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BATTERIES FOR 4214 VOLT AUTOMOTIVE ELECTRICAL SYSTEMS

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RAPID CABIN HEAT. ELECTROMAGNETIC VALVETRAINS. NEW DUTY CYCLES ... MIT CONSORTIUM CONDUCTED AN OEM SURVEY INQUIRING ABOUT FUTURE LOADS ON 42V SYSTEMS ... – PowerPoint PPT presentation

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Title: BATTERIES FOR 4214 VOLT AUTOMOTIVE ELECTRICAL SYSTEMS


1
BATTERIES FOR 42/14 VOLT AUTOMOTIVE ELECTRICAL
SYSTEMS
  • DELL A. CROUCH, JR. AND
  • GARY L. BALLARD
  • DELPHI AUTOMOTIVE SYSTEMS
  • INDIANAPOLIS TECHNICAL CENTER

2
INTRODUCTION
  • 42/14 VOLT SYSTEMS CAUSE NEW REQUIREMENTS FOR
    BATTERIES
  • NEW LOADS
  • EPS
  • HEATED CATALYTIC CONVERTER
  • RAPID CABIN HEAT
  • ELECTROMAGNETIC VALVETRAINS
  • NEW DUTY CYCLES
  • HIGHER LOADS ON THE ELECTRICAL SYSTEM AT LOW
    ENGINE SPEEDS
  • MORE STARTING CYCLES
  • TRADITIONAL DUTY CYCLE
  • STILL REQUIRED

3
EFFECTS OF NEW LOADS
  • MIT CONSORTIUM CONDUCTED AN OEM SURVEY INQUIRING
    ABOUT FUTURE LOADS ON 42V SYSTEMS
  • MAXIMUM CURRENT REQUIREMENTS RANGED FROM 100A TO
    1000A
  • DIFFERENT ASSUMPTIONS AT VARIOUS OEMS

4
42/14V SYSTEM BATTERY ALTERNATIVES
  • TWO BATTERIES
  • 12/14V
  • 36/42V
  • ONE BATTERY
  • USE DC-DC CONVERTER TO COVER 14V LOADS

5
TWO BATTERIES OR ONE?
  • RECENT STUDY SHOWS NOT MUCH MASS DIFFERENCE
  • LESS THAN 10
  • SOME HAVE SUGGESTED ONE POWER BATTERY AND ONE
    ENERGY BATTERY
  • HOW OFTEN IS THE POWER BATTERY USED BETWEEN
    RECHARGE OPPORTUNITIES?
  • TO WHAT DEGREE?
  • DETERMINES ENERGY CONTENT - (mass and volume)

6
BOTTOM LINE
  • NEW LOADS AND DUTY CYCLES FORCE US INTO TWO
    ALTERNATIVES
  • NEW BATTERY
  • LARGER LEAD-ACID BATTERY
  • IF THE BATTERY IS LARGE ENOUGH TO HANDLE ALL OF
    THE ENERGY STORAGE REQUIREMENTS OF THE VEHICLE,
    THE POER REQUIREMENT MAY BECOME LESS CRITICAL

7
BATTERY EVALUATION CRITERIA
  • PERFORMANCE
  • RATE, TEMPERATURE
  • RAW MATERIAL COST
  • COST/WATT-HOUR and COST/WATT
  • AT THE SPECIFIED RATE AND TEMPERATURE
  • UTILIZATION
  • RATIO CURRENT COLLECTORACTIVE MATERIAL
  • AVAILABLE DSOC FOR POWER
  • CYCLE LIFE

8
SPECIFIC ENERGY RAGONE CURVE
9
ENERGY DENSITY RAGONE CURVE
10
MATERIAL INFLUENCES
  • ACTIVE MATERIAL DENSITY
  • LOW DENSITY MATERIALS REDUCE MASS AND INCREASE
    VOLUME
  • HIGH DENSITY MATERIALS - VICE VERSA
  • NON ACTIVE MATERIALS
  • CURRENT COLLECTORS
  • CELL CONNECTORS AND BATTERY TERMINALS
  • ELECTROLYTE (in Pb-A, its active)
  • SEPARATORS
  • CASES, COVERS, VENTS, ETC.
  • UTILIZATION - AT A RATE AND TEMP.

