Browse Topic: Energy storage systems

Items (3,481)

Basic Science and Art of Aircraft Wreckage Reconstruction

R-48004/23/2025

Basic Science and Art of Aircraft Wreckage Reconstruction is a unique title which addresses important aspects of investigating crashes, who does this kind of work, and how a healthy attitude and open mind are required to properly perform investigations. It also discusses what to expect from the on-scene part of the investigation, and the fundamental approaches to common types of wreckage reconstruction. Written by Don Knutson, a veteran of this industry, Basic Science and Art of Aircraft Wreckage Reconstruction is intended for the practitioner, student, or those who are simply curious about how aircraft wreckage is reconstructed. Full references are provided in the various chapters for additional reading and research. Many examples of aircraft crash scenarios and circumstances are presented in a "generic" form but relate to actual investigations, which should prove as a useful investigative resource whether you are an apprentice or an experience professional with a government aviation

Knutson, Donald F.

3D-CFD Simulations of H2 ICEs: A Preliminary Evaluation of a Laminar Flame Speed Correction for Thermo-Diffusive Instability

2024-32-007404/18/2025

In recent years, climate change and geopolitical instability have intensified the focus on sustainable power generation. This shift seeks alternatives that balance environmental impact, cost-effectiveness, and practicality. Specifically, in transportation and power generation, electric motors face challenges against internal combustion engines due to the high cost and mass of batteries required for energy storage. This makes electric solutions less favorable for these sectors. Conversely, internal combustion engines, when properly fueled, offer cost-effectiveness and a quasi-environmentally-neutral option. To address these challenges, researchers have explored e-fuels derived from renewable sources as a carbon-neutral supply for internal combustion engines. Among these, hydrogen is particularly promising. In hydrogen-powered internal combustion engines, 3D-CFD (Computational Fluid Dynamics) in-cylinder models are crucial. Once validated, these models can speed up the design process. A

Sfriso, Stefano, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Cordisco, Ilario, Leite, Caio Ramalho, Brequigny, Pierre, Foucher, Fabrice

Traction Voltage Level in Two-Wheelers: Considerations on Safety and Performance

2024-32-006204/18/2025

Most electric 2-wheelers on the market today seek to replace combustion engine vehicles from 50cc to 150cc which equates to an electric motor power between 2 and 12 kW. The traction voltage level of these vehicles is mostly between 44V and 96V. However, the actual choice of voltage on a specific vehicle seems to be arbitrary and higher voltage does not necessarily correlate with higher motor power. This paper seeks to highlight considerations and tradeoffs which feed the choice of traction voltage levels. Important criteria are electrical safety standards and their impact on vehicle electrical architecture, the performance and availability of key electronics parts such as capacitors, MOSFETs, and gate drivers, while also highlighting functional safety aspects. This paper shows by a comprehensive analysis of the motor drive that for the vehicle class mentioned above the traction voltage level can be kept below 60V without any performance impact, while also ensuring electrical and

Schmitt, Stefan

Effect of Mesopore Structure of Carbon Gel on Improving the Capacity of Electric Double-Layer Capacitors

2024-32-002604/18/2025

Electric double-layer capacitors (EDLCs) store charge by adsorbing ions at the electrode-electrolyte interface, offering fast charge/discharge rates, high power density, minimal heat generation, and long cycle life. These characteristics make EDLCs ideal for memory backup in electronic devices and power assistance in electric and hybrid vehicles. However, their energy density is lower than that of batteries, necessitating improvements in electrical capacity and potential. Traditionally, activated carbon with a high specific surface area has been used, but recent research focuses on mesoporous carbon materials for better ion diffusion. This study uses resorcinol-formaldehyde-carbon cryogel (RFCC) with mesopores and organic electrolytes with a wider electrochemical window. Various RFCCs with different pore sizes were synthesized and evaluated. Comprehensive investigations into the pore structures and surface properties of both synthesized carbon gels and commercial mesoporous materials

Cheng, Zairan, Okamura, Tsubasa, Ohnishi, Yuto, Nakagawa, Kiyoharu

Predictive Battery Thermal Management System Control Strategy and Simulation in Electric Vehicle

2025-01-502704/03/2025

With the global issue of fossil fuel scarcity and the greenhouse effect, interest in electric vehicles (EVs) has surged recently. At that stage, because of the constraints of the energy density and battery performance degradation in low-temperature conditions, the mileage of EVs has been criticized. To guarantee battery performance, a battery thermal management system (BTMS) is applied to ensure battery operates in a suitable temperature range. Currently, in the industry, a settled temperature interval is set as criteria of positive thermal management activation, which is robust but leads to energy waste. BTMS has a kilowatt-level power usage under high- and low-temperature environments. Optimizing the BTMS control strategy becomes a potential solution to reduce energy consumption and overcome mileage issues. An appropriate system simulation model provides an effective tool to evaluate different BTMS control strategies. In this study, a predictive BTMS control strategy, which adjusts

Huang, Zhipei, Chen, Jiangbo, Tang, Hai

Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit

2025-01-501703/21/2025

Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed

Birgül, Çağrı Emre, Meydan, Ömer

Internet of Things Enabled Automatic Battery Cooling System Using the Peltier Effect

