Browse Topic: Lithium-ion batteries

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Analysis of Second-Life electric vehicle batteries value maximizing through repurposing and resale, ways to achieve optimal performance and standardization challenges for testing and certification2026-26-01931/16/2026
As electric vehicle (EV) adoption accelerates globally, a growing volume of lithium-ion batteries are reaching end-of-life in their primary automotive application—despite retaining 60 to 80% of their original capacity. This presents a significant opportunity to extend battery utility through second-life applications such as stationary energy storage, microgrid support, and commercial backup systems. This paper analyzes the strategies for maximizing the residual value of second-life EV batteries through repurposing and resale, while also addressing the challenges associated with performance optimization and standardization of testing and certification procedures. The study evaluates the techno-economic viability of second-life batteries compared to new systems, emphasizing cost savings, environmental impact, and emerging market demand. Techniques for enhancing second-life performance are examined, including advanced state-of-health (SoH) diagnostics, machine learning models for usage
Agarwal, Pranjal, Penta, Amar
Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-04141/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery pack has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events. This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material
BHAT, SADASHIV C, Sugumar, Mohanraj
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-03761/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
Transforming Battery Management: The Role of Artificial Intelligence and Machine Learning in Digital Twin Technologies2026-26-03821/16/2026
The traditional Battery Management System (BMS) faces certain limitations in fully utilizing battery capacity and performance during the long cycle life operation of Electric Vehicles (EVs). These constraints include limited real-time data collection, low processing speed, lack of predictive maintenance, and very limited accuracy in predicting health and degradation chemistry. A Battery Digital Twin (BDT) can effectively address these limitations of the BMS. Battery Digital Twins (BDT) can be viewed as a cyber-physical system comprising four key elements: virtual representation, bidirectional connection, simulation, and connection across the life cycle phases of an EV battery. The performance of a Li-ion battery largely depends on the cathode chemistry, component design, and operating conditions. The battery should be manufactured in a manner (such as cylindrical or prismatic cell) that prevents explosion, leakage, and gas generation inside the battery. To enhance the performance and
Chaturvedi, Vikash, M, Venkatesan, Lanke, Siddhi, Subramaniam, Anand, Karle, Manish, Pandit, Rugved, Gupta, Drishti, Karle, Ujjwala Shailesh
Comparative Assessment of Lithium-Ion Battery Recycling Strategies: Unveiling Challenges, Optimizing Benefits, and Exploring Future Potential.2026-26-02011/16/2026
This research paper offers a comprehensive evaluation of lithium-ion battery recycling methods, tracing the entire journey from global demand to the practical challenges and solutions for sustainable battery recycling. It starts with the analysis of worldwide LIB demand growth alongside the exponential growth in volumes of spent batteries and recycling rates. The study focuses on the imbalance in production and recovery of critical battery components and its environmental and economic effects. The paper then systematically examines six major recycling methodologies: mechanical, pyrometallurgical, hydrometallurgical, biotechnological, direct, and ion-exchange recycling. It goes into detail about their advantages, limitations, and roles in maximizing the recovery of valuable metals such as lithium, cobalt, and nickel. Traditional techniques like hydrometallurgical and pyrometallurgical methods, and emerging approaches including bioleaching and ion-exchange, are evaluated for their
Jain, Gaurav, PREMLAL, P, Pathak, Rahul, Gore, Pandurang
Integrated Simulation of Electric Vehicle Model Using the ROM Approach2026-26-03691/16/2026
The growing demand for Electric Vehicles (EVs) has highlighted the importance of efficient and accurate simulation tools for design and performance optimization. The architecture of electric vehicles is distinct from that of internal combustion engine vehicles. It consists of on-board charger, DC-DC converter, Lithium ion battery pack, Inverter, electric motor, controllers and transmission. The battery pack supplies electric current to the traction motor, which then converts this electrical energy into mechanical energy, resulting in the rotational motion needed to drive the vehicle. Wide range of Multiphysics is involved in the simulation which involves Power electronics, Electromagnetics, Fluid Mechanics, Thermal engineering. This paper presents an integrated simulation and range prediction methodology for Electric Vehicles (EVs) using the Reduced Order Model (ROM) approach. The methodology includes simulation in both 3D and 1D domain. Computational fluid dynamics (CFD) simulation is
