Battery for Hybrid and Electric Vehicle

Engineering
Lecture 2
Battery: Glossary and Terminology

Lecture
3
Instructor: Gholam-Abbas Nazri
2016

Typical Components of HEV

IC Engine

Battery

Transmission
Hybrid Powertrain
Major Components

Control Strategy

Thermal
management

Motor and
Power
Electronics

HEV - Hybrid Electric Vehicle

Three types of HEV exists.

Micro - Engine is off at traffic light. This action eliminates or mitigates the
idling losses by turning the engine on and off.
Mild - Recharge during the deceleration as well like Honda Civic
Full or strong Like Toyota Prius
Plug-in It can be recharged by plugging it to electric outlet, like GM Volt &
recent Bold
Energy Storage
System

Battery
I
C
E

Transmission

Startor/
Alternator

Startor/
Alternator

Fuel
Reservoir

Micro Hybrid

Startor/
Alternator

I
C
E

Transmission

E Motor

I
C
E

Energy
Storage
System

Fuel
Reservoir

Full Hybrid

Transmission

E Motor

Fuel
Reservoir

Mild Hybrid

Different Hybrid Electric

Hybrid Electric Vehicles: Series

A series HEV completely separates

the mechanical link between the
engine and the wheels.
The engine solely produces
electricity which is used to power
the electric motor directly or to
charge the batteries when the
engine power is not needed

Hybrid Electric Vehicles: Parallel

Freedom to choose the combination of

IC engine and electric motor for
propulsion
Requires smaller battery and engine
than HEV series
Requires complicated electronic control
system for propulsion

Engine operates at peak efficiency

Reduction of engine wear and tear
Larger battery and motor since they
are the only propulsion to the wheel

ICE

No Mechanical link between ICE and wheels

Battery

Hybrid Architecture Overview

Degree of Electrification

Fuel Economy Improvement

Serial, power split or parallel

Serial
architecture

Hybrid Architecture Summary

Reliance on Battery/Motor Performance

Glossary
and
Definition

Definition and Terminology

This summary provides an introduction to the
terminology used to describe, classify, and
compare batteries for hybrid, plug-in hybrid, and
electric vehicles.
It provides a basic background, defines the
variables used to characterize battery operating
conditions, and describes the manufacturer
specifications used to characterize battery
nominal and maximum characteristics.

Categories of Batteries
There are three types of chemical battery as such:
Chemical
Batteries
Chemical energy Electric Energy

Primary Batteries
(Non-Rechargeable)
Secondary
Batteries
(Rechargeable)

Batteries

Other
Batteries
Physical Energy
Batteries
Physical Energy
-- Electric Energy

1. Zinc-carbon batteries
2. Alkaline manganese
batteries
3. Lithium metal batteries
4. Others
1. Lead-acid batteries
2. Ni-Cd Alkaline
batteries
3. Ni-MH batteries
4. Lithium ion batteries
5. Others
Reserve batteries
Fuel cell
Solar cell, Nuclear
Energy

Primary and Secondary Battery Cells

Batteries are categorized into two types:

Primary batteries are not rechargeable. And mainly are designed
for a single discharge
Primary Battery - Alkaline zinc battery (e.g. Duracell Copper Top
battery) is an example of primary battery application.

Secondary Battery is a galvanic on discharge and electrolytic on

recharge. Battery described for hybrids, plug-ins and electric vehicle are
secondary batteries and are re-chargeable.
Secondary batteries are for HEV/EVs.
Typical secondary batteries:

Lead-acid (Pb-acid)
Nickel-cadmium (NiCd)
Nickel-metal-hydride (NiMH)
Lithium-ion (Li-ion)
Lithium-polymer (Li-poly)
Sodium-sulfur

Commercially Aqueous Primary Batteries

Zn/MnO2

Zinc/AgO

Zinc-carbon batteries are the least expensive primary batteries and thus a popular choice by
manufacturers when devices are sold with batteries included. High-power alkaline ZnMnO2
batteries
with superior discharge performance have been constructed using MnO2
nanowires/nanotubes and
electrolytic zinc powder as the cathode and anode active materials,
Ag-Zn is an aqueous alkaline system with very high specific power and energy (119Wh/kg),
but
operates over a small temperature range (5C to 40C) and is quite expensive due to the use
of silver.
They are still used in selected applications, such as launch vehicles (rockets) and torpedoes.
Typically
used in small button or coil cells, used for watches, calculators, etc.

Zinc/HgO

The first U.S. spacecraft, Explorer 1, which was first to detect the Van Allen Radiation Belt,
used a Zinc - Mercury Oxide (Zn-HgO) Battery. The mission lasted for 3.8 Months and the
battery made up approximately 40% of the payload weight. These cells have high volumetric
energy density, a very flat discharge profile, and good shelf life, but they are expensive, and
exhibit reduced performance below 0C.