2025-01-500401/23/2025

Electric vehicles (EVs) have developed rapidly and are popular due to their zero emissions and efficiency. However, several factors limit electric car development, including battery performance, cost, lifetime, and safety. Battery management is crucial for achieving maximum performance under various conditions. The battery thermal management system (BTMS) plays an important role in controlling the battery’s thermal behavior. A BTMS manages the battery’s operating temperature by either dissipating heat when it is too hot or providing heat when it is too cold. Various methods of cooling batteries include air cooling systems, liquid cooling systems, refrigerant cooling systems, and phase change material cooling systems. This study focuses on an innovative BTMS utilizing a Peltier module, regulated via the Internet of Things (IoT) platform for real-time temperature monitoring and control. The objective of this research is to design and develop a temperature-controlled cooling system for EV

Gunasekar, N., Abishek, H., Bharath, N. S., Gokul, G.

Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials

2025-01-500301/23/2025

Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96

Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.

New Battery Cathode Material Could Revolutionize EV Market and Energy Storage

TBMG-5214212/01/2024

A multi-institutional research team led by Hailong Chen, an Associate Professor with appointments in the George W. Woodruff School of Mechanical Engineering and the School of Materials Science and Engineering, has developed a new, low-cost cathode that could radically improve lithium-ion batteries (LIBs) — potentially transforming the electric vehicle (EV) market and large-scale energy storage systems.

Researchers Discover a Surprising Way to Jump-Start Battery Performance

TBMG-5214012/01/2024

A lithium-ion battery’s very first charge is more momentous than it sounds. It determines how well and how long the battery will work from then on — in particular, how many cycles of charging and discharging it can handle before deteriorating.

Solving the Battery Recycling Challenge

TBMG-5214812/01/2024

Dormant Capacity Reserve in Lithium-Ion Batteries Detected

TBMG-5214312/01/2024

Lithium iron phosphate is one of the most important materials for batteries in electric cars, stationary energy storage systems, and tools. It has a long service life, is comparatively inexpensive and does not tend to spontaneously combust. Energy density is also making progress. However, experts are still puzzled as to why lithium iron phosphate batteries undercut their theoretical electricity storage capacity by up to 25 percent in practice. To utilize this dormant capacity reserve, it would be crucial to know exactly where and how lithium ions are stored in and released from the battery material during the charging and discharging cycles. Researchers at Graz University of Technology (TU Graz) have now taken a significant step in this direction. Using transmission electron microscopes, they were able to systematically track the lithium ions as they traveled through the battery material, map their arrangement in the crystal lattice of an iron phosphate cathode with unprecedented

Second Life of Lithium-Ion Batteries Could Take Us to Space

TBMG-5214412/01/2024

The global use of lithium-ion batteries has doubled in just the past four years, generating alarming amounts of battery waste containing many hazardous substances. The need for effective recycling methods for spent lithium-ion batteries is becoming increasingly critical. In the journal ChemElectroChem, scientists from various Polish research institutions, including Bydgoszcz University of Science and Technology (PBS), the Institute of Fundamental Technological Research of the Polish Academy of Sciences, the Institute of Physical Chemistry of the PAS in Warsaw, and Wroclaw University of Science and Technology, presented a promising solution to this issue.

Crafting Safe, Long-Cyclable Lithium Metal Batteries for High Temperatures

TBMG-5213912/01/2024

Existing commercial battery technologies, which use liquid electrolytes and carbonaceous anodes, have certain drawbacks such as safety concerns, limited lifespan, and inadequate power density particularly at high temperatures. This has prompted researchers to search for solid electrolytes that are safe and compatible with lithium metal anodes, which are known for their high theoretical specific power capacity.

Where Do EV Batteries Go When They Die?

TBMG-5213812/01/2024

At Cox Automotive’s EV Battery Solutions center in Oklahoma City, the conglomerate most famous for its KBB, Autotrader, and Manheim auction brands, has become a go-to for EV battery research, repair, remanufacturing, and recycling.

An Efficient and Cost-Effective Solution for Battery Recycling

TBMG-5084906/01/2024

Used lithium-ion batteries from cell phones, laptops, and a growing number of electric vehicles are piling up, but options for recycling them remain limited mostly to burning or chemically dissolving shredded batteries. The current state of the art methods can pose environmental challenges and be difficult to make economical at the industrial scale.

Cost-effective techniques for SCEV to improve performance & life of battery and motor by using efficient thermal systems

2024-26-027501/16/2024

The automotive world is moving towards electric powertrain systems. The performance of an electric powertrain and its electric components majorly depends on the operating temperature of the components. In the small commercial vehicle segment overall vehicle cost is a very sensitive parameter while competing in the market. This paper presents advanced efficient cost-effective thermal techniques for small commercial electric vehicles (SCEV) to improve the performance & life of major electric components. It is observed that from the literature survey, this technology is a novel technology for small commercial electric vehicle applications. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the battery and traction cooling system during battery charging and vehicle driving scenario for different ambient conditions. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which help

Chormule, Suhas Rangrao, Warule, Prasad, Jadhav, Vaibhav, Nagpure, Rahul

An Experimental Approach towards Sustainable Solution for Material Recycling of ELV Plastic Bumpers and EV Batteries

