Browse Topic: Thermal runaway

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Basic Science and Art of Aircraft Wreckage ReconstructionR-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.
Reference
Simulation Based Validation of Battery Structural Integrity for Mechanical Abuse as per AIS 1562024-26-024201/16/2024
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
Technical Paper
A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack2024-26-010901/16/2024
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
Technical Paper
Adaptive derating algorithm for EV application based-Li-Ion battery for safe and healthy operation2024-26-010801/16/2024
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
Technical Paper
A Review on Fire Prevention and Suppression Solutions for EV Battery Packs2024-26-001201/16/2024
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
Technical Paper
Effect of Ceramifiable Silicone Rubber Composite based Thermal Insulators in Battery Packs2024-26-035101/16/2024
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
Technical Paper
Predicting the Onset of Vent Valve Opening in 18650 Cell During Thermal Runaway2022-28-041711/09/2022
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
Technical Paper
Study of Various Battery Thermal Management Systems & its Benefits2022-28-041411/09/2022
Electric Vehicle is the need of hour as the excessive usage of IC Engine driven Vehicles has depleted the ozone layer to a significant level. With new technology into the market, challenges come hand in hand because of Electric Vehicle. In comparison to IC Vehicle, areas of thermal management or the number of components for which thermal management needs to be done is higher and rather complex. As the thermal management system is the second highest energy consuming source after the powertrain of the electric vehicle, an efficient and reliable design becomes inevitable to ensure last mile driving range. Thermal Management of the Electric Vehicle has been identified as one of the critical parameters in defining the life, durability, range of the vehicle and the safety of its occupants. One of the major concerns in the development of lithium-ion battery packs for EVs is thermal management. The temperature of all cells must be strictly maintained within a few degrees C across the entire
Anandan, Ram
Technical Paper
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
Technical Paper
Development of a New Flammability Test Method: Enabling Material-Level Evaluation of Polymeric Materials for Electric Vehicle Battery Enclosures2022-01-084603/29/2022
The drive for reducing the weight and cost of battery systems for electric vehicles has led to continued interest in metal-to-plastic substitution and mixed-material designs for battery enclosures. However, the extreme performance requirements, such as thermal runaway mitigation, pose a challenge for plastic materials to meet. In an effort to design a cost-effective, lightweight next-generation battery enclosure while meeting the latest requirements, the Materials Development Department at the Hyundai-Kia America Technical Center has screened material performance of several plastic types. A new thermal runaway test set-up was developed with support from Underwriters Laboratory (UL), to create a scaled-down test representative of a full battery assembly in real-world conditions. The objective of this development was to provide a comprehensive matrix of test data that can inform material selection and design of next-generation battery enclosures based on performance requirements and
Nummy, Amanda
Technical Paper
Novel Nanocrystalline Silver Alloy Coatings to Boost Performance of EV High Voltage Interconnects and Charging Interfaces2022-01-087403/29/2022
Electric vehicle performance needs challenge connector designers and powertrain engineers with new paradigms for performance under more rigorous operational conditions. Traditional connector design protocols direct the engineer to silver plating for the contact interface, but these coatings have a maximum interface temperature of 170 C (ambient temperature plus T-rise). To avoid thermal runaway, engineers have to derate the ampacity of powertrain connections, which reduces available energy delivery as the temperature increases. This is especially true during transient power events like regenerative braking and acceleration. The soft nature of silver coatings make them well suited for power delivery and low contact resistance, but requires an engineering trade-off for wear durability. This is especially problematic for charging connectors which require tens of thousands of mating cycles before failure. In this work, we demonstrate the performance enhancements that can be achieved using