Zinc/Air

Popular hearing aid battery, larger batteries used by the military

An aqueous solution is a solution in which the solvent is water.

It is usually shown in chemical equations by appending (aq) to the relevant
formula.
The word aqueous means pertaining to, related to, similar to, or dissolved
in water.

Commercially Aqueous Secondary Batteries

Lead acid

Nickel Cadmium (NiCd)

Nickel Metal Hydride (NiMH)

Common Battery Size and Standards

This is a chart that illustrates the approximate sizes of the various rechargeable lithium
batteries that we sell. The numerical designation of the battery gives an approximation of
the size. For example, a 10280 battery is approximately 10mm in diameter and 28mm tall,
the final 0 indicates that it is round.

10180 battery - 10mm x 18mm (1/3 AAA size)

10280 battery - 10mm x 28mm (1/2 AAA size)
10440 battery - 10mm x 44mm (AAA size)
14250 battery - 14mm x 25mm (1/2 AA size)
14500 battery - 14mm x 50mm (AA size)
16340 battery - 16mm x 34mm (nominal CR123a size)
17335 battery - 17mm x 35mm (nominal CR123a size)
17500 battery - 17mm x 50mm
17670 battery - 17mm x 67mm
18500 battery - 18mm x 50mm
18650 battery - 18mm x 65mm

UN Number of Battery Type

Cell, Module and Packs

The battery cell, which is the smallest packaged form of the
battery, generally supports 1-6 volts. When combined, the
cells form a module connected parallel or in series.
The modules are then assembled to form the battery pack.
This type of pack is normally that of hybrid and electric
vehicle and it is normally high voltage.

Argonne Pack
Cell

Module

Pack

20-cell 80-volt 8-kW Li-ion battery

module designed by ANL for Hybrid
Electric Vehicle Application

High Power or High Energy cell design

A battery can either posses high power or high energy, but not both.
Therefore, manufacturers will rank batteries by using these categories.
Another class is high durability which enables the battery to operate with a longer
life at the expense of power, energy or both
active layers >105 microns thick

Energy Battery Max Discharge Rate = 3C

active layers ~35 microns thick

Power Battery - Max Discharge Rate = 12C

Energy vs. Power

For a given battery chemistry, the energy stored in the battery is
proportional to the amount of active materials (i.e. anode + cathode
powder).
For a cell of a given size, the higher the packing fraction of the powders,
the more energy the battery can store and the longer your device can run
before it needs recharging.

The power (rate of energy delivery) depends on having sufficient mass and
electrical transport throughout the electrodes. In theory, higher power can
be achieved with:

smaller particles
higher surface area
larger fraction of porosity (i.e. more electrolyte)
thinner electrodes

Careful design of electrodes is required in order to produce electrodes

with the desired balance between high power and high energy.

Discharge Current - C Rate

This current is usually described as C-rate which is a
measure of the rate of battery discharge in relation to
its maximum capacity.
Rankings of the C-rate will contain a number before it
which inversly relates to the amount of time of discharge
in hour. (1C = 1 hour discharge, 2C means hour)

If a battery has 100 Amp-hrs, its discharge rate will be

100 Amps per hour and is described as 1C. A C/2 rate is
50 Amps or 2-hour discharge rate.

State of Charge - SOC (%)

This is the state of charge and is the percentage
of maximum capacity.
It is calculated using current integration and will
predict the battery capacity change over time.

Depth of Discharge - DOD (%)

This is a percentage of capacity which is discharged from the
maximum capacity.

The depth of discharge of at least 80% is considered as a deep

discharge.
Example: 20 Ah cell with 10 Ah capacity remaining = 50% DOD

Resistance (Internal)
Resistance (Internal)
While dependent on the SOC, this refers to the
internal resistance which is normally different for
charging and discharging.
As the resistance increases, the efficiency of the
battery decreases and thermal stability is reduced
while the charging energy is converted to heat.

Maximum Internal Resistance

Refers to the resistance within the battery which is
normally different for normal charging and
discharging

Nominal & Cut-Off Voltage (V)

Open-Circuit Voltage:
The measured voltage of
the cell or battery without
a load

Nominal Voltage: A nominal value

to be used to indicate the battery
average voltage; for the Sealed
Lead-Acid Battery; the nominal
voltage is 2V I cell.

Cut-Off Voltage: The voltage that

normally describes the empty
battery state or its minimum
allowable voltage.