2024-26-016401/16/2024

The automotive industry in India generates a significant amount of waste and pollution through end-of-life vehicles (ELVs). This paper addresses the current state and challenges of ELV recycling in India and presents a sustainable solution for recycling waste bumpers and electric vehicle (EV) batteries. With the Indian domestic passenger vehicle sales reaching 3.9 million units in 2022-2023, the need for effective recycling measures is becoming increasingly critical. The study estimates that in FY 2023-24 alone, the Indian automotive passenger vehicle industry will produce approximately 2.9 million tons of scrap, with 0.1 million tons attributed to plastic materials. Considering the 15-year end-of-life period for vehicles and the historical sales figures, this scrap generation is expected to grow exponentially each year. To address this issue, the paper proposes a comprehensive recycling approach that focuses on two key aspects: plastic recycling and the recovery of precious metals

Baviskar, Ajay, Khera, Pankaj, Telgote, Ashish, Dhuria, Himanshu, Sharma, Amit

Development of an efficient vehicle energy management system for fuel cell electric vehicles.

2024-26-017301/16/2024

Fuel cell electric vehicles generally have two power sources – the fuel cell power system and a high voltage battery pack - to power the vehicle operations. The fuel cell power system is the main source of power for the vehicle and its operations are supported by the battery pack. The battery pack helps to tackle the dynamic power demands from the vehicle such as during acceleration, to which the response of the fuel cell might be slower. The battery is also used to recover the energy from regeneration during braking and can also be used to extend the range of the vehicle in case the storage tanks runs out of hydrogen. In order to maximize the fuel efficiency of the fuel cell power system it is critical that these two power sources are used in conjunction with each other in an optimal manner. The two power sources must operate such that the power demand from the vehicle is met at all times without over exerting either of these two sources as this can lead to drop in life and health of

Jacob, Joe, Brahmbhatt, Smitan, Adsul, Aniket, PRASAD, PULUGURTHA

A Comparative Analysis and Novel Powertrain Topology for FCEVs, Integrating Ultracapacitor and Batteries.

2024-26-016801/16/2024

This paper proposes a comparative analysis and novel topology for a fuel cell electric vehicle bus (FCEV-Bus) that combines the advantages of fuel cells, ultra-capacitors, and batteries. The integration of these three energy storage devices aims to enhance the overall performance, efficiency, and reliability of the FCEV while addressing the challenges associated with traditional fuel cell systems. The proposed topology utilizes a FC stack as the primary power source, which provides a steady and efficient supply of electricity. To overcome the limitations of fuel cells in responding to sudden power demands, ultra-capacitors are incorporated into the system. Ultra-capacitors can rapidly discharge and absorb high power, making them suitable for capturing regenerative braking energy and delivering power during acceleration or other high-power events. Moreover, to address the issue of slow-response and transient power variations, a battery-system is integrated into the topology. In which

Bhardwaj, Rohit, Saurabh, Saurabh, Gadve, Dhananjay, Amancharla, Naga Chaithanya

Simulation Based Validation of Battery Structural Integrity for Mechanical Abuse as per AIS 156

2024-26-024201/16/2024

Battery is one of the safety critical systems in EV. As the number of EVs increases, battery safety becomes an important task to avoid any mishap during its use, as even small accidents may slow down the adaptation of EVs. Automotive environment being one of the harshest operating environments, it is important to ensure both mechanical and electrical safety of the battery pack. Li-Ion batteries are most popular among traction batteries, due to their high energy density, long life, and fast charging capabilities. But mechanical damage, overtemperature, short-circuit, etc. may lead to battery thermal runaway, causing a major accident. Mechanical abuse of battery can be one of the reasons that may lead to the damages mentioned above, eventually causing thermal runaway in batteries. That’s why all major battery safety standards have requirements for vibration and mechanical shock tests. In this paper, we will be developing a methodology to evaluate the structural integrity of a battery

Dandge, Sunil, Mahamuni, Ameya, Sevda, Gaurav, H, Rajesh, Kumar, Ravindra, Mahajan, Rahul

A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack

2024-26-010901/16/2024

EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of

Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar

Adaptive derating algorithm for EV application based-Li-Ion battery for safe and healthy operation

2024-26-010801/16/2024

Battery packs used in Electric Vehicles (EVs) pose significant safety risks and can incur additional costs and downtime when facing extreme conditions such as thermal and undervoltage hard cut-off. This article emphasizes the importance of implementing thermal and voltage based derating techniques to ensure the safe operation of battery packs. Thermal derating controls the maximum allowed battery current to prevent thermal runaway along with maintaining the health of the cells. While voltage derating prevents cut-off at low SOC regions by managing the cell voltage operating range through real time calculation of DCIR based voltage drop. By adopting these methods, battery packs can operate more safely and reliably in various environment conditions, which is essential in many applications. The article introduces the adaptive derating index, which utilizes State of Health (SoH) and real-time measurements of battery parameters such as temperature, voltage drop, and current to adjust the