Shandilya, Anand, Kumar, Vivek
Impact of Electric Exhaust Heater Power Electronics unit (EHPE) and Energy Storage Systems on Economy and Performance of Heavy-Duty Mild Hybrid Vehicles2026-26-01841/16/2026
With stringent emission norms enforced by governments and public authorities, advancements in internal combustion (IC) engine-based vehicles have become crucial. Cold starts and low-temperature combustion contribute significantly to vehicle emissions and need to be addressed to comply with upcoming stringent emission norms. An electric exhaust heater is known to reduce emissions by maintaining optimal exhaust temperature. For efficient energy management, exhaust heaters are typically powered by an onboard Energy Storage System (ESS), charged by electric machines. These electric machines in hybrid architecture provide efficient energy management by utilizing the recuperated braking energy of vehicles. However, the addition of a 48V hybrid system increases overall vehicle weight, and the vehicle effectiveness depends significantly on the vehicle application and ESS type used. The focus of this study is to investigate the impact of mild hybrids on fuel economy and performance for
Sadaraboina, Vidyasagar, Mehta, Kavish, Patil, Lalit Murlidhar, Busdiecker, Matthew, Karrer, Ben
State of Health correction based on dynamic cell behaviour in EVs.2026-26-01831/16/2026
In electric vehicle (EV) applications, accurate estimation of State of Health (SOH) of lithium-ion battery packs is critical for ensuring performance reliability, operational safety and user confidence. SOH is a key parameter monitored by Battery Management System (BMS) to assess the remaining usable life of the battery and to make informed decisions regarding charging, discharging, power delivery, and maintenance scheduling. In traditional SOH estimation techniques often rely on simplistic full-cycle charge-discharge data or single-parameter tracking (such as voltage or internal resistance and other method like coulomb counting and kalman filter ), which do not account for variable field conditions such as partial and full state-of-charge usage condition, dynamic load profiles, and non-uniform aging. As a result, these methods can produce significant deviations in SOH prediction, potentially causing premature system-level shutdowns, inaccurate range estimation, and delayed detection
Nikam, Ashish, Tiwari, Awanish Shankar, Sodha, Nirav, Hariyani, Ganesh, Ambhore, Yogesh Gajanan
State of Health Estimation in Lithium-Ion Batteries: Methods, Comparisons, and Future Directions2026-26-02081/16/2026
As the world is moving towards electric vehicles , we are observing a wide use of Lithium-Ion batteries in modern transportation. Lithium-Ion Batteries offer several advantages over conventional battery systems, including higher energy density that is energy stored per unit mass, longer Cycle Life, faster Charging rates, low Self-Discharge, lighter weight, and ease of maintenance as the memory effect present in other batteries is absent . Of course, challenges remain, e.g. accurate battery State of Health (SOH) estimation which stays as an indispensable parameter for safety and useability. Inaccurate SOH estimation can lead to unexpected vehicle behavior and a degraded end-user experience, especially due to incorrect "distance to empty" predictions. Also, different battery chemistries present various challenges, creating need of tailored models. In this paper, different SOH estimation techniques are reviewed and compared in detail . The SOH estimation approaches are broadly classified
Patel, Parvez, Bhagat, Ayush
Optimization and Evaluation of Thermal Interface Material Thickness and Distribution Patterns for Improved Heat Transfer in Liquid-Cooled Battery Pack2026-26-04321/16/2026
Battery Thermal Management Systems (BTMS) play a critical role in ensuring the longevity, safety, and efficient operation of lithium-ion battery packs. These systems are designed to effectively dissipate the heat generated by the cells during vehicle operation, thereby maintaining a uniform temperature distribution across the battery modules, preventing overheating and mitigating the risk of thermal runaway. However, one of the primary challenges in BTMS design lies in achieving effective thermal contact between the battery cells and the cooling plate. Non-uniform or excessive application of Thermal Interface Materials (TIMs) without ensuring robustness and uniformity can increase interfacial thermal resistance, leading to significant temperature variations across the battery modules, which may trigger power limitations via the Battery Management System (BMS) and these thermal gradients can cause inefficient cooling, ultimately affecting battery performance and lifespan. In this study
K, Mathankumar, Jahagirdar, Manasi, Kumbhar, Makarand Shivaji
Comprehensive Insights on Techniques for Managing and Preventing Thermal Runaway in EV Lithium-Ion Batteries.2026-26-01711/16/2026
