101 03 06
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1. OHM Cycles Vectrix Blue Sky Design / BugE ZENN Tesla Miles ZX40 GM Green LineHEV IKOO Transporter SECMA / Qpod Electric Th!nk / City imiev Aixam-MEGA / Mega MultiTruck LEXUS 450h/HEV Myers Motors / NmG Subaru R1e leaf Smith Electric Vehicles / Edison Honda Insight Yamaha / EV Nissan / EV Phoenix Motorcars SUT Honda Accord HEV Segway Toyota Auto Body / COMS Smart EV Th!nk Ox Cruise Car / Kudo 14 Ford Escape HEV Dynasty Electric Car / IT BMW MINI-E GM / Volt II TOYOTA PRIUS 3
挿 4
xev Example Total Energy HEV 1-2kWh PHEV 5-12kWh BEV 20-30kWh 4 5
& AC AC DC DC DC AC DC 6
imiev 2 7
EV - TOYOTA LEXUS VW Porsche GM Chevrolet GM SATURN HONDA FORD M-Benz Nissan Mitsubishi Cayenne Prius III RX400h II Hybrid Volt Vue Green Line 2 CR-Z EDGE Smart EV Leaf i-miev 2009 2009 2010 2009 2009 2009 2010 2010 2010 2009 HEV HEV HEV PHEV PHEV HEV HEV EV EV EV 6 8
Tier 1 9
2. 1.Cell/Module 2.Sense& Control, Battery Control Unit (BMS) 3.Thermal System 4.HV Power IF 5.V & A Sensors 6.Switches & Fuse 7.HVIL 8.Safety Plug 9.Communication 10.Enclosure 2 9 2 7 8 1 5 6 4 1 3 Enclosure 10 10
BMS Battery Disconnect System Battery Pack Thermal System Communication Diagnostics Contactor Control SOC/SOH/Power Algorithms Thermal Control Contactor Control Pack Voltage Sense Cell Balancing Pack Current Sense Battery Management System HV/LV Isolation Vehicle Vent FAN or Pump High Voltage Main Contactor Service Disconnect Fusing Pre-Charge Contactor Current Sensor HV Connector and Cables V/T Sensors Cells Mechanical Structure Harness Cell Inter- Connects Thermal Vehicle Plenums Or hoses Thermal System Battery Disconnect System Isolation Fault Detector Battery Pack Mechanical System Battery System Electrical System 11
/ Battery Enclosure Battery Pack Fixture Cooling Inlet/Outlet Sensor Connector Power Output Service Breaker & Fuse 12
13
Ragone Plot HEV-High Power, PHEV-Power/Energy, BEV- High Energy Ragone plot 9 14
LG Chem/CPI Battery Pack A123 Cells in Volt s T-Shaped Pack NISSAN Leaf Battery Pack ITRI CP e-van Battery Pack 15
3. Battery Management System (BMS) SOC/ SOH 16
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18
BMS LTC 6802 Base CAN CAN Gateway CAN Gateway Source: LTC website CAN Gateway 19
Ricardo BMS VTBM CAN BCM VTBM BCM 20
ITRI BMS BMU CAN BCU BMU BMU8 BMU7 BMU6 BMU5 BMU4 BMU3 BMU2 BMU1 CAB B BCU CAN A BCU To Vehicle BMU9 BMU10 BMU11 BMU12 BMU13 BMU14 BMU15 BMU16 BCUx1+BMUx16 ITRI Battery Pack 21
SOC/SOH/Power Prediction/Cell Balancing/Diagnostics/ Thermal Management 24 22
SOC SOC ( ) SOC ( AC DC) ( ) SOC SOH 23
SOC BMS Warning Protect 24
CC( ) CV ( ) 3 25
4.20V (NCM) or 3.60V (LFP) 26
SOC/SOH SOC SOH Deliverable Energy (kwh) Deliverable Power (W) Deliverable Charge (Ah) Load Prediction SOC SOH Age, Condition SOH Condition Voltage Current Time Temperature Knowledge of Essential Battery Parameters 27
SOC SOC SOC SOC Ah 1. OCV OCV Curve BCUON ON 3 30 2. Ah Ah= I dt= I* t I t Kalman filter for SOC Estimation 3. 28
SOC OCV LFP NMC LFP (DOD)5%~95% Vcell 3.32V-3.18V OCV SOC 90 % 140mv SOC OCV NMC (DOD)0%~100% Vcell 4.2V-3.32V OCV SOC 100 % 880mv SOC OCV 29
SOC OCV SOC Ah Embedded System 30
SOH ) SOH=Detected Capacity/Original Capacity SOH=Detected Conductance/Original Conductance 31
Charge Current Discharge Current Charge 1 Usable capacity Nominal capacity 1 when first Cell is full 2 2 Discharge 3 3 when first Cell is empty 32
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Top-Balancing Bottom-Balancing Balancing between Blocks Stack + Secondary side Block + SP2 Block + S 3 N P N n S n Cell n S P1 Block - Primary side N 3 S 3 Cell 3 Block + N 2 S2 Cell 2 S P2 S 1 S 2 S 3... S N I/O µc ADC in I/O GND Filter S P1 N 1 S 1 Cell1 Block - S P1 S 2 Block - Stack - 35
36
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/ Prius & Insight 23 38
/ 23 39
Pre-Charge 40
FMVSS 305 500 /V 1. 2. 12V 3. 4. 5. 6. / / / / 41
4. 42
18650 Cell Nail Penetration Test 43
18650 Cell Impact Test 44
Cells Vibration Testing 45
ARC 46
LEV50 Tests based on the FreedomCAR test manual shock Shock Test immersion crush Immerseion Test Modules Controlled Crush Test Variations Test 47
Without PTC With PTC 18650 Cell with PTC/CID 48
Nissan Leaf Battery System 49
Mitsubishi imiev Battery System Environsment Tests 50
ARTC 51
52