Battery Cells Research Articles

Development of an electrochemically approximated simulation model and a hardware substitution cell approach for thermal management battery system tests

AbstractBattery tests require a high degree of safety-related preparation and constant monitoring of the operating parameters to guarantee the smooth running of tests without incidents or exceptional events such as a thermal runaway. As the handling before, during, and especially after the tests is relatively complex and sometimes just as costly, it is important to reduce these risks and costs as well as to find an alternative to conventional battery tests. Such an approach is being developed by the T-cell project of the Institute of Thermodynamics and Sustainable Propulsion Systems at Graz University of Technology, founded by the Austrian Research Promotion Agency (FFG). A thermal substitution cell, which resembles a battery cell on the outside, is to reflect the surface temperature distribution of a chemical cell without there being any cell chemistry inside the substitution cell. Rather, the interior should not be part of the observation and the thermal requirements should be provided by an internal heating option. Such a measurement approach requires, among other things, a control and regulation unit, without which it would not be possible to transfer the thermal behavior of a battery cell to the substitution cell. Together with the electronic structure of the substitution cell and a circuit environment including a battery simulation model established at a later date, this control/regulation module forms an overall package that considerably facilitates investigations at cell, module, and pack level by substitution of a certain amount of cells using system symmetry advantages. A suitable simulation model was constructed and parameterized for this purpose from an electrochemical and a thermal network. As a first step, the data, which were partly determined empirically but also derived from real cell measurements in the literature, were adapted to the requirements of the simulation environment, so that the real cell used could be simulated thermally in principle. The simulation observations represent the state of the art of the model and are continuously improved by measurements carried out at the institute, thus building up the overall system in more detail.

Influence of Temperature and Pressure on the Wetting Progress in 21700 Lithium‐Ion Battery Cells: Experiment, Model, and Lattice Boltzmann Simulation

AbstractThe electrolyte filling and subsequent wetting of the active material is a time‐critical process in the manufacturing of lithium‐ion batteries. Due to the metallic cell housing, the process phenomena are insufficiently accessible, preventing the replication of the wetting processes by mathematical or simulative methods and hindering efforts to accelerate the wetting process. Therefore, this publication employs a glass cell housing for electrolyte filling of a 21700 cylindrical cell to investigate the wetting at different temperatures and process pressures. In parallel, a mathematical replication of the wetting, as well as a lattice Boltzmann pore‐scale simulation, is used to evaluate the influence of these varying process boundary conditions. The results show a strong temperature dependence on electrolyte wetting and the positive effect of pressure changes in the wetting process. These findings are particularly relevant to the process design of large‐scale cylindrical cell manufacturing.

Novel SoC-Based FBG Calibration Method for Decoupled Temperature and Strain Analysis within LIB Cells

Abstract Internal temperature monitoring of battery cells can be very useful, as the core temperature can deviate significantly from that of the housing, especially in case of cells with a thick electrode stack. Conventional resistance temperature detectors can accurately measure temperature, but are limited to the outer surface of the cell due to induction effects. They are therefore not suitable for internal in situ measurements. Fiber Bragg grating (FBG) sensors are unaffected by the electric field as they operate by reflecting light. However, a specific difficulty is the distinction of temperature vs. strain effects as the grating is sensitive to both. In this work a calibration routine to separate the influences of temperature and strain in a lithium-ion battery cell is presented and examined for two multi-layer stack pouch cells (10 and 20 Ah). The obtained in situ temperature data reveal a difference of up to 2°C between center and cell housing at elevated discharge rate (4C) and a delay in detection of temperature peaks by the external sensor by 12 s. Strain data correlate with numbers of electrode layers in the stack and yield a stress of up to 27.3 MPa in the center of the 20 Ah cell.

Simulation-Based Investigation on Thermal Propagation in Li-ion Battery Modules with regard to the Thermal Management System

Abstract Thermal propagation in Li-ion battery systems is affected by a wide range of influencing factors including chemical cell properties as well as thermal transport phenomena. Due to the dependence on thermal surroundings it is crucial to regard the entire battery system including peripheral components when assessing thermal runaway and propagation risks. This study proposes a simulation-based approach to support design and dimensioning of potential safety measures. It is based on a chemical model for the thermal runaway decomposition reactions combined with 3D thermal simulations. This is applied on exemplary ten cell battery pack in order to investigate on effects on heat transfer during thermal propagation. Insulation and cooling systems are included in the simulation environment for that purpose. It is found that propagation behavior significantly depends on their positioning within in pack and on thermal boundary conditions. Placing too many barriers may exacerbate hazardous situations instead of mitigating them due to heat accumulation effects. Cooling systems are shown to be able to support thermal runaway mitigation strategies but their effectiveness is limited by thermal transport inside the battery cells.