Gautam, Ashish, SJ, Janarthanan, Badiger, Kartik, Soni, Lokesh

A Traffic Microsimulation Based Study of an Electric Road System with Dynamic Wireless Power Transfer

2024-26-010201/16/2024

Electrification of road transport is a critical step towards establishment of a sustainable transport ecosystem. However, a major hindrance to electric mobility is the high cost and weight of the battery pack. Downsizing the battery pack will not only address these issues, but will also reduce embedded emissions due to battery manufacturing. One approach towards reducing battery pack size and still offering the user of electric vehicles similar mobility experiences as in case of conventional vehicles is to set up extensive network of charging or battery swapping stations. Another approach is to provide the vehicle with required energy while it is on the move. However, conventional systems such as overhead line or conducting rails have several disadvantages in the urban environment. One solution that has come up in this regard in recent times is the concept of Electric Roads System (ERS), which involves dynamic wireless power transfer (DWPT) to the vehicles from power transmitters

Sardar, Arghya, Prasad, Mukti

A Multistage adaptive charging algorithm for Li-Ion battery-based EV Applications

2024-26-010301/16/2024

With the increase of electric vehicles and lack of standardization in charging infrastructure, the variance in the charger cable length, battery health, and battery capacity can result in unevenness in the charging of lithium-ion batteries (LIBs), which increases the charging time and can deteriorate the battery’s health. Enabling adaptive charging of LIBs can accelerate the commercial application of electric vehicles (EVs). Charging of LIBs is critical and can be optimized to curtail the effective charging time. In this paper, a multistage adaptive charging strategy is presented for LIB-based EV applications to boost the SOC of the battery system in the shortest time. In the proposed charging strategy, initially, multiple pre-charge CC stages are employed to bring the battery out of the deep discharge state and to simultaneously calculate the resistances of the harness (line resistance), and the battery. These resistance values are then used to estimate the charging currents as the

RAJAWAT, SHIV PRATAP, Moorthi, Sathiya, Soni, Lokesh

Effect of Busbar Design on the Thermal Performance of Battery Packs

2024-26-013501/16/2024

Li-ion batteries face challenges which is not usually present with other chemistries is cell balancing. If a high imbalance occurs within a parallel circuit, possibly because of the poor cell -grading or due to temperature localization, the other cells will charge the unbalanced cell and it may be possible that the imbalance never completely fades away and the other cells also end up unbalanced, One of the key solutions to maintaining cell balance is to ensure that all cells within a battery pack are kept at a uniform temperature. This requires careful thermal management, which can be achieved through a combination of conduction and convection circuits. In this paper, a 1D-3D simulation study has been performed on a 12 V 4s4p pack by varying the thickness of HV busbars and temperature localization effects and temperature uniformity has been observed. The holder has 16 cells with a 4*4 grid pattern, each cell has a diameter of 18 mm and a length of 65mm. The cells are connected in

Jagtap, Aditya, Khan, Faiz, Shah, Harsh, Malani, Shekhar

A review and modelling of PMSM drive technology for Electric vehicle application

2024-26-012701/16/2024

The increased pollution and environmental damage caused by rapid consumption of fossil fuel as the increased number of vehicles on road given a strong impetus to the growth and development of fuel-efﬁcient vehicles. INDIA has already adopted the stringent CAFÉ II norms in 2022 which penalizes the CO2 levels above the corporate average target. This will give a push to automotive manufacturer to reduce their carbon footprint. Considering all the above-mentioned factors, Electric Vehicles are proving to be a promising solution to curb the Carbon footprint and limit the dependence on the fossil fuel which will dampen the effect of increased fuel prices on customers as well. The main advantage to EVs is that the motor and battery configuration allows the vehicle to operate more efficiently. The main components of Electric vehicles are HV battery, E-Drive (Motor), Inverter, On board charger, Power distribution Unit. The performance of EVs greatly depends on these components and its

Sharma, Prashant, V, Suryanarayanan, Redii, Ashok, Raut, Sandip, Hareesh, Sangaraju

A Review on Fire Prevention and Suppression Solutions for EV Battery Packs

2024-26-001201/16/2024

The lithium-ion batteries are susceptible to fires or explosions due to their extremely volatile nature. The energy-dense batteries, such as LiNi_0.8 Mn_0.1 Co_0.1 O_2/Graphite (NMC811) battery that meets the consumer range demands, are most vulnerable under thermal events. A wide number of solutions are being explored to suppress or prevent battery fires. The solutions range from integrating active cooling techniques, passive heat dissipation using heat carrier pads, thermal insulating materials to prevent thermal propagation, safety vents to remove ejecta, and protection circuitries with advanced battery management system. In this paper, we review various safety solutions employed in battery packs for preventing or suppressing potential fire during any thermal runaway event. The identified safety solutions also feature distinctive methods such as usage of hydrogel agents, aerosol fire suppressants and design features. Among the reviewed countermeasures, we provide a detailed analysis

H, Manjunatha, Nambisan T M, Praveen Kumar, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan

