CELL-INTEGRATED BMS - Shmuel De-Leon Energy · SMART CELLS | Cell-integrated BMS for modular...

CELL-INTEGRATED BMS for EV & Renewables

Power Sources Conference, Herzelia, May 2013

I. INTRODUCTION > Technology comparison

II. BatteryMan’s BMS > Cell-integrated topology

> Power Line Communication

IV. BENEFITS

V. APPLICATIONS…

AGENDA

© Power Sources Conference, Herzelia, May 2013

I. INTRODUCTION > Market drivers

II. OBRIST’s HyperHybrid > HICE

> Li-Ion Battery Pack

> E-Drive

> Thermal Management

PROBLEM | UNBALANCED CELLS

Operation mode

Uneven aging

Temperature distribution

in stack

Production tolerance


BMS PRINCIPLE

©

BMS OBJECTIVES

Protection from abuse

Enhancing battery life

Control charge/ discharge

Maintain battery in application-specified state

BMS FUNCTIONS

Retrieve data on cell-level (U, T, I, Z, SoH, SoH)

Data logging for cycle analysis + load strategy optimization

Controlled charging/discharging

Cell-balancing/ Pack balancing

Emergency load shut-off

Keep battery in designated operation conditions

Monitoring in standby-mode

…

Source: Woodbank Communications Ltd

STAR TOPOLOGY (Master/ Slave)

Cells equipped with temperature sensors and

connections to measure the voltage

Multiple cells (module) connected to one slave

Various slaves connected to one master

©

BENCHMARK | Conventional BMS topologies


Source: Woodbank Communications Ltd

BENCHMARK | Conventional BMS topologies

RING TOPOLOGY (Daisy Chain)

Slave PCB connected to each cell

Communication transceiver for data

transmission and receipt

Three wire data bus for master/slaves

connection


REAL-LIFE BMS | Complex Wiring & Periphery

Source: BRUSA, 16kWh 400V with fix12cell-module platines Source: Hella & Bender Source: Bundesverband IT-Sicherheit e.V.

Source: EV Power, Australia Source: WatchMojo.com, Bluecar EV pack Source: GreenMicrotech.net


Archive BatteyMan Technology GmbH. Source: PickeringTest.net Source: GreenMicrotech.net

BENCHMARK | Summary Of Classical BMS


Some say, a BMS is a highly

sophisticated and complex system…

Some say, a BMS is a highly

sophisticated and complex system…

DC Power Line

Plus

Minus

BatteryMan Route Map BATTERY CELL MANAGER INSIDE

… we don’t.

We take the direct line.

„The BatteryMan BMS avoids all data-

wiring, connectors, sense calibration

work and significantly simplifies the

integration process resulting in

scalable storage modules for all

battery applications.”

BMS INNOVATION | Cell-integrated BMS

© BatteryMan

conventional Ring topology

conventional Star topology

- +

M

S S

S

S S M

S

- +

1 Master 20 Slaves Cable circuit

1 central Master 5 starform slaves Starform cabling

Cell-integrated sensors Power line communication No cabling on periphery Highest flexibility

topology

BENCHMARK | Now what would you prefer?


CELL-INTEGRATION | BMS Uses DC Power Line

DC/AC Inverter E-motor

Local Monitor Unit LMU per cell measures T, U, SN

Power line communication

CAN, USB,

RS232, RS485…

V

M

DC

AC

X Monitoring in standby mode

Local Monitor Unit (LMU) measures and monitors

U_cell, T_cell

Localization by Serial Number on LMU-MCU

Data transmission over DC power line to master Battery

Control Unit (BCU) via current modulation technique in 24Bit

Code

Microcontroller connects additional load for µs

Decrease of load current

Pulses extracted from DC power line

BCU with digital signal processing (DSP)

Most cost-effective PLUG & PLAY solution

PLC & BMS Cell-Integration


Exceeding voltage

By-passing over shunt

©

CELL-BALANCING


©

CELL-BALANCING


NOISE IMMUNITY | DSP

LMU Signal output Cell Voltage under load


REAL-TIME EVENT-DRIVEN UPDATES

Event: „Zone Entry“ Frequent Updates

2,0

2,2

2,4

2,6

2,8

3,0

3,2

3,4

3,6

0% 20% 40% 60% 80% 100%V

olt

age(

V)

Discharge Rate(%)

Discharge Rate Characteristics (LiFeP04 3,2V 10Ah, Type 1865130 by Xinchi)