Fault detection method for electric vehicle battery pack based on improved kurtosis and isolation forest

ABSTRACT Early detection of abnormal battery characteristics is crucial for ensuring personnel safety and minimizing property damage. Conventional fault diagnosis methods often struggle to detect minor faults in their early stages. To address this challenge, this paper proposes a fault diagnosis method for lithium-ion batteries in electric vehicles that utilizes real-world operational data. Initially, a wavelet threshold denoising algorithm is used to effectively remove voltage data noise while retaining fault characteristics. Subsequently, an early fault warning method based on improved kurtosis index is proposed, which is capable of capturing the weak abnormal features of the battery and issuing warnings. Furthermore, a faulty battery cell localization method based on two-dimension feature extraction and Isolation Forest algorithm is proposed to capture minor fault features and accurately locate faulty cells. Finally, experiments conducted on four operational electric vehicles demonstrated that the early fault warning method could promptly detect faults and issue alarms, while the faulty battery cell positioning method accurately identified the faulty cell, achieving 100 % Accuracy and 0 % False Positive Rate. This confirms the effectiveness of the proposed method. Additionally, Bootstrap was used to evaluate the performance metrics, further verifying the robustness of the method.

Selective Oxidation of Biomass derived 5-Hydroxymethylfurfural (HMF) to 2,5-Diformylfuran (DFF) over Spent Dry cell battery cathode material (BCM-2)

Selective Oxidation of Biomass derived 5-Hydroxymethylfurfural (HMF) to 2,5-Diformylfuran (DFF) over Spent Dry cell battery cathode material (BCM-2)

Low-Cost Laser Security System with Intrusion Detection and Alert Mechanism

Security becomes necessary factor nowadays. The crime gang improves their technology to perform their operation along with the development of technology. Hence, technology of security should be more improved to protect the crime works. We have decided to make a security project. In this project we have used laser light for security purpose. We know laser light goes through long distance. When any person or object passes through the laser line, the security alarm will start to ring. There are two parts of the system. One is transmitter and other is receiver. The transmitter side consists of a pair of dry cell batteries and an on-off switch. The receiver side, there is a focusing LDR (Light Dependent Resistor) sensor to sense the laser ray. It is connected with the main driver circuit which has two parts. One is signal of discontinuity ray and other is alarm circuit. When anybody passes through the ray, the main circuit sense the discontinuity and turn on the alarm circuit. The alarm will be ringing until the off button is pressed. There are two methods of ringing. One is the duration of ringing depends on preset timer and another is reset manually. Any option can be set by DPDT switch. We have used second method for our project. Mirrors are attached at every corner to reflect the ray coming from the laser. The reflected ray coming from the last mirror will hit the LDR directly. The system has built with low cost and high performance. The power consumption of the system is very low.

Comprehensive Study on Cell Components in High‐Voltage Pouch Cells with Lithium Perchlorate: Decomposition, Transesterification, Chlorination, Deposition, and Self‐Discharge

AbstractBattery development has traditionally focused on high energy and long lifetime cells, but there is now a shift towards their sustainability and safety. One example of this trend is the search for fluorine‐free conductive salts. The overwhelming majority of lithium‐ion conductive salts contain fluorine, which is critical regarding their environmental impact, sustainability, and toxicology. In this study, we perform a comprehensive investigation of the performance and aging mechanisms of cell components with LiClO4 as conductive salt in high‐voltage NMC622‖Graphite pouch cells. The cells containing LiClO4 show poorer electrochemical performance compared to their LiPF6 equivalents. However, to the best of our knowledge, a mechanistic understanding of the effect of LiClO4 on the aging of electrode and electrolyte components for high‐voltage cells is largely missing. Developing such an understanding will pave the way toward designing alternative salts to LiPF6, ultimately leading to fluorine‐free and more sustainable battery cells. Our results show, that the chlorination of ethyl methyl carbonate at both methyl and ethyl groups and the formation of large (Liw)AlxOyClz composite deposits on the cathode surface result from perchlorate degradation at the cathode. This leads to increased cell resistance, reduced capacity retention, and accelerated degradation of the LiClO4‐containing electrolytes.