Griffiths, Peteris, HILTY, Robert, Chan, Lisa, Cahalen, John
Technical Paper
Comparative thermal runaway behavior analysis of high-nickel lithium-ion batteries with different specifications2022-01-086203/29/2022
High-nickel lithium-ion batteries extend the driving mileage of electric vehicles (EVs) to 600km without much cost increment. However, thermal accidents commonly occur due to their poor thermal stability, such as thermal runaway. To address the issue, a comprehensive analysis of the thermal runaway behavior of high-nickel lithium-ion batteries with different specifications is conducted. The thermal runaway process is divided into five stages based on self-heating generation, voltage drop, safety valve rupture, and thermal runaway triggering for the three tested cells. The three tested cells demonstrate similar behaviors during each stage of the thermal runaway process. However, there are still apparent differences between their characteristics. Four aspects of characteristic temperature, the relationship between sudden voltage drop and characteristic temperatures, temperature recovery, and thermodynamics, are discussed. Although Cell 01 has the highest T1, its T2 is the lowest. In
Chen, Siqi, Wei, Xuezhe, Zhang, Guangxu, Wang, Xueyuan, Zhu, Jiangong
Technical Paper
Identifying key aspects of thermal runaway modelling for lithium-ion battery cells2022-01-087003/29/2022
Electrification and hybridization of powerplants in the transportation sector is one of the most important changes in the last few decades. Lithium-ion batteries are the main energy storage systems, but despite the maturity of this technology, it has certain contains compared to traditional internal combustion engines in the day-to-day usage. As the operating conditions of the batteries are pushed to the limits to overcome certain disadvantages relative to other conventional systems like charge and discharge times or vehicle autonomy, new concerns and safety limitations must be considered. High power rates and cooling deficiencies can produce excessive operating temperatures within the cells, leading to problems with degradation or even unchain chemical reactions that can end in thermal runaway, one of the most worrying failure modes attaining electric platforms nowadays. One of the main challenges in the ordeal of designing the system considering these effects is the crossed
Garcia, Antonio, Monsalve-Serrano, Javier, Sari, Rafael, Fogué Robles, Álvaro
Technical Paper
A Comparative Study of Lithium-Ion Cathode Chemistry Correlations with Emissions Initiated by Nail Penetration Abuse in the Presence of an Immersive Coolant2022-01-084703/29/2022
The batteries tested during this work were common batteries used in existing automotive applications, and they included a nickel manganese cobalt (NMC) battery from a Chevrolet Bolt, a lithium manganese oxide (LMO) battery from a Chevrolet Volt, and a lithium iron phosphate (LFP) battery in a hybrid transit bus. The battery abuse and emissions tests were designed to intentionally drive the three different battery chemistries into thermal runaway while measuring battery temperatures, battery voltages, gaseous emissions, and feedback from volatile organic compound (VOC) sensors. A conductive nail was used to pierce the battery cell separator membrane which provided direct electrical contact between the positive and negative electrodes. The electrical contact between the electrodes acted as a low resistance path for a significant amount of current to pass between the electrodes which caused heat generation leading to thermal runaway of a single cell inside a module. During this testing
Surampudi, Bapiraju, Jones, Kevin
Technical Paper
3D FEA Thermal Modeling with Experimentally Measured Temperature Gradient Function from Large Format Ultra-Fast Charging Battery Module used in EVs 2022-01-084303/29/2022
In an electric vehicle (EV), due to a number of single cells connected either in series or parallel, generates a large amount of heat because of electrochemical reactions and physical changes, and that would result in the battery degradation (performance and capacity) and thermal runaway issues, and hence demands for an efficient battery thermal management system (BTMS). In this paper, an efficient BTMS is designed and developed for a large format Lithium-ion battery module using a liquid cooling technique. Experiments are conducted on 31Ah NMC/Graphite battery cell which is sandwiched by foams and heat sinks on both sides. A battery module is also developed with three batteries connected in parallel and four cold plates. A total twenty T-type thermocouples are used for this experimental work to measure thermal characteristics including the cell and foam surface temperature, heat flux distribution, and the heat generation from batteries under 2.5C and 3.5C constant power loss tests