1C

5C

10C

Individual Trigger Points 3 COMMUNICATION LEVELS

I. Frequent Updates according relevance

II. Real-time event driven updates (redundant zone entry signals, 3-zone priorizing)

III. Synchronous Measurement of all cells at tx at individually set trigger points for crititcal stages


REAL-TIME EVENT-DRIVEN UPDATES

Events: „Zone Entry“

Individual Trigger Points possible

3 COMMUNICATION LEVELS

I. Frequent Updates according relevance

II. Real-time event driven updates (redundant zone entry signals, 3-zone priorizing)

III. Synchronous Measurement of all cells at tx at individually set trigger points for crititcal stages

Voltage Sensor signal


REAL-TIME UPDATES

Charging

& Balancing 3,3V

Balancing 3,0V

Balancing 3,24V

Charging

Balancing 3,24V

No charging

Load

Balancing 3,24V

Charging


PLUG & PLAY | Fastest Pack Design

SMART CELLS | Cell-integrated BMS for modular composition

SCALABLE | Easy upscaling & individual design (Plug & Play)

UNIVERSAL | 1 BMS for all chemistries, forms, sizes and interfaces

FLEXIBLE | Avoids data lines, connectors, BMS design, installation of

sensors and cabling for modifications + variations

LOWEST-COST | Enables adequate battery dimensioning with smart cell


CELL-INTEGRATION | The Cost Saver

COST

REDUCTION

MATERIAL SAVING


BMS MARKET | Application Fields

EV, HEV, PHEV

Electric Bikes (two-wheelers)

Forklift Trucks

Medical Devices

Robots/ Automation

ESS for Renewables

Off-Grid ESS

Prototyping

©

Source: BatteryMan archive


Continuous Progression 3rd generation BCU master board with DSP processor for optimized noise filtering, with standard USB and RS485 plus optional CAN interface.

ESS Energy Storage System| Module 2,5 kWh Ready to install packs with isolated MC4 connectors, for households and industry

Plug&Play Energy Storage System (ESS) First BMS using power line communication for cell data monitoring!

Container ESS Ready-to-operate and stand-alone Energy Storage System for solar and wind power

“Smart Solar Manager” | Off-grid system 48V Solar battery pack as off-grid ESS Including PV string monitoring and energy management for solar towers

APPLICATION: EV Li-Ion Battery Pack

©

OBRIST Powertrain Pack

Capacity 10.1 kWh

Voltage nominal 360 V (250V-420V)

Output 100 kW (peak 150 kW)

Number of cells 1400

C-rate discharge 10 C (15 C – peak)

C-rate charge 10 C (15 C – peak)

Weight w/o fluids 84 kg


Customized product development LMU adoptions for powerline communication for customer-specific product developement.

I. INTRODUCTION > Technology comparison

II. BatteryMan’s BMS > Cell-integrated topology

> Power Line Communication

IV. BENEFITS

V. APPLICATIONS…

AGENDA


I. INTRODUCTION > Market drivers

II. OBRIST’s HyperHybrid > HICE

> Li-Ion Battery Pack

> E-Drive

> Thermal Management

BMS

Thermal management

Packaging interface

Durability tests

Power Sources Conference, Herzelia, May 2013 ©

Customized Battery Adaptation

Driving of HyperHybrid System:

Acceleration

Deceleration

Charging

Discharging

Constant drive

Hybrid controller settings and

algorithms adaptation


Hybrid Controller Development

60

80

100

120

140

160

180

200

220

2008 2010 2012 2014 2016 2018 2020 2022 2024 2026 2028

Year [ - ]

CO2 emission

[ g/km ]

2,5

3,3

4,2

5,0

5,9

6,7

7,6

8,4

9,3

EU (NEDC)

Expected for 2025

US (CAFE)

Japan (10-15 Mode)

Gasoline

[ l / 100km ]

120g/km (FE: 130g/km, complimentary: -10g/km

EU

Japan

US


Market Drivers

Legislation

High Fuel prices

Peak oil

Social

Reduce carbon

footprint

City EV

III. High-performance E-drive

IV. Smart Thermal Management

II. Optimized high power Li-Ion battery

I. Development of an ultra-compact & high

efficient internal combustion engine

Lowest cost | Best fuel efficiency | +1000km driving range

HyperHybrid (HH) Innovative serial plug in hybrid (PHEV) powertrain


HyperHybrid Powertrain

Combustion Engine (HICE) with generator and inverter

Motor with energy recovery

Downsized Li-Ion battery

Power Electronics

Charger


Highly compact 1098cc 2 cylinder 4 stroke engine with generator

Power: 40kW generator @ 400V (or 60kW @ 600V)

Noise: Twin crankshaft for total mass balancing

Efficiency: Spec. fuel consumption 215g/kWh (test result)