11
AVAILABLE SOC CHANGE
  • AUTOMOTIVE BATTERIES TYPICALLY OPERATE AT 80
    SOC
  • POWER CAPABILITY VARIES NON- LINEARLY WITH SOC

POWER
50
80
SOC
12
A BATTERY FIGURE OF MERIT
  • NEED SYSTEMATIC APROACH
  • FIGURE OF MERIT INCLUDES ALL OF THE FACTORS
    MENTIONED EARLIER
  • BASED ON FIVE COMPONENTS
  • SPECIFIC ENERGY
  • ENERGY DENSITY
  • CYCLE LIFE
  • DSOC
  • PERCENT ACTIVE MATERIAL UTILIZATION
  • ALL MEASURED AT A SPECIFIC RATE AND TEMPERATURE

13
A BATTERY FIGURE OF MERIT
  • SET MAXIMUM FIGURE OF MERIT 10
  • FIVE CATEGORIES - MAX SCORE FOR EACH IS 2
  • USE SPREADSHEET FORMULA TO CALCULATE MULTIPLIER
    IF THE BEST BATTERY IN EACH CATEGORY GETS A 2 FOR
    THAT CHARACTERISTIC

14
EXAMPLE - COLD CRANKING AT 0F
15
EXAMPLE - 20 HR RATE AT ROOM TEMPERATURE
16
CYCLE LIFE
  • THE NEW LOADS REQUIRE US TO RE-EVALUATE CYCLE
    LIFE
  • WHAT TEST SHOULD WE USE?
  • IT MUST SIMULATE USAGE
  • ATEST THAT CAUSES A CERTAIN FAILURE MODE IS NOT
    USEFUL WHEN THE FAULURE MODE IS NOT KNOWN

17
CYCLE LIFE TEST CAVEATS
  • CYCLING AT EXCESSIVE DOD SHORTENS THE TEST BUT
    MAKES IT LESS RELEVANT
  • RAISING THE TEMPERATURE SHORTENS THE TEST, BUT IT
    CAN CAUSE UNIQUE FAILURE MODES
  • THE CURRENT DENSITY AT A GIVEN HOURLY RATE IS
    RELATIVELY CONSTANT, REGARDLESS OF BATTERY
    VOLTAGE
  • WE CAN USE 12 VOLT BATTERIES TO ESTIMATE THE LIFE
    OF 36 VOLT BATTERIES

18
A STARTING POINT FOR A START-STOP CYCLE LIFE TEST
  • DETERMINE THE 20 HR RATE CAPACITY AND THE VOLTAGE
    AT 20DOD (80 SOC)
  • DETERMINE THE COLD CRANKING RATE
  • DISCHARGE THE BATTERY TO 10 DOD (90 SOC) AT THE
    20 HOUR RATE
  • CYCLE THE BATTERY AT 40 C AS FOLLOWS ROR 1000
    CYCLES
  • 10 SECONDS DISCHARGE AT CCA RATE
  • 20 SECONDS CHARGE AT 42 VOLTS OR EQUIV.

19
A STARTING POINT FOR A START-STOP CYCLE LIFE TEST
  • MEASURE PERFORMANCE AT 20 DOD
  • 20 HR RATE
  • CRANKING
  • RESET SOC TO 80
  • REPEAT CYCLING
  • TEST ENDS WHEN
  • 20 HR RATE TIME TO 20 DOD IS DOWN 75
  • COLD CRANKING PERFORMANCE TO 50 DOD IS DOWN 50

20
CRUX OF THE TEST
  • LIMIT THE EXCURSIONS TO VERY LOW SOC (lt60)
  • INCREASE THE NUMBER OF HIGH RATE CYCLES
  • CHARGE DURING CYCLING AT SYSTEM VOLTAGE
  • MODERATE INCREASE IN TEMPERATURE TO START - 40C

21
OTHER ALTERNATIVES
  • DRIVING CYCLES
  • WHICH ONE?
  • HOW IS THE ELECTRICAL SYSTEM DESIGNED?
  • GENERATOR POWER VS RPM VS LOADS
  • HOW MUCH POWER FROM THE BATTERY?
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