Zhao, Ziyu, Panchal, Satyam, Kollmeyer, Phillip, Emadi, Ali, Gross, Oliver, Dronzkowski, David
Technical Paper
Investigation on the impact of high-temperature calendar and cyclic ageing on battery overcharge performance2022-01-087203/29/2022
With the degradation of lithium-ion batteries, the battery safety performance changes, which further influences the safe working window. In this paper, pouch ternary lithium-ion battery with a rated capacity of 4.2 Ah is used as the research object to investigate the impact of high-temperature calendar and cyclic aging on the tolerance performance. The overcharge-to-thermal-runaway test is performed on the fresh cell and aged cell (90% SOH). the inflection point of voltage for aged cell appears earlier than that of fresh cell, while the voltage corresponding to the inflection point is the same for them, which means that the voltage at which lithium plating occurs is the same. However, the voltage plateau and the crest voltage before thermal runaway of aged cell is significantly higher than that of fresh cell. Besides, for the thermal runaway triggering, ohmic heat, reversible heat, and side reaction heat all make contribution, among them, the side reaction heat plays a dominant role
Zhang, Guangxu, Chen, Siqi, Zhu, Jiangong, Dai, Haifeng, Wei, Xuezhe
Technical Paper
Comparison of Representative Wet and Dry Fire Suppressants to Retard Fire Propagation in Lithium-Ion Modules initiated by Overcharge Abuse2022-01-086003/29/2022
The batteries tested during this work were common batteries used in existing automotive applications, and they included a nickel manganese cobalt (NMC) battery from a Chevrolet Bolt, a lithium manganese oxide (LMO) battery from a Chevrolet Volt, and a lithium iron phosphate (LFP) battery in a hybrid transit bus. The battery abuse and emissions tests were designed to intentionally drive the three different battery chemistries into thermal runaway while measuring battery temperatures, battery voltages, gaseous emissions, and feedback from volatile organic compound (VOC) sensors. Overcharge tests simulated a failure in the devices responsible for ensuring the battery remained within safe operating limits during charging. Overcharging a battery can cause lithium plating and other exothermic reactions that will lead to thermal runaway. During the testing, VOC sensors were used to determine what, if any, amount of forewarning they may provide in the event the battery enters thermal runaway
Surampudi, Bapiraju, Jones, Kevin, Shuvodeep Bhattacharyya , Bhattacharyya
Technical Paper
Battery Heat Load Estimation and modeling its Thermal management using Air Conditioning System of an Electric Vehicle2021-28-023110/01/2021
The performance of lithium-ion batteries and its service life depends on its operating temperature. Operating the battery above 45 °C degrades the performance of the battery and reduces its service life. The high-temperature operation also leads to thermal runaway. So there is a need to monitor the operating temperature and voltage output of the battery using a battery thermal management system to ensure its safety. Battery Thermal Management System (BTMS) is a part of the battery management system. The effectiveness of the battery thermal management system depends on the battery pack design, battery chemistry, vehicle operating characteristics and ambient conditions. In this work, a refrigerant-based BTMS is modeled using MATLAB Simulink. Refrigerant R134a used in the air conditioning system of an Electric Vehicle is used as an evaporative cooling medium to cool the batteries. The battery pack is submerged in the pool of refrigerant for cooling and to control the battery temperature
Kaliaperumal, MuthuKrishnan
Technical Paper
Failure of Li-Ion 18650 Cylindrical Cells Subjected to Mechanical Loading and Computational Model Development2021-26-031809/22/2021
To enhance the crashworthiness of electric vehicles, designing the optimized and safer battery pack is very essential. The deformed battery cell can result in catastrophic events like thermal runaway and thus it becomes crucial to study the mechanical response of battery cell. The goal of the research is to experimentally investigate the effect of mechanical deformation on Lithium ion battery cell. The paper thoroughly studies the phenomenon of short circuiting at the time of failure. Various experiments are carried on 18650 cylindrical cells (NCA chemistry) under custom designed fume hood. The setup captures the failure modes of battery pack cell. The loading conditions have been designed considering the very possible physical conditions during crash event. The study has been done for radial compression, semicircular indentation, hemispherical indentation, flat circular indentation and case of three point bending. A detailed computation model is developed in Hypermesh to study the