A Study on Traction Battery Mounting Arrangements in Different EV Buses

2024-26-012101/16/2024

This paper provides an overview of the different types of traction battery mounting arrangements available in electric buses globally. The paper describes a key comparison of all the types of traction battery mounting strategies used in EV buses along with their dominance and limitations. In EV buses, bigger sized batteries are used which directly affect vehicle architecture, assembly & serviceability. On the other hand, larger-sized batteries are used in buses which carries heavy mass, which influences vehicle dynamics & performance characteristics such as vehicle ride, handling, braking & NVH. The most important consideration in EV vehicles is safety, which comes in first place, so this paper gives some ideas to carefully design battery mounting arrangements for EV bus applications. There has been seen a very positive adaptation of EV buses in the last few years due to the rise in Co2 and global warming. Many EV bus manufacturers have entered the market with their innovative ideas of

Jain, Gaurav, Pathak, Rahul, Gore, Pandurang

Electric Powertrain - Standardization of Adaptable Software in Loop System

2024-26-011701/16/2024

Motivation With an increase in the complexity involved in modern-day ECUs (Electronic Control Unit), it is very important to verify and validate robustness, functionality, and reliability of ECUs. Till date, Hardware in Loop (HiL) based validation or vehicle level validation is generalized approach used for testing. However, this method requires physical setup, which can incur more cost and time during the development phase. Solution We believe in minimizing the software testing time using Software in Loop (SiL) validation. Creating virtual-ECUs and the plant models is an important step in SiL. We are presenting the modularized and scalable plant models in this paper. Adaptable SiL Solution for EV This paper focuses on the standardization of electric vehicle plant models, which can help users to reduce the software development and software testing time. We created the standardized plant models for following virtual ECUs, which can be used as modular units. • Battery Management System

Sajnani, Abhishek, Vernekar, Kiran, Gosavi, Rupesh, Naik, Venkatesh

System Validation with Battery-in-the-Loop Configuration using a Virtual Testing Toolchain

2024-26-011601/16/2024

Challenge Today, the battery development process for automotive applications is relatively decoupled from the vehicle integration and system design validation phase. Battery module design targets are very much linked to vehicle-level requirements, such as performance, lifetime and cost but are often disregarded at very early design phases. Converging these requirements to more specific battery pack criteria is not straightforward and often based on previous vehicle generation data or cell testing measurements usually performed after prototyping and via artificial charge and discharge patterns Solution To reduce time to market, AVL proposes here a methodology guided by virtual testing techniques to consider vehicle-level validation steps at the very early phase of battery testing. In a first step, AVL utilises a vehicle system simulation supported with real-world test scenarios and high-fidelity battery models. To generate such realistic scenarios, AVL uses an online digital map and

Kolar, Ales, Santiago, Prabhu, Kural, Emre

Enhancing Electric Vehicle Performance and Battery Life through Flywheel Energy Storage System: Modelling, Simulation, and Analysis

2024-26-013601/16/2024

This research paper focuses on the modelling and analysis of a flywheel energy storage system (FESS) specifically designed for electric vehicles (EVs) with particular emphasis on the flywheel rotor system associated with active magnetic bearings. The methodology used simulation approaches to investigate the dynamics of the flywheel system. The objective of this study is to explore the effects of implementing the flywheel energy storage system on the performance of the EV. The paper presents a comprehensive model of the flywheel energy storage system, considering the mechanical and electrical aspects. The mechanical model accounts for the dynamic behaviour of the flywheel, including parameters such as rotational speed, inertia, and friction. The electrical model describes the interaction between the flywheel and the power electronics, such as the converter and motor/generator. To evaluate the benefits of the flywheel energy storage system, simulations are conducted. Simulation studies

Akhtar, Juned

Electrifying the Giants: Green mobility solution for M&HCVs in India.

2024-26-013101/16/2024

Diesel operated Medium and Heavy Commercial Vehicles (M&HCV) account for nearly 70% of all road transportation in India which is expected to quadruple, from 4 million in 2022 to roughly 17 million trucks by 2050. Despite comprising a mere 5% of total vehicle fleet, they consume nearly 57% of fossil fuel used by the transport sector and responsible for 71% ,74% and 55% of CO2 ,PM and NOx emissions respectively. This necessities the transition of M&HCV into green mobility solution. Furthermore, smaller vehicles like 2W, 3W, 4 wheeler like cars and buses are adopting EV technology at a faster pace coupled with incentivization through government policies like FAME-I, FAME-II etc., advocates an immediate intervention on electrification of M&HCVs to multifold the impact. This paper suggests a collaborative approach amongst M&HCV manufactures and government agencies to realize the transition while integrating the benefits of reduced emissions, lower operating costs, quieter operation

Saurabh, Piyush, Giri, Debabrata

Utilizing Computed Tomography for Cell Characterization, Quality Assessment, and Failure Analysis

2024-26-018901/16/2024

This abstract presents an experimental study on using Computed Tomography (CT) scan technology for analyzing battery cell failures. Lithium-ion battery cells with known failure modes were subjected to cyclic test under different temperature and C-rates. CT scans provided high-resolution cross-sectional images of internal structures, revealing failure-related features. The advanced image processing techniques quantitatively assessed electrode morphology, active material distribution, and separator integrity. The study demonstrated CT scan's potential in non-destructive analysis, enabling a deeper understanding of failure mechanisms and informing improvements in cell design and manufacturing processes.