Greatly Enhanced Oxygen Reduction Reaction in Anion Exchange Membrane Fuel Cell and Zn-Air Battery via Hole Inner Edge Reconstruction of 2D Pd Nanomesh.

Platinum group metals (PGM) have yet to be the most active catalysts in various sustainable energy reactions. Their high cost, however, has made maximizing the activity and minimizing the dosage become an urgent priority for the practical applications of emerging technologies. Herein, a novel 2DPd nanomesh structure possessing hole inner reconstructed edges (HIER) with exposed high energy facets and overstretched lattice parameters is fabricated through a facile room-temperature reduction method at gram-scale yields. The HIER enhances the catalytic performance of Pd in electrochemical oxygen reduction reaction (ORR), achieving superior mass activity (MA) of 2.672 A mgPd -1, which is 27.8 fold and 23.6 fold higher, respectively, than those of the commercial Pt/C (0.096 A mgPt -1) and Pd/C (0.113 A mgPd -1) at 0.9 VRHE. Most significantly, in H2-air anion exchange membrane fuel cell (AEMFC) and Zn-air battery (ZAB) applications, this unique Pd catalyst delivers a much-outperformed peak power density of 0.86 and 0.22W cm-2, respectively, compared with 0.54 and 0.13W cm-2 of the commercial Pt/C catalyst, indicating a novel pathway in electrocatalyst designs through HIER engineering.

Design and Performance of High-Capacity Magnesium–Air Battery for Power Generator System

Efforts to achieve carbon neutrality, which aims to reduce the net carbon emissions to zero by decreasing carbon emissions from human activities and increasing carbon absorption, are actively underway. Additionally, the search for clean energy alternatives to fossil fuels has become a global research trend. This paper presents research on metal–air batteries, focusing on the development of energy supply technologies that do not generate carbon emissions during power generation and require less space for power generation compared to existing renewable energy sources. The proposed Mg–air battery (MAB) in this study uses magnesium as the metal anode and theoretically offers a maximum open-circuit voltage of 3.1 V and a high energy density of 6.8 kWh/kg. While previous research has primarily focused on designing small-capacity cells and maximizing the performance of metal anodes, this study differentiates itself by designing a large-capacity MAB cell and optimizing its electrical performance. For the large-capacity cell design, the weight, shape, and size of the anode were designed based on MAB performance factors, and research was conducted on manufacturing methods to optimize the performance of the air cathode. Furthermore, to enhance usability and extend the lifespan of the MAB cell, it was designed to allow electrolyte circulation, and the electrolyte circulation performance was verified through simulations of fluid flow within the cell. Based on the study of the power performance of the newly designed large-capacity MAB cell, the feasibility of constructing a kW-class system using multiple Mg–air battery cell stacks was confirmed.

Electrochemical and Thermal Analysis of Lithium‐Ion Battery Pack With Different Cell Configurations

ABSTRACTThe primary purpose of this research is to analyze and evaluate the effects of various discharge rates and cell configurations on the electrochemical and thermal behavior of a Li‐ion battery pack that is exposed to ambient air throughout the discharge process. The three‐dimensional numerical model is designed to accomplish this purpose and discusses two different cases. While the discharge rate is changed from 0.5 C to 2 C (stepping by 0.5 C) for each cell configuration considered in the first case, the numerical solutions are obtained for the various cell configurations (6S4P and 8S3P) by keeping the discharge rate constant at 1 C. The results obtained from these solutions show that the discharge rate affects a considerable amount of the battery performances and discharge times of the battery packs, activation, and ohmic losses occurring inside each battery cell. Moreover, 6S4P discharges over a longer period (about 25%) than 8S3P. While both activation and ohmic losses decrease with the increase of discharge rate, these losses remain almost constant at 0.5 C discharge rate in all analyzed conditions. As a result, having a battery pack with a long discharge time while maintaining low temperatures is useful and desired. With this in mind, while evaluating battery packs, the 6S4P battery pack looks to have the best arrangement.

