Abstract
The paper describes the development and realization of standard battery modules 12 V, made by LiFePO4 cells selected in a previous study by ENEA and the University of Pisa. Module means the group of four cells series connected, the electronic battery management system, the thermal management system and the mechanical case. Standard means that the same battery module can be used for different applications: in fact, the previous study showed that three standard battery modules, 30 Ah (little size), 60 Ah (medium size) and 100 Ah (large size), are sufficient to reach the levels of voltage/capacity requested by the most part of the applications in the field of the starting/auxiliary supply batteries (also for the nautical sector) and traction of off-road electric vehicles. More units of standard modules can be series/parallel connected to build complete battery systems able to satisfy the required performances. The development and realization of the modules mostly consisted of testing the selected cells to verify their suitability for the above mentioned applications, to make a thermal battery characterization so to define the thermal management system, to develop an electronic battery management system and to build a mechanical case. The paper shows all these aspects in detail.
Highlights
Among means of transportation, a large portion is occupied by off-road vehicles used in a variety of commercial and industrial applications
A recent study made by ENEA on the Italian market for mobile work machines gives a good idea of the relevance of these kinds of vehicles and the impact of their electrification [4]
12 V is the standard voltage for starting batteries and the LiFePO4 chemistry was proved to be the best solution for the application as starting lighting ignition batteries [5]
Summary
A large portion is occupied by off-road vehicles used in a variety of commercial and industrial applications. 12 V is the standard voltage for starting batteries and the LiFePO4 chemistry was proved to be the best solution for the application as starting lighting ignition batteries [5] This is due to the compatibility with the working voltages of the electric suppliers commonly used in the vehicles, the big current capacity (the so called “cold cranking amperes”, CCA), the particular conditions of the working environment (high temperature and vibrations). The series connection of four LiFePO4 cells equals the working voltages of the lead battery currently used as starting lighting ignition batteries on board the vehicles. This is not possible with other lithium batteries. The main characteristics of the cells used in the standard modules are shown in Table 1, 2 and 3
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