Singh, Sathya Prakash, Baidya, Kapil Krishna, ADHALE, Pratik

Study Of Derived Battery Features for Real Time Estimation of SOH And RUL Of EV Battery Using Data Analysis

2024-26-012301/16/2024

Lithium-ion batteries have been widely used in EV’s. It is desired to predict the SOH of batteries to achieve optimal operation and health management. The most significant obstacle to accurately predicting battery health is choosing battery features. In this study, numerous data analysis strategies are introduced to manage feature irrelevancy and help in determining which features can be selected and used in real time. The first step in manually crafting features is to analyses the evolution pattern of numerous essential characteristics of battery. Second, correlation between selected features and degraded capacity analyses. Then, selected features are fed into representative machine learning regression model to effectively predict remaining capacity of battery to find the SOH status. Finally, the remaining capacity of battery is selected as feature to predict the RUL in terms of remaining charge-discharge cycles.

Nangare, Kapilraj, Nidubrolu, Kranthi, Gaikwad, Pooja

Effect of Ceramifiable Silicone Rubber Composite based Thermal Insulators in Battery Packs

2024-26-035101/16/2024

Silicone and rubber composite, often called Ceramifiable Silicone Rubber (CSR) has proven to show excellent mechanical and thermal properties. CSR materials have been mainly used in industrial applications like electrical insulating cables, decorations, and fire-proof materials. The mechanical and ceramifiable properties of CSR can be altered by changing the silicone rubber matrix and by adding the right additives or fillers. In this work, we prove the potential of CSR composites as thermal insulating materials in battery packs. Specifically, we explore the usage of CSR inside the battery pack to improve safety during thermal events. We also characterize the material properties before and after exposing the CSR composite to elevated temperatures and flame. Finally, we investigate the effectiveness of the CSR composite sheet in preventing or delaying cell-to-cell thermal propagation during a thermal runaway event inside the battery pack. Our experiments show that the CSR composite sheet

Nambisan T M, Praveen Kumar, H, Manjunatha, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan

A Real-World Range Testing and Analysis Methodology Development for Battery Electric Vehicles

2024-26-012401/16/2024

Range anxiety is one of the major factors to be dealt with for increasing penetration of EVs in current Automotive market. The major reasons for range anxiety for customers are sparse charging infrastructure availability, unreliable range prediction and uncertain real-world range values. The uncertainty in real world range is due to the variation between the testing condition during vehicle development and real-world customer usage condition. This paper illustrates a more accurate test methodology development to derive the real-world range in electric vehicles (LMV) with experimental validation and system level analysis. The test methodology developed will be replicating the real-world usage scenario and bridge the gap between testing and Indian customer usage condition. Test conditions are developed based on matrix consisting of different routes, drive modes, Regeneration levels, customer drive behavior, time of drive, locations, ambient conditions etc. Based on the real world

B, SAKTHIVEL, Shams, Tausif, Lalasure, Santosh, Karnure, Shabbir Lalaso, Rajakumar, K., Omprasad, Karthick

Design and Development of E-axle as a retro and OE fitment solution for Light Commercial Vehicles ranging from 1.5 to 5 Ton GVW

2024-26-011901/16/2024

The Light commercial vehicle (LCV) is primarily used for the last mile delivery and it holds the volume share of around 61% in the commercial vehicle segment. The last mile delivery services have seen a massive surge after the CoVID-19 pandemic resulting is the increase sale of LCV in last few years and is expected to grow further by 8-11% in the coming years. However, city logistic is also responsible for most pollution and noise in the city. Hence, policymakers are aiming to reduce carbon footprint by promoting the use of Electric vehicle by providing incentive to automakers though schemes like FAME-I and FAME-II. In order to effectively reduce the carbon footprint within city it is important to increase the use of new electric vehicle and convert the old polluting vehicles to electric. Hence, a retro fitment solution for converting used LCV to electric can help in reducing emission as well as noise pollution. Later the same solution can be offered as OE fitment solution. Though

VAIBHAV, KUMAR, Mulik, Rakesh Vilasrao, Shrikrishna Ramdasi, Sushil

Immersion Cooled Portable Battery Pack Concept for Small EVs

2024-26-011101/16/2024

India is amid of a mobility revolution with the adaption of electric vehicles (EV). Such large-scale EV adoption comes with critical safety challenges related to thermal management of batteries. EVs catching fire during running & parked conditions has been widely noticed throughout the country. The cause of fire in most of the cases is poor thermal management and thermal mitigation strategies. Owing to this in Sep-2022, the Government of India amended the EV battery testing standards and implemented Amendment-3 of AIS-156 in a phased manner, with Phase-1 came into effect from Dec-2022 & Phase-2 from Mar-2023. This paper introduces a battery thermal technology that will address these automotive safety needs and government requirements by achieving better thermal management of EV batteries and reducing thermal failures. Present EV battery thermal management systems are either air (active & passive) or liquid-based cooling systems. Most liquid cooling technologies usually incorporate a

Jadhav, Jeevesh, Neve, Gaurav, Hiremath, Vinodkumar, Nagpure, Shrikant, Emran, Ashraf

