Lithium-ion cell thermal and chemical modeling a methodology to support battery pack cooling

design

ANTUNES Benoît

Powertrain Engineer at Faurecia Clean Mobility, France

GT conference – 07&08/2019, Frankfurt, Germany

CONCLUSION & NEXT STEP5

2

CONTEXT1

METHODOLOGY APPLIED TO A PRISMATIC CELL2

THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3

COOLING LOCATION STUDY FOR A PRISMATIC CELL4

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda

3

Faurecia Clean Mobility use its knowledge

in thermal management & ultra-light weigth material in

order to equipped innovent zero emission vehicle

Battery Pack Design

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context

4

Faurecia Clean Mobility use its knowledge

in thermal management & ultra-ligth weight material in order to equipped innovent zero emission vehicle

Top Cover

Battery Pack + integratedfunctions

Full Battery System

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context

5

Faurecia Clean Mobility use its knowledge

in thermal management & ultra-ligth weight material in order to equipped innovent zero emission vehicle

Top Cover

Battery Pack + integratedfunctions

Full Battery System

FCM technical proposal :

lightweight solution with integrated functions

(crash, thermal management, EMC)

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context

6

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context

From the cell to the full battery pack

→ Understand Lithium « cell behavior »

→ Extend knowhow to the « Pack »

Cell level

Module level

Battery Pack level

Which tools are used in ordre to support battery pack activities ?

Taitherm and StarCcm+ : Use in 3D desing

GT-SUITE/AutoLion : Thermal & Electrical cell profile

7

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context

From the cell to the full battery pack

→ Understand Lithium « cell behavior »

→ Extend knowhow to the « Pack »

Cell level

Module level

Battery Pack level

Which tools are used in ordre to support battery pack activities ?

Taitherm and StarCcm+ : Use in 3D desing

GT-SUITE/AutoLion : Thermal & Electrical cell profile

CONCLUSION & NEXT STEP5

8

CONTEXT1

METHODOLOGY APPLIED TO A PRISMATIC CELL2

THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3

COOLING LOCATION STUDY FOR A PRISMATIC CELL4

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda

9

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

Model building methodology

Because it is difficult to find this kind of

information on Google

I’m feeling lucky

10

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

Model building methodology

1D Electrochemical

model

Get a battery pack

Cell tomography

Cell teardown

Battery pack teardown

Get cell specifications & Dimensions

3D Thermal model

11

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

Segment C vehicle : PHEV (Plug in Hybrid Electrical Vehicle)

Teardown

Cell characteristics,

→ Cell shape & chemistry : Prismatic, NMC 111→ Cell capacity : 25 Ah

More information is needed

Tomography & Destructive analysis is needed ☺

SegC 90 kW

12

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

Lithium cell teardown objectives :

→ Get internal geometry of the cell

→ Get internal material of the cell

CAD Electrodes and coating dimensions

ANODE

CATHODE

Tomography

☺

☺

Now, enough data are available in order to build models

13

Model Building from extracted data

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

1D Electrochemical model 3D Thermal model

GTsuite – AutoLion StarCcm+ – Full thermal model

Data from teardown analysis

(Electrode types and dimension)

Data from teardown analysis

(Components dimensions and thermal properties)

14

Model Building from extracted data

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

1D Electrochemical model 3D Thermal model

GT-SUITE – AutoLion StarCcm+ – Full thermal model

Data from teardown analysis

(Electrode types and dimension)

Data from teardown analysis

(Components dimensions and thermal properties)

☺

☺

15

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

1D Electrochemical model 3D Thermal model

GTsuite – AutoLion StarCcm+ – Full thermal model

Data from teardown analysis

(Electrode types and dimension)

Data from teardown analysis

(Components dimensions and thermal properties)

Model Building from extracted data

16

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell

1D Electrochemical model

Heat generation

3D Thermal model

External conditions

(Cooling, warm-up, …)

Outputs : inside and outside the casing

- Maximum temperature

- Temperature gradients

- Flux

…

No temperature feedback

Model Building from extracted data → Open loop model (first draft)

CONCLUSION & NEXT STEP5

17

CONTEXT1

METHODOLOGY APPLIED TO A PRISMATIC CELL2

THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3

COOLING LOCATION STUDY FOR A PRISMATIC CELL4

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda

18

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

Model validation methodology

Experimental data

3D Thermal model

Validation by Results&Data comparaisons

Supply1D Electrochemical

model

CALIBRATION

Experimental Tests

19

1D Electrochemical model validation → Set Up

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

DOE parameter list :

- Cathode capacity loading

- Anode N/P ratio

- Cathode/Anode first charge/discharge capacity

- Collector contact resistance

Parameter optimization by genetic algorythm

(DOE GT-SUITE)

From Experimental adiabatic discharge at 1C rate

20

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

1D Electrochemical model validation → Results

Vs.