This paper presents a comprehensive investigation into the mechanisms, risks, and mitigation strategies associated with thermal runaway in lithium-ion batteries used in electric vehicles (EVs). It begins by emphasizing the urgency of the issue, identifying key vulnerabilities within EV battery systems that contribute to runaway events. A multiscale, stage-wise breakdown of thermal runaway progression is provided, illustrating how physical, chemical, and thermal interactions compound during failure scenarios. The study analyzes global incident data from 2000 to 2025, revealing trends in human health impacts, vehicle damage, and public safety concerns. Particular attention is given to how battery aging, manufacturing defects, and external abuse conditions elevate the likelihood and severity of thermal runaway. Current emergency response protocols and state-of-the-art mitigation technologies are critically evaluated to identify best practices and existing gaps in safety management. A
Jain, Gaurav, PREMLAL, P, Pathak, Rahul, Gore, Pandurang
Lithium-ion Battery’s State of Health Prediction: A Deep Learning Framework2026-26-01621/16/2026
The growing adoption of electric vehicles (EVs) has increased the need for reliable and efficient battery health monitoring systems. Lithium-ion batteries, widely used in EVs, undergo performance degradation over time, making the prediction of their health status a crucial task for ensuring safety, longevity, and operational efficiency. Traditional model-based approaches often face challenges due to their reliance on complex physical models and sensitivity to varying operational conditions. To overcome these limitations, data-driven methods are increasingly preferred for predictive maintenance. In this study, a data-driven framework is proposed for estimating the State of Health (SoH) of lithium-ion batteries. The framework is developed using data collected from multiple battery cells under diverse operating scenarios. Key steps such as data preprocessing, feature engineering, and model development are carried out to build robust machine learning and deep learning models. A focus is
Suryawanshi, Chaitanya Balasaheb, Nangare, Kapilraj, Gaikwad, Pooja
Performance based packaging standard for lithium batteries as cargo on aircraftAS6413 (Current)11/26/2025
This standard is intended to demonstrate and document the control of the potential hazards from lithium cells or batteries (UN 3090 and 3480) when transported as cargo on aircraft. [still need to identify if we are addressing global (external fire) or local (battery internal failures)] This standard addresses the need to control the hazards which might arise from a failure from an individual cell by containing the hazards within the package. This specific hazards addressed within this standard are: • Uncontrolled fire • Rapid overpressure pulse within compartment
G-27 Lithium Battery Packaging Performance
Recommendations and Background Material for Battery Package TestingAIR6840 (Current)11/26/2025
AS 6413 and slash sheets /1 & /2 hold the main information for testing of battery packaging. This document holds further information and expansion of philosophy, clarification etc. surrounding the testing and industry needs.
G-27 Lithium Battery Packaging Performance
SAE TOMORROW TODAY BRIEFS - Perfecting Solid-State Battery Production135063/13/2025
When it comes to electrification, Honda has been focused on long-term strategy, emphasizing that the transition to EVs is a marathon, not a sprint. Recently, however, the company has been bullish on solid-state battery technology. By using a solid electrolyte instead of a liquid one, solid-state batteries offer advantages like higher energy density, reduced weight, and improved safety compared to liquid lithium-ion batteries. After perfecting the production of solid-state batteries in a lab environment, Honda is now focused on mass production. The company recently opened a test factory to produce battery packs for future EVs and to refine the production process. To learn more, Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sat down with Chris Martin, Technological Director of Communications, to discuss Honda's advancements in solid-state battery technology and the company's future plans for electrification. For more information on the evolution of
Hineman, Marcie
SAE TOMORROW TODAY: SAE J3108: Alerting First Responders to Lithium-Ion Batteries135053/8/2025
Less than one-third of first responders are trained on lithium-ion battery incidents, leading to potentially dangerous situations that can occur during vehicle fires, especially as the adoption of EVs grows. To help address this challenge, first responders must first know whether a vehicle is equipped with a lithium-ion battery or another alternative fuel source. In this episode of the SAE Tomorrow Today podcast, we sit down with Robert Swaim, Founder, HowItBroke.com, to discuss the SAE J3108 standard which proposes vehicle stickers to indicate fuel type, aiming to alert first responders on the scene. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders, innovators and strategists making it all happen--and give us a review on your preferred podcasting platform. Follow SAE on
Hineman, Marcie
New Battery Cathode Material Could Revolutionize EV Market and Energy StorageTBMG-5214212/1/2024
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 PerformanceTBMG-5214012/1/2024
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.