Design of a triple port integrated topology for grid-integrated EV charging stations for three-way power flow

Environmental fluctuations, solar irradiance, and ambient temperature significantly affect photovoltaic (PV) system output. PV systems should be efficient at the Maximum Power Point in various weather climates to maximize their potential power output. The Maximum Power Point Tracking (MPPT) technique is employed to plan a specific location that yields the maximum amount of power. Operating dispersed alternative energy sources connected to the grid in this situation makes energy control an unavoidable task. This research article suggests designing a power electronics converter topology that links sustainable resources and electric vehicles to the power grid. There are four modes of operation for this proposed converter topology: grid-to-vehicle, vehicle-to-grid, renewable-to-vehicle, and renewable-to-grid discussed. The three power electronic converters and their uses are discussed, and their controllers are also designed to maintain the energy balance and stability in all cases. The battery characteristics indicate the operating mode. The work primarily focuses on the converter’s Triple Port Integrated Topology (TPIT) power flow and voltage control. Here, three power converters integrate the TPIT with three systems-the electric grid, renewable energy, and electric vehicles-into one system. The source battery and solar photovoltaic (PV) array cells are integrated using unidirectional and bidirectional DC-DC converters. The future scope of the work is to investigate the potential of adding additional ports for integrating other energy resources, such as hydrogen fuel cells or additional renewable sources, to create a more versatile and robust energy management system for EV charging stations.

Model‐Based Exploration of Web Guiding Behavior for a Novel Battery Cell Stacking Process

Innovative production processes are required to meet the rapidly growing demand for batteries and the associated material trends. In particular, the process step of stack assembly using new machine concepts promises a high potential for optimization. However, these concepts are untested in practice. The use of digital models makes it possible to develop corresponding optimization approaches. This article presents the development of a model for the web guiding systems of electrodes and its integration into an overall machine model for a novel machine concept. Finally, optimization approaches are identified by determining appropriate controller parameters for the web guiding systems.

Factors influencing management of dry cell battery waste: a case of Greater Accra Region in Ghana

Indiscriminate disposal of dry cell battery (DCB) waste contributes to environmental and public health issues in developing countries such as Ghana, due to the toxic nature of this specific waste. Accordingly, a study was conducted in Accra, Ghana, to determine the socio-economic and demographic factors influencing handling DCB waste, aiming a sustainable environment. Using a random sampling technique, a descriptive cross-sectional survey was conducted, encompassing 367 respondents from the Accra-Tema Metropolitan areas and Tema West Municipal Assembly in Greater Accra, Ghana. Using descriptive and multivariate statistical methods, the survey data were analysed with the Statistical Package for Social Sciences (SPSS) version 27. The results of this study show that female gender and residential area are likely to positively influence the use of DCB at home. Education significantly affects the use of DCB and its proper disposal. The results also suggest that 78% of the respondents disposed of DCB waste in waste bins. The mean monthly income of the respondents stands at USD 270, which is average and likely partially to positively influence the disposal of the DCB. The data collected revealed that female gender, age group, family size, and education level influence the indiscriminate disposal of DCB waste and DCB waste recycling. The results highlight that educated females above the age of 55, with a monthly income, are likely to properly segregate DCB waste. This study contributes to the knowledge gap in relation to dry cell battery waste management (DCBWM) in developing countries, aiming to advance global sustainability. This study is expected to contribute to educate and create awareness in managing DCB waste to reduce its indiscriminate disposal which leads to environmental pollution and negatively affects human health and environmental sustainability in Ghana.

A flow battery cell testing facility for versatile active material characterization: Features and operations

Technological development plays a fundamental role in view of the successful realization of large Flow Battery (FB) systems. This work firstly presents the design, construction and commissioning of FB-Cell Testing Facility (FB-CTF), a bench for testing electrolytes, electrodes, membrane and cell configurations under controlled conditions. Several construction aspects related to the hydraulic system, power conditioning system, and flow battery management system are described in detail. FB-CTF has been conceived and built to accurately measure the main thermal, hydraulic, electric, and energy quantities which define the performance of FBs. A comprehensive experimental campaign has been carried out on FB-CTF to characterize some widely used electrodes and membranes for Vanadium FBs (VFBs), produced by some major manufacturers. The paper presents the developed testing protocols and the test results, specifically focusing on electrical and hydraulic characterization. In addition, a methodology using FB-CTF data in the prediction of the electric and hydraulic performance of large stacks is proposed. More generally, FB-CTF measurements can be used to address the design of industrial-scale FBs. FB-CTF can provide insights for the design of large flow battery systems, to help bridge the gap between academic research and industry.