Experimental tests

21

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

Constante discharges – Voltage correlations

OCV curve

(C/10 → 2,5 A)

Discharge curves

(from 30 → 80 A)

1D Electrochemical model validation → Results

Vs.

Experimental tests

Vo

ltag

e (V

)V

olt

age

(V)

Time (s)

Time (s)

22

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

Constante discharges – Temperature correlations

OCV curve

(C/10 → 2,5 A)

Discharge curves

(from 30 → 80 A)

1D Electrochemical model validation → Results

Vs.

Experimental tests

Tem

per

atu

re (

K)

Tem

per

atu

re (

K)

Time (s)

Time (s)

23

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

Transient current profile – Voltage correlations

HPPC Cycle – 25°C

Full HPPC

cycle First Peak

1D Electrochemical model validation → Results

Vs.

Experimental tests

Vo

ltag

e (V

)

Time (s)

Vo

ltag

e (V

)

Time (s)

24

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

Transient current profile – Temperature correlations

1D Electrochemical model validation → Results

Vs.

Experimental tests

HPPC Cycle – 25°C

Tem

per

atu

re (

K)

Time (s)

Tem

per

atu

re (

K)

Time (s)

Full HPPC

cycle First Peak

25

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

3D Thermal model validation

– Results

Access to internal thermal behavior

Model validation by external

temperature analysis

Model vs. Experimetal

A-A Cut view of the cell

A

A

26

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation

3D Thermal model validation

– Results

In the worst case, there is a maximal temperature

deviation about 1°C

Model vs. Experimetal – Constante discharge

Temperature sensor locations

Tem

per

atu

re (

K)

Time (s)

TC type K 0,5mm

The model match

27

CONTEXT1

METHODOLOGY APPLIED TO A PRISMATIC CELL2

THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3

COOLING LOCATION STUDY FOR A PRISMATIC CELL4

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda

CONCLUSION & NEXT STEP5

28

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Cooling location study for a prismatic cell

Cooling location scenarios

Bottomcooling

Tabscooling

Sidescooling

Get external&internaltemperature

Get temperature

gradients

Cooling location ranking at the cell level

Time (s)

Tem

per

atu

re (

K)

Tmax

Cell run dry

29

CONTEXT1

METHODOLOGY APPLIED TO A PRISMATIC CELL2

THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3

COOLING LOCATION STUDY FOR A PRISMATIC CELL4

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda

CONCLUSION & NEXT STEP5

30

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step

WORKFLOW ADVANTAGES,

- GT-AutoLion is able to generate cell heat source for any scenarios

- The 3D model give us cell thermal behavior in function of the cooling strategy

and increase our level of expertise

31

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step

WORKFLOW ADVANTAGES,

- GT-AutoLion is able to generate cell heat source for any scenarios

- The 3D model give us cell thermal behavior in function of the cooling strategy

and increase our level of expertise

WORKFLOW DISADVANTAGES,

- The entire model (1D + 3D) is an open loop model. The 1D model must takes

care about cell temperature variations

32

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step

- Investigate in close coupled model possibility

GT-AutoLion 3D

1D3D

33

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step

- Investigate in close coupled model possibility

- Study impact of the cooling location on cell ageing

Bottomcooling

Tabscooling

Sidescooling

Ongoing Experimental tests

GT-AutoLion 3D

1D3D

34

LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step

- Investigate in close coupled model possibility

- Study impact of the cooling location on cell ageing

- Extend workflow to module level

Bottomcooling

Tabscooling

Sidescooling

Ongoing Experimental tests

Cell level

Module level

GT-AutoLion 3D

1D3D

35

LITHIUM-ION THERMAL AND CHEMICAL MODELING

36