Dormant Capacity Reserve in Lithium-Ion Batteries DetectedTBMG-5214312/1/2024
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 SpaceTBMG-5214412/1/2024
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.
CAM-7®/LTO Lithium-Ion Cells for Logistically Robust 6T Vehicle Batteries2024-01-362911/15/2024
ABSTRACT CAMX Power is developing Li-ion pouch cells and batteries based on its proprietary CAM-7® cathode material and commercially available lithium titanate (LTO) anode material to provide high power, high charging rate capability, long life, safety and configurational flexibility in military vehicle batteries. The CAM-7®/LTO technology can be discharged to 0 V with no loss in performance, has excellent tolerance for cell voltage reversal and cell overcharge as well as having excellent elevated-temperature storage stability, making it ideally suited for batteries that can be logistically managed with little or no maintenance or environmental controls. These same properties make CAM-7®/LTO technology well-suited for implementing in damage-tolerant, minimally managed, batteries that are structurally distributed and integrated in military vehicles.
Ofer, David, Kaplan, Daniel, Menard, Mark, Yang, Celine, Dalton-Castor, Sharon, McCoy, Chris, Barnett, Brian, Sriramulu, Suresh
An Efficient and Cost-Effective Solution for Battery RecyclingTBMG-508496/1/2024
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.
SAE TOMORROW TODAY BRIEFS - The Trouble With EV Mineral Sourcing134575/29/2024
From human rights abuses to detrimental environmental impacts, mineral sourcing for EV batteries and electric motors has a dark side. Listen in as Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sits down with Tim Stevens, a freelance journalist who recently wrote an article for Motor Trend about the troubling side of EV mineral sourcing. Listen in as they discuss what Tim's research uncovered, potential solutions like the battery passport and electric motors without rare earth minerals, and how we can ensure more accountability throughout the EV supply chain. For more information on the evolution of sustainability, head on over to sustainablecareers.sae.org. There you can read about how lithium-ion batteries continue to be the best bet for some EV applications and that the technology around these batteries continues to evolve.
Hineman, Marcie
Multifidelity Uncertainty Quantification in Battery Performance for eVTOL Flights Under Material and Loading UncertaintiesF-0080-2024-11675/7/2024
This study addresses safety concerns within the rapidly evolving Electric Vertical Takeoff and Landing (eVTOL) aircraft domain, focusing on efficient tools to quantify uncertainties in lithium-ion battery behavior - a critical aspect of eVTOL. One major issue with quantifying uncertainty is the prohibitive computational cost associated with many queries of an expensive-to-evaluate computational model. This work employs three physics-based battery models models of varying fidelity and cost to estimate the mean and the variance of the selected quantities of interest through a multifidelity method to reduce the computation cost. By combining information from multiple cheaper, lower-fidelity models through the Multifidelity Monte Carlo method, we significantly reduce the number of high-fidelity samples required for a prescribed mean-squared error, consequently reducing computational costs down to a tractable level. The proposed methodology is applied to estimate the mean and the variance
Diaz Flores Caminero, Alvaro, Kim, H. Alicia, Chaudhuri, Anirban, Guibert, Alexandre
Study Of Derived Battery Features for Real Time Estimation of SOH And RUL Of EV Battery Using Data Analysis2024-26-01231/16/2024
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
Utilizing Computed Tomography for Cell Characterization, Quality Assessment, and Failure Analysis2024-26-01891/16/2024
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
Twin Motor System for Electric Vehicle Propulsion by Means of Two Energy Sources2024-26-01131/16/2024
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
Simulation Based Validation of Battery Structural Integrity for Mechanical Abuse as per AIS 1562024-26-02421/16/2024
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
Effect of Busbar Design on the Thermal Performance of Battery Packs2024-26-01351/16/2024
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 Multistage adaptive charging algorithm for Li-Ion battery-based EV Applications2024-26-01031/16/2024
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
A Review on Fire Prevention and Suppression Solutions for EV Battery Packs2024-26-00121/16/2024
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
