCE s-bms 15kW brushless motor 60kWh twin pack arrangement with automatic power balancing Transit Speed 25 km/h 8 hour operation 21

22 Tennant. Solution overview. Dual Li-ion battery pack (72V 400Ah), i.e. cells (LFP), BMS (sbms, #100160), switchbox (LiBAL Std. LV Switchbox) and a fast charger (6,4kW). Solution is in production. Dual pack: 1. Drive 2. Vacuum cleaner and tools

23 Banke Accessory Drives Revolutionary idea for reducing noise and tailpipe emissions during garbage collection. 700volt system powering and electric power take off (e-pto) to drive the compactor no engine revving and one battery charge lasts all day

24 Cargotec truck mounted forklift Replacement of existing internal combustion engined solutions with Li-ion battery powered solutions 1. Price premium offset against continually more stringent exhaust emissions legislation 2. Ability to operate 24/7 low noise emissions 3. Ability to operate indoors/outdoors or around foodstuff 4. On truck charging, always ready for deployment 5. Reduced service costs electric vs ICE technology

25 Marine SWE Engineering LiTHIUM BALANCE s-bms 100kW power Class winner in electric boats racing

26 World s first manned electric helicopter Flew in August 2011 In the Guiness book of records 50kW peak volts LiTHIUM BALANCE s-bms battery management used

27 HGV for local distribution MAN Truck LiTHIUM BALANCE s-bms kW DC brushless motor 120kWh modular 310 volts Range 150 km/charge Max vehicle weight 12 tonnes 27

28 Thank you for your attention Be sure to visit our website 28