Current and voltage profiles during constant current constant voltage charge

Voltage Charge

Current - mA

Voltage - V
Current
Voltage

This is constant voltage

charging

Its schemes consist of a constant

current charging until maximum
charge state then gradually tapers the
constant voltage charging.
Current

Time, Minutes

Capacity or Nominal Capacity (Ah for a specific C-rate)

The total amount of electrical charge that a cell

can hold. Typically measured in amp-hours (Ah).
Its also described as the total Amp hours
available for battery discharge at a particular
discharge current (or the C-rate) which is
derived from the 100% charged state to the cutoff voltage.
This is calculated by multiplying the discharge
current in Amps by the discharge time in hours.
It decreases with an increasing C-rate.

Terminal Voltage (V)

This refers to the voltage between the terminals
with an applied load.
This voltage varies with the SOC and discharge
and charge current.

Open-circuit Voltage (V)

The voltage difference between the anode and
the cathode. Aqueous batteries typically 1-1.5 V,
non-aqueous batteries typically 3-4 V
This refers to the voltage between the terminals
with no applied load and is dependent on the
SOC, increasing as the SOC increases.
Battery
System

Pb/acid

Zn/MnO2
alkaline

Zn/AgO

Ni/Cd

Ni/Metal
Hydride

Li/MnO2

Li
ion/LiCoO2

Cell
Voltage

2.0

1.4 1.5

1.5

1.2

1.2

3.0

3.7

Energy (Wh) for a Specific C-rate

Energy (Typically measured in watt-hours/kilogram (Wh)
This is the energy capacity or the total Watt hours available when the battery is
discharged at a certain C-rate from 100% to the cut-off voltage.
This energy is calculated by multiplying the discharge power in watts by the
discharge time in hours.

Specific Energy (Typically measured in watt-hours/kilogram (Wh/kg)

The total amount of electrical energy stored by a battery per unit of weight..also
knows as the gravimetric energy density. It determines the battery weight needed
for a given electric range.

Energy Density (Typically measured in watt-hours/kilogram Wh/L)

This is the battery energy per unit volume, also known as the volumetric energy
density. As Specific energy and Specific power, its also a battery characteristic. It
determines the battery size required to achieve a given electric range.
It is also described as total amount of electrical energy stored by a battery per
unit of volume.

Power Density (W/L)

This refers to the maximum available power per
unit volume.
It determines the size of a battery for a given
performance target.

Cycle Life
This refers to the number of discharge/charge
cycles of the battery before performance failure.

It is an estimate for these conditions and the

actual life is affected by rates and depths of
cycles, temperature, humidity, etc.
Cycle life = f( rate, temp, depth of cycles, )

Example:

Battery Longevity vs. cycle life

70%

50%

4000

Source: Christian Rosenkranz (Johnson Controls) at EVS 20

Continuous Discharge Current

Maximum Continuous Discharge Current
The max current of continuous discharge. Its normally
limited by the manufacturer to prevent excessive discharge
rates that could damage the battery or reduce
performance.
It defines the top sustainable speed and acceleration of
the vehicle, alone with maximum continuous motor power.

Maximum 30-second Discharge Pulse Current

The maximum current of discharge for pulses up to 30
seconds and is limited by the manufacturer. It defines the
acceleration performance ranging from 0-60 mph along
with the peak power of the motor.

EPA Driving Cycles

The fuel economy prediction is quantified by U.S.
Environmental Protection Agency (EPA) driving cycle.
EPA driving cycle is divided into urban and highway
drive cycles.
The urban cycle contains lower vehicle speeds and
more Stop and Go (or acceleration, deceleration, and
idle).
A cold start fuel penalty is included in urban cycle

The highway cycle includes higher vehicle speeds and

steady state cruise segments ( cruising).

Urban & Highway Driving Profiles

Vehicle Speed MPH

Vehicle Speed MPH

Urban
FUDS Federal
Urban Driving
Cycle

Urban and highway cycles are

combined into a formula to
obtain the metro-highway fuel
economy value which appears
on new vehicles
The combined fuel economy in
miles per gallon( MPG) is
computed as:

Highway
FHDS Federal Highway
Driving Cycle

Power = Speed x Torque

Vehicle Level Requirements - ICE Vehicles

Typical operating performance of the internal combustion engine vehicles

Range

200 to 600

miles/tank

Tank Capacity

10 to 20

gallons

Fuel Economy *

10 to 60

miles/gallon

Fill up time

5 to 15

minutes

Gasoline Cost

1.5 to 5

$/gallon

Vehicle Cost

10,000 to 40,000

Acceleration, 0 to 60mph

12 to 6

seconds

Vehicle Weight

2000 to 4000

lb

Operating Temp. Range

-30 to 50

deg C

Valence Technology Inc

* CAF Standards for Passenger Cars 34.1 mpg by 2016.