Twin Motor System for Electric Vehicle Propulsion by Means of Two Energy Sources

2024-26-011301/16/2024

The transport sector in all domains like personal vehicles, public transport and logistics has seen a tremendous growth over the past decade, more so in the last 5 years. The main reasons for this rapid growth is the development of new energy storage systems in battery technology ( Lithium ion ,sodium ion ,aluminum air etc.), hydrogen fuel cells, super capacitors etc. On the other hand there has been tremendous development in the motor drive technology with the availability of brushless dc motors (BLDC Motors), induction motors, Permanent magnet synchronous motors (PMSM,IPMSM). Each motor having its own special characteristics and usage suited for a very specific application in terms of torque and load bearing capacities. In this paper we describe a unique platform with twin motor drive system electric vehicle which is powered by an artificial intelligence (AI) enabled electronic module DuoPackR. The basic platform is described with the help of a bicycle which has two BLDC motors on

PRATIWADIBHAYANKARAM, Ashwini Kumar Krishnaswamy, K A, Rakesh, Sangam, Manjunath

Data Driven Parameter Estimation for Battery Modelling Using System Identification Technique

2024-26-009901/16/2024

The battery models have become an important part for the design of battery-powered systems. The first step in the development of an accurate battery model is to build and parameterize an equivalent circuit that reflects the battery’s nonlinear behavior and dependencies on temperature, SOC, SOH, and current. These dependencies are unique to each battery’s chemistry and need to be determined using measurements performed on battery cells of exactly the same type as those of the controller. This paper gives an overview, methodology and result on data driven battery model using system identification technique. Derived by the common approaches using standardized tests, e.g. hybrid pulse-power capability (HPPC), with predetermined charge and discharge sequences, the existing parameter based battery model are in use. Equivalent linear circuit battery models of different complexity were then tested and evaluated in order to identify parameter dependencies at different state of charge levels and

Minz, Susanta Kumar, AHMAD, MD SAIF, Ranjan, Ashish, Mudliyar, Karuna

Research on the Control Method of Staggered Parallel Boost Structure in Fuel Cell System

2023-01-702810/30/2023

Fuel cells’ soft output characteristics and mismatched voltage levels with subordinate electrical devices necessitate the use of DC/DC converters, which are an important part of the power electronic subsystem of the fuel cell system. The staggered parallel Boost topology is commonly employed in fuel cell DC/DC converters. This paper focuses on the control characteristics of the two-phase interleaved parallel Boost topology in the context of a fuel cell system. Specifically, we derive the small-signal model and output-control transfer function of the topology, and design a controller based on frequency characteristic analysis. Our proposed controller uses a cascaded double-ring structure and supports both constant current and constant voltage switching modes. To evaluate the effectiveness of our proposed control strategy, we conduct simulation and prototype testing. The simulation and DC/DC converter prototype are configured according to the output characteristics of the fuel cells, and

Ma, Tiancai, Liu, QiLin, Xie, Jiaojiao

Knee-Point Identification of Battery Degradation Trajectory Based on Constant Voltage Charging Capacity Variation

2023-01-703310/30/2023

The turning point in the process of nonlinear aging is a key feature to identify the nonlinear aging behavior of lithium-ion batteries. In order to identify the knee-point online, this paper studies the capacity “diving” phenomenon of the battery during the experiment and the regulation of the appearance of the turning point during the nonlinear aging process. Then, a knee-point identification method based on constant voltage charging capacity is proposed, and the linear and nonlinear stages of battery decay are redefined. Based on the change of constant voltage charging capacity in the constant current and constant voltage charging strategy, the method defines the aging process in which the constant voltage charging capacity remains invariant as the linear decay stage of the battery, and the aging process in which the constant voltage charging capacity rises rapidly as the nonlinear decay stage. The intersection of linear and nonlinear decay is the knee-point of the battery’s aging

Chen, Jianguo, Sun, Tao, Zheng, Yuejiu, Han, Xuebin

Sensitivity Analysis of Advanced Non-Linear Observer for States Estimation of Lithium ion Batteries

2023-01-700010/30/2023

Control observer-based estimation methods are getting a very rapid appreciation due to their better reliability, stability and ease of implementation in already controller-packed electric vehicles and energy storage systems. As a careful sensitivity analysis is the one vital tool to enhance the accuracy and robustness of lithium-ion battery’s states estimation, an experimental sensitivity analysis is proposed to enhance the accuracy and efficiency of battery states and parameter estimation of non-linear control observer. This paper categorically uses INR21700-M50T cells for experimental characteristic analysis of lithium-ion batteries. The results of this practical work are then used in the successful design, simulation and validation of an advanced proportional integral observer. The validated proportional-integral (PI) observer is then used to carry out the proposed sensitivity analysis, and deviations resulted in estimation accuracy due to the sensitivity of each parameter are

Saeed, Muhammad, Khalatbarisoltani, Arash, Zhongwei, Deng, Lu, Shuai, Xiaosong, Hu

Simulation Study on High Expansion Ratio Dedicated Hybrid Engine for Hybrid Commercial Vehicle Application