An Experimental Approach towards Sustainable Solution for Material Recycling of ELV Plastic Bumpers and EV Batteries2024-26-01641/16/2024
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
Knee-Point Identification of Battery Degradation Trajectory Based on Constant Voltage Charging Capacity Variation2023-01-703310/30/2023
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 Batteries2023-01-700010/30/2023
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 Application2023-01-700510/30/2023
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
Research on NVH Performance of Pulse Heating System of One Vehicle2025-01-00785/5/2023
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
Development of a Detailed 3D Finite Element Model for a Lithium-Ion Battery Subject to Abuse Loading2023-01-00074/11/2023
Lithium-ion batteries (LIBs) have been used as the main power source for Electric vehicles (EVs) in recent years. The mechanical behavior of LIBs subject to crush loading is crucial in assessing and improving the impact safety of battery systems and EVs. In this work, a detailed 3D finite element model for a commercial vehicle battery was built, in order to better understand battery failure behavior under various loading conditions. The model included the major components of a prismatic battery jellyroll, i.e., cathodes, anodes, and separators. The models for these components were validated against the corresponding material coupon tests (e.g., tension and compression). Then the components were integrated into the cell level model for simulation of jellyroll loading and damage behavior under three types of compressive indenter loading: (1) Flat-end punch, (2) Hemispherical punch and (3) Round-edge wedge. The comparisons showed reasonable agreement between modeling and experiments. With
Development of a Detailed 3D Finite Element Model for a Lithium-Ion Battery Subject to Abuse Loading2023-01-0007-TEST-REC4/11/2023
Lithium-ion batteries (LIBs) have been used as the main power source for Electric vehicles (EVs) in recent years. The mechanical behavior of LIBs subject to crush loading is crucial in assessing and improving the impact safety of battery systems and EVs. In this work, a detailed 3D finite element model for a commercial vehicle battery was built, in order to better understand battery failure behavior under various loading conditions. The model included the major components of a prismatic battery jellyroll, i.e., cathodes, anodes, and separators. The models for these components were validated against the corresponding material coupon tests (e.g., tension and compression). Then the components were integrated into the cell level model for simulation of jellyroll loading and damage behavior under three types of compressive indenter loading: (1) Flat-end punch, (2) Hemispherical punch and (3) Round-edge wedge. The comparisons showed reasonable agreement between modeling and experiments. With
Numerical Investigation of cylindrical Li-Ion Battery Pack Thermal Management2022-28-041811/9/2022
Rapid movement of vehicle industry towards electrification has generated need for efficient and time saving methods to predict temperature across battery pack in different operating conditions which will assist in designing effective cooling methods for battery. The main requirements for efficient working of Li-Ion battery are (a) optimum operating temperature range and (b) small variation of temperature across the battery pack cells. Temperature across pack increases during charging and discharging cycles of battery in different operating cycles of machine. Especially due to high current rates in discharging, there is large temperature rise in battery. Elevated temperature profiles inside battery adversely affects many performance parameters like power, charge acceptance, life cycle and influences electrochemical reaction inside cells. Temperatures above the specified limits will cause degradation of performance and deterioration of material. If dissipation of heat is not efficient
Dewangan, Nitin
1-D Thermal Simulation and Experimental Validation of Li-Ion Battery Pack Cooling System2022-28-042911/9/2022
In today’s world EV plays an important role in reducing fuel consumption, pollution and global climate change. In EVs, Li-ion batteries are most preferred ones and their optimum operating temperature should be 15 °C to 30 °C, for that Battery Cooling System (BCS) is needed during charging and discharging for better performance in tropical regions. A flexible design methodology is required to evaluate and enhance the performance of BCS before the prototyping. This study mainly focused on 1-D thermal analysis and experimental validation of BCS. The simulation results and tests data shows good agreement within ±10% variation.