Physics-Informed Data-Driven Approaches to State of Health Prediction of Maritime Battery Systems

Battery systems are increasingly being used for powering ocean going ships, and the number of fully electric or hybrid ships relying on battery power for propulsion and maneuvering is growing. In order to ensure the safety of such electric ships, it is of paramount importance to monitor the available energy that can be stored in the batteries, and classification societies typically require that the state of health (SOH) of the batteries can be verified by independent tests – annual capacity tests. However, this paper discusses physics-informed data-driven approaches to online diagnostics for state of health monitoring of maritime battery systems based on a combination of physical knowledge, physic-based models, insights from extensive characterization tests and operational sensor data collected from the batteries during actual operation. This represents an alternative approach to the annual capacity tests for electric ships that is found to be sufficiently robust and accurate under certain conditions. Previous attempts with purely data-driven models, including both cumulative and snapshot models, semi-supervised learning and simple models based on the state of charge did not achieve the required reliability and accuracy for them to be utilized in a ship classification perspective, as presented at previous PHM conferences. However, preliminary results from the physics-informed data-driven method presented in this paper indicate that it can be relied on for independent verification of state of health as an alternative to physical tests. It has been tested on battery cells cycled in laboratory degradation tests as well as on field returns from batteries onboard ships in service. Notwithstanding, further validation and verification of the method is recommended to further build confidence in the model predictions.

Design and analysis of automatic assembly line for battery cell and reed pipe

Design and analysis of automatic assembly line for battery cell and reed pipe

Recent Advancements and Future Prospects in Lithium‐Ion Battery Thermal Management Techniques

ABSTRACTLithium‐ion batteries (LiBs) are the leading choice for powering electric vehicles due to their advantageous characteristics, including low self‐discharge rates and high energy and power density. However, the degradation in the performance and sustainability of lithium‐ion battery packs over the long term in electric vehicles is affected due to the elevated temperatures induced by charge and discharge cycles. Moreover, the thermal runaway (TR) issues due to the heat generated during the electrochemical reactions are the most significant safety concern for LiBs, as inadequate heat dissipation can be potentially hazardous, leading to explosions and fires. Considering the safety of EVs and for better performance, understanding the mechanism of TR is of paramount importance. This review provides a comprehensive analysis of the TR phenomenon and underlying electrochemical principles governing heat accumulation during charge and discharge cycles. Furthermore, the article explores the cell modeling and thermal management techniques intended for both individual lithium‐ion battery cells and larger battery packs, with a particular emphasis on enhancing fire prevention and safety measures. The main goal of this review paper is to offer new insights to the developing battery community, assisting in the development of efficient battery thermal management systems (BTMS) using enhanced cooling methodologies. This article could also support the advancement of next‐generation electric vehicle battery packs equipped with built‐in safety features to improve the cycle life of LiBs and prevent thermal runaway accidents.

Cost modeling for the GWh-scale production of modern lithium-ion battery cells

Battery production cost models are critical for evaluating the cost competitiveness of different cell geometries, chemistries, and production processes. To address this need, we present a detailed bottom-up approach for calculating the full cost, marginal cost, and levelized cost of various battery production methods. Our approach ensures comparability across research fields and industries, reflecting capital and imputed interest costs. We showcase the model with case studies of a prismatic PHEV2 hardcase cell and a cylindrical 4680 cell in four different chemistries. Our publicly available browser-based modular tool incorporates up-to-date parameters derived from literature and expert interviews. This work enables researchers to quickly assess the production cost implications of new battery production processes and technologies, ultimately advancing the goal of reducing the cost of electrified mobility.

Generation of hydrogen fuel on board vehicles with internal combustion engines

This article discusses advances in the design of hydrogen fuel engines; the main characteristics of the hybrid engine are studied; prospects for further research are outlined; development and improvement of engine designs, research of processes in engines running on natural gas and hydrogen. Transport is one of the key elements of modern civilization. Its condition and development prospects largely depend on the ability to supply transport power plants with fuel. The depletion of liquid hydrocarbon fuel reserves and problems of environmental pollution may present humanity with a choice - either to reduce transport transportation or to find new ways to supply energy to transport. OBJECTIVE: To review the electrochemical technologies used for the production of hydrogen at gas stations and the operation of hybrid electric vehicle engines using fuel cell batteries. Conduct a comparative analysis of the production and use of energy by electrochemical and traditional methods in vehicles. METHODS are based on analysis of literature data and mathematical calculations. For a passenger electric vehicle, the amount of electricity that can be obtained in a fuel cell by processing 1 kg of hydrogen was calculated. It has been shown that the specific fuel consumption for a hydrogen electric vehicle averages 1 kg of hydrogen per 100 km. Hydrogen has the potential to be the sustainable fuel of the future, reducing global dependence on fossil fuel resources and reducing carbon emissions from the transportation industry.