Fuel: unleaded, ethanol, LNG, CNG

Thermal management: Heat storage

Operation: Full load condition

Weight: 76kg with generator

Mounting position: any

215

510

HICE

590


I. Innovative HICE For Serial Hybrid and REX

OBRIST Powertrain Pack

Capacity 10.1 kWh

Voltage nominal 360 V (250V-420V)

Output 100 kW (peak 150 kW)

Number of cells 1400

C-rate discharge 10 C (15 C – peak)

C-rate charge 10 C (15 C – peak)

Weight w/o fluids 84 kg

A „C“ discharge rate of 10 means that an 8 kWh battery can be discharged with 10 times 8 kW hence 80kW c


Li-Ion Low Cost Battery System

HV Li-Ion Battery Key Target Data

Modular high power battery system with 10-17kWh (400V)

High power cylindrical 18650 cells; 8,5C discharge (15 C peak)

Liquid cooling for homogenous temperature (max ΔT = 2-3 K)

Regular 20% DOD during operation

L x W x H: 589 x 312 x 320mm

Few mounting restrictions

Innovative internal cell fixation system

Compact system, Plug-In chargeable

External interface for cooling and heating

Variable design options

High power and high energy application applicable

Integrated BMS with PLC, no wiring for modularity


Li-Ion Low Cost Battery System

25

2m

m

twin motor design with 2x60kW (peak)

continuous power 2x40kW

weight approx. 101kg

PM e-motor with hybrid technology *

inverter with torque vectoring left/right

2 integrated sets of gear wheels

2 integrated inverters left/right

2 coolant loops left/right

* PM hybrid technology: rotor with embedded permanent magnets

hybrid technology generates reluctance at failure mode

with hybrid technology save e-motor operation

Ø 2

20

mm

809mm

38

6m

m


Key Data Twin Electrical Motor

Surface Temperature:

Average tap surface temperature spread below 2K over the whole battery pack

Coolant Temperature:

Average coolant temperature increase below 1,5K over the whole battery pack


Battery Thermal Management CFD Results

Innovative “HICE” insulation

use of the HICE as a “Energy Storage Unit”

improved compartment heating

emission reduced warm start up

Battery insulation system

minimization of energy demand for thermal management

extension of battery operating range (Hot and cold application)

optimization of battery lifetime

simplified cooling architecture for high and mid temperature loops

Interior thermal management

more effective heating and cooling system to maximize mileage


Innovative Thermal Management


Thermal- and Noise Insulation

Customized vibration absorbers

Customized thermal and noise insulation

INV

_M

1

INV_HICE BMS/ISO PDU

Charger

Power Train Bus System

Vehicle Safety Bus System

ESP / ABS

r1

r2

a

a

CAN 500kB/s (10ms)

ECU

CAN 500kB/s (1ms)

CAN 500kB/s (100ms) Hyperhybrid

Controller

HVAC

Vehicle Bus System

T

Screen

Ele

ctr

ic m

oto

r


Customized System Structure


System Efficiency @ Constant Speed 60kph

Combustion Diesel

h=20% h=93% Diesel

79,29g/kWh

250gCO2/kWh

430g/kWh

h=19 113g CO2/km

HyperHybrid Gasoline h=41% h=81% Gasoline

82,85g/kWh

257gCO2/kWh

279g/kWh

h=33 73gCO2/km

*1

*2

*3

*4

*5

Legend: *1 Specific calorific value *2 Specific CO2 emission per kWh *3 Specific fuel consumption *4 CO2 emissions per km

Prius Gasoline h=31% h=93% Gasoline

82,85g/kWh

257gCO2/kWh

290g/kWh

h=19 75g CO2/km


C-Max Energi @ NAIAS, Detroit

Controller

HICE 40kW Battery

11kWh

Electric front drive (85kW)


HyperHybrid Powertrain eFWD


HyperHybrid Powertrain eFWD

Controller

HICE 40kW Battery

11kWh

Electric front drive (85kW)

All components are mounted to a car specific frame which uses

the existing mounting points


HyperHybrid Powertrain eAWD


HyperHybrid Powertrain eAWD | Alternative configuration


HyperHybrid Powertrain eAWD | Alternative configuration (Underfloor)

Battery 17kWh

HICE 60kW

Twin electrical front and rear motor (4x85kW)

HyperHybrid power controller with charger and DC/DC

E-Torque vectoring for all wheels


HyperHybrid Powertrain eAWD | 340kW

And when will we supply you ? We are looking forward to your projects !

CELL-INTEGRATED BMS - Shmuel De-Leon Energy · SMART CELLS | Cell-integrated BMS for modular...

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Transcript of CELL-INTEGRATED BMS - Shmuel De-Leon Energy · SMART CELLS | Cell-integrated BMS for modular...