Jangir, Kuldeep Kumar, Srivastava, Umang
Predicting the Onset of Vent Valve Opening in 18650 Cell During Thermal Runaway2022-28-041711/9/2022
Oven exposure testing is a standard benchmark that Li-ion cells must pass to get approval for sale by the regulating bodies. These tests are designed to ensure the safety of battery user. However, these tests can be costly and time consuming. The development of simulation capabilities, which can replace the physical test to a certain extent helps both battery manufacturers and OEMs not only in the cost cutting but also to optimize the critical parameters which can directly influence the safety criterions. In this paper, a numerical model of 18650 Li-ion cell in an oven test condition is developed to study the thermal runaway, cell venting, internal pressure, and gas flow dynamics behavior using ANSYS FLUENT commercial software. k-ϵ Reynolds-Averaged Navier-Stokes model is used to describe the turbulent flow out of the cells. Thermal abuse reactions are described using by a four-equation lumped reaction model which considers the reaction kinetics of Solid Electrolyte Interface (SEI
U, Reghunath, Gudi, Abhay, Bonala, Sastry
Numerical Modeling of Electro-Thermal Behavior of a Typical Lithium-Ion Cell and Pack Level Using NewmanP2D Approach2022-28-040911/9/2022
Numerical simulation of lithium-ion batteries (LIB) has become extremely vital in the understanding of thermal behavior of LIBs in order to develop active and passive battery thermal management systems. The LIB is popular in consumer electronics. Beyond consumer electronics, the LIB is also growing in popularity for the automotive applications such as hybrid electric vehicles (HEVs) and battery electric vehicles (BEVs) due to its high energy density, high voltage, and low self-discharge rate. High amount of heat generally gets developed during charge and discharge of LIB based on the C-rate at which it is being discharged or charged. Hence, there should be a mechanism to understand the thermal behavior of these cells. Thus, in this paper a numerical procedure has been developed to model electrochemical-thermal behaviour of commercially available 21700 Li-ion cells. NewmanP2D approach is used to arrive at electrochemistry performance of Li-ion cell and pack. Well known commercial code
Gudi, Abhay, U, Reghunath, Bonala, Sastry
Performance Analysis of Integrated Battery and Traction Motor Cooling Systems for Two-Wheeler Electric Vehicles Applications2022-28-041311/9/2022
The automotive industry is a huge industry as millions of vehicles are running on the road & it's growing at a rapid rate. The emission from these vehicles are harmful in nature & are bigger concerns for the human being as its increasing day by day at an alarming rate. The emissions are causing various global problems such as global warming, green house effects, air pollutions etc. due to the use of fossil fuels in abundance. This drives to think for alternative solutions, which are eco-friendly & having less or no emissions. The electric vehicles (EVs) are the most reliable solution as it is having high performance & efficiency without emissions. EVs are most suitable option to reduce global warming & greenhouse effects etc. The evolution of EVs has fueled the two-wheeler EVs industry to flourish at a fast pace. Li-ion battery & traction motor is the most important components in two-wheeler EVs. Li-ion batteries are compact, light-weight, fast-chargeable, having low self-discharge
Suman, Saurabh, Kushwah, Yogendra Singh
Investigation on Thermophysical Characterization of Nano Composite Phase Change Materials for Battery Cooling in EV2022-28-042011/9/2022
Li-ion batteries are preferred for Electric Vehicles (EV) due to its high energy density, high power, long life cycles and low self-discharge rate. The performance of Li-ion batteries and life span are limited by its operating temperature, the safest operating temperature of the Li-ion batteries are below 500C, The operating temperature exceeded during fast charging and discharging which causes internal heating of battery it is essential to increase the dissipation of heat generated by the battery rapidly. Nano Enhanced Phase change Material (PCM) is proposed as Battery Thermal Management System. by nature the pure paraffin has low thermal conductivity and sub-cooling characteristics . In order to increase the thermal conductivity of PCM, thermal conductive substance such as nanoparticles are added to PCM, SiO2 nanoparticles were dispersed into paraffin wax tosynthesisSiO2 –PCM nanocomposites. The chemical, physical and thermal properties of CPCMs were determined by various material
Deepan Kumar, Sadhasivam, Dhayaneethi, Sivaji, Gopal, Mathiselvan, VISHNU, ANANDAN
Electric Vehicle Battery Thermal Load Estimation Under Different Drive Cycles, Capacity Fade Model Development and Life Prediction2022-28-043811/9/2022
The lithium-ion batteries are used in the rechargeable energy storage system (RESS) in electrical vehicles. The RESS system need to be accesses for thermal performance and life prediction. During the vehicle life time the ability of Li-battery to store the energy decreases and this is know as capacity fade. Capacity happens due to cycling and also because of edging in the storage. There is need to estimate the capacity fade for warranty purpose. There are multiple reason for capacity fade and ways to model the cell. The detailed chemistry model can capture the battery inside physics and required forty different battery parameters. The vehicle manufacturer (OEM) can not access these parameters as these parameter are the cell supplier proprietary data. We used new empirical equation based model to capture capacity loss. The model use the cell test data. The cell model developed is used for predicting the cell capacity loss for standard drive cycle.