2023-01-700510/30/2023

The fuel economy and emission of the hybrid vehicle depend largely on the selected engine. And the dedicated hybrid engine (DHE) can be controlled to operate in the optimal operating range because DHE can be decoupled from the vehicle transmission system. The main purpose of this paper is to improve the thermal efficiency of the diesel engine under common operating conditions combined with high compression ratio (CR) and early or late intake valve closing (IVC) angle. According to the vehicle road spectrum data, the optimal operating range of the engine is determined to be 1200-1400 rpm and 70%-90% load. Then CR and IVC angle are optimized by using the calibrated one-dimensional thermodynamic model of the engine under limited peak combustion pressure (Pmax). The results show that the adjustment of IVC angle and CR can control the thermal state at the end of compression stroke. The combination of CR and IVC angle can achieve the optimal fuel consumption improvement. The minimum brake

Wang, Xiaosa, Lin, Zhiqiang, Wang, Hu, He, Hua, Liang, Depu

Design of a Permanent Magnet Biased Radial Magnetic Bearing for Energy Storage of Vehicle Flywheels

2023-01-702110/30/2023

In order to exert the maximum capability of flywheel energy storage system( FESS), a permanent magnet biased radial magnetic bearing (PMRB) was designed for the FESS. In this paper the authors walk systematically through design and verification of the PMRB. Sections 1 and 2 introduce the working principles and mathematical models. Sections 3 and 4 details design and simulation process. In section 5, a comparison of the current stiffness and displacement stiffness are made between analysis and measurements. Finally, a brief summary and forecast was made.

Jing, Li, Yang, Binglin, Sha, Yingdi

Distributed Co-Simulation for Effective Development of Battery Management Functions

2023-01-120006/26/2023

Electrification calls for a range of system components, that need to be developed and tested. On one hand, these system components include hardware components, like battery cells, modules, and packs, and battery management systems (BMS). On the other hand, software components are used for testing, e.g. algorithms for BMS or simulation models for batteries. Execution of tests on real batteries is typically time- and cost-intense, and includes considerable risks, leading to safety hazards. In this paper, we introduce a novel development and test approach for battery systems, that is driven by a unified, standardized interface between hardware- and software components and physical devices alike. Whereas established Hardware-in-the-Loop (HiL) systems are built on proprietary systems and environments, our approach is based on both open-source and industrial simulation software solutions. The Distributed Co-Simulation Protocol (DCP) is used to encapsulate and virtualize these components, as

Hrvanovic, Dino, Haberl, Hannes, Krammer, Martin, Scharrer, Matthias K.

Evaluating Vibration Test Profiles for Battery Electric and Hybrid Vehicles

2025-01-000905/05/2023

As the automotive industry transitions to electrification, understanding the differences in ambient operating vibration environments between a conventional internal combustion engine (ICE) propulsion system, battery electric vehicles (BEV), and hybrid electric vehicles (HEV) becomes increasingly important. Many current automotive vibration testing standards use frequency and amplitude levels based on historical ICE data. Some note the potential inaccuracies of using this data to test BEV/HEV and recommend using recorded field data when possible, while others make no note. Preliminary comparisons of BEV, HEV, and ICE vehicle ambient operating vibration environments show variations due to battery cell pack weight and engine vibration, among other reasons. As accurate testing is tantamount to vehicle safety and longevity, the automotive testing industry must confirm the suitability of current standards for BEV and HEV or create new standards. This paper delves into real-world vibration

Achatz, Tom, Stoll, Cherie

The DANA EV NVH Laboratory

2025-01-000705/05/2023

A cutting-edge EV powertrain NVH laboratory has been established at DANA Incorporation’s world headquarters in Maumee, enhancing their capabilities in EV powertrain NVH development. This state-of-the-art and industry lead laboratory is designed to meet various NVH requirements for EV powertrain development and sign-off processes. This laboratory supports the use of a live motor for input and is equipped with an input module that allows for detailed examination of NVH characteristics of new powertrain configurations before prototype motors are available, significantly reducing development time for new drivetrain systems. Key features of the laboratory include a hemi-anechoic chamber, two AC asynchronous load motors, an acoustically isolated high-speed input motor, and two battery emulators that cover both low and high voltage requirements. The NVH laboratory enables engineers to assess system performance and correlate it with digital twin models. DANA engineers can develop and optimize

Cheng, Ming-Te, Zugo, Chris

Research on NVH Performance of Pulse Heating System of One Vehicle

2025-01-007805/05/2023

When the ambient temperature is too low, the performance of the lithium-ion battery will deteriorate, and the car will have the problems of difficult charging, fast power consumption, and even difficult to start, so the battery needs to be heated before use to provide a comfortable working environment for the lithium-ion. The high-frequency pulse heating system can quickly and evenly raise the temperature of the battery, but there is noise during operation, which affects the NVH performance of the vehicle itself, and its noise comfort needs to be further optimized. Firstly, the high-frequency pulse heating system is discussed in detail, and the parameters affecting NVH performance and heating efficiency are explored. Secondly, NVH testing and subjective and objective evaluation were carried out based on different system parameters, relevant data were collected to establish a model, the influence of each parameter on the two was demonstrated, multi-objective optimization was carried out

YUN, ZHAO, Shouhui, Huang, zhou, changshui, Teng, Charlie

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