dol, yogesh pradeep
Utilizing Machine Learning Algorithms in a Data-Driven Approach to the Prediction of Vehicle Battery State of Charge with BMW i3 Datasets2022-01-508810/17/2022
The state of charge (SoC) in an electric vehicle must be assessed and projected for any scenario, using the array of data points that can be extracted from a vehicle. In this paper, we explored the utility of data-driven approaches to SoC prediction that do not rely upon any internal or equation-based understanding of the device operation. We leveraged three unique machine learning algorithms to predict the battery SoC using data from other features of electric vehicles. We leveraged a publicly available dataset describing vehicle parameters and trip details for 70 trips in EV BMW™ i3 (60 ah) vehicles and evaluated aforementioned machine learning algorithms for predicting SoC percentage. We utilized a data processing technique (delta and stagger) to extract different perspectives from each trip record and demonstrated that machine learning techniques can be effectively used to predict battery SoC for a wide range of driving conditions and trip parameters.
Puri, Shreya
Theoretical Analysis of the Thermal Resistance Network for Battery Thermal Management2022-01-508710/12/2022
Battery thermal management for electric vehicles have gained significance over recent years, especially for the present lithium-ion batteries. However, high operating temperature and uneven temperature distribution inside the battery cell can significantly reduce capacity and lifetime. The temperature difference between the battery cells needs to be minimized to avoid premature aging of specific cells exposed to a higher temperature. The most common way to dissipate heat from the battery cells is to use air or liquid cooling. Air cooling is less complex than liquid cooling, but the extremely high ambient temperature dramatically limits the usage of air cooling. This paper developed a thermal connector that could be repeatedly assembled and disassembled between the battery cell. The thermal connector can effectively dissipate the heat into the refrigeration cycle while providing constant thermal resistance among the battery cells, which can be as lower as 0.115°C/W. Heat transfer
Lian, Yubo, Liu, Jianjian, Liao, Yinsheng, Xu, Haolun
Component Sizing of Electric Vehicles: A Programming Approach2022-01-508510/6/2022
The rising demand for battery electric vehicles has resulted in market saturation in terms of various start-ups, and established automakers are also introducing new models every year. The automakers have to put a lot of effort into sizing powertrain components optimally to get the best performance and efficiency. This paper proposes a programming approach for estimating the preliminary component sizing based on analytical equations regarding electric motor power rating and battery-pack energy capacity. Estimating tractive force for various vehicle performance goals dictates the motor power rating. The battery sizing for lead-acid and Li-ion batteries is proposed based on the empirical relationship between vehicle curb weight and battery-pack weight and the energy consumption approach. The validation and verification of the program based on output accuracy and user experience are presented.
Pednekar, Nihar, Patil, Satyajit
Urban Fuel Cell Bus Feasibility Study Approach Based on the Geospatial Data Analysis2022-01-11308/13/2022
The interest and number of sales of hydrogen urban buses has growth among Public Transport Operators significantly at the turn of 2010s and 2020s. The application of vehicles equipped with fuel cells can lead to eliminating several drawbacks of electric buses equipped with current generation of lithium-ion batteries. The hydrogen buses can offer greater single charge distance than electric buses and allow quick refueling to ensure high daily operability. However fuel cell propulsion systems are more sensitive to specific work conditions, such as high average speed or harsh topographic driving profile. The most common and conventional approach to check the possibility of a vehicle to operate on the selected route is to perform a test drive. As of the beginning of year 2022 the fuel cell buses and hydrogen refueling stations appear only in several cities across Europe, so for most use cases it is not possible to obtain hydrogen bus for the field testing. The approach proposed by the
Adamczyk, Dariusz
Rule-based Power Management Strategy of Electric-Hydraulic Hybrid Vehicles: Case Study of A Class 8 Heavy-Duty Truck2022-01-09013/29/2022
Mobility in the automotive and transportation sector has been experiencing a period of unprecedented evolution. A growing need for efficient, clean and safe mobility has made a strong momentum toward sustainable technologies in this sector. Toward this end, battery electric vehicles have drawn keen interest and the market share is expected to grow significantly in the coming years, especially in light-duty applications such as passenger cars. Although battery electric vehicles feature high performance and zero emissions characteristics, economic and technical issues such as high battery cost, a short driving range, and limited infrastructure should be tackled. In particular, the low power density of battery electric vehicles limits their broad adoption in heavy-duty applications such as class 8 long haul trucks due to a size and weight of battery. In this work, motivated by the high power density and potential for improving energy efficiency through regenerative braking of a hydraulic
Yoon, Yongsoon, Romero, Giovanni, Nkemdilim-Dantzler, Emil, DelVescovo, Dan, Guessous, Laila
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