Aphale, Siddharth, H, Rajesh, Dandge, Sunil, Mahajan, Rahul, Nandurdikar, Vijay, Murugkar, Milind
Technical Paper
Comparison of different thermal management strategies in tropical conditions for Li ion batteries and the effect of using Phase change materials (PCM)2021-26-014009/22/2021
The automobile sector is moving towards electrification as a replacement for the conventional IC Engine as the power source of vehicles. In electric vehicles, Li-ion battery is the widely used energy source for traction and is a major differentiator among various sub components that affect vehicle performance, safety and efficiency. The life of the battery pack is affected by different stress factors like SoC (state of charge), DoD (depth of discharge), C-rates (charge and discharge currents) and battery temperature. Out of the mentioned stress factors, the life of batteries is most influenced by the temperature excursion seen by the li-ion cells in the battery pack. There are various thermal management strategies available to keep the temperature under control like air cooling , chilled liquid cooling and hybrid cooling systems. The benefit of using Phase Change Materials (PCM) in case of hybrid cooling systems in mitigating thermal runaway propagation within the battery pack and the
Kumar, Tirukoti Mohan, C, Vijay Ram
Technical Paper
A Review on Thermal Management in electric vehicle battery system by liquid cooling2021-28-014509/15/2021
With the advent of sophisticated technologies and complexity of electronics and mechanical system for mobility applications, the challenges for better heat management is paramount. The challenge is largely driven by integration of most innovative auto subsystems and their demand of being tightly packed into a lower volume, mass and relatively higher power consumptions compared to the older version. One of the examples is the thermal management in electric vehicle battery system. Electric Vehicles has been on the front burner as an aftermath of the recent announcement of the Government to make India an all-electric passenger vehicle market by 2030. The mirage of having electric vehicles on the roads is now transforming to a pleasant but perplexed reality as it comes with plethora of technical and feasibility challenges. According to current design the Lithium-ion batteries are the single most important component of an electric vehicle, comprising 40% of total production cost which is
Sahoo, Pranati
Technical Paper
NAWA aims for 5-minute EV charge21AUTP03_0203/01/2021
A new nano-based carbon electrode is key to reducing electric-vehicle charging time. A French nanomaterials company has developed a technology that it claims can significantly increase the storage efficiency of electric vehicle batteries. NAWA Technologies' Ultra-Fast Carbon Electrode (UFCE) is a key to bringing EV battery-charging time into parity with gasoline-refueling time, while improving battery life-cycle performance by a factor of up to five, according to company founder and CTO, Pascal Boulanger. In an interview with SAE's Automotive Engineering, Pascal Boulanger said the UFCE technology can help deliver 1,000-km (620-mi) operating range for mass-market EVs, with a time of five minutes for an 80% charge. “The uniqueness of the technology is its 3D structure and use of vertically aligned carbon nanotubes [VACNT],” he noted. Each nanotube is formed from a graphene sheet that is rolled in a cylindrical shape. The tubes have “the same aspect ratio [between diameter and length] as
Birch, Stuart
Magazine Article
STATIC TESTING of EV components20AUTP09_0409/01/2020
Firing nails into your latest Li-ion battery pack is but one of many regimens in the comprehensive testing of new electric vehicles. The market for electric vehicles (EVs) continues to grow. To offset the immense weight of their batteries, a heightened focus has been put on lightweighting, which has brought many new materials and components into the global automotive supply chain. These components and assemblies, including polymer films used for Li-ion battery cell separators and the packs they ultimately form, require development and production quality testing to verify their mechanical properties. One of the methodologies, static mechanical testing, is commonly performed by universal testing machines operated within manufacturing and research labs. Put simply, universal testing machines are designed to hold a test specimen and subject it to tensile (pull) or compression (push) forces by moving the machine's crosshead up or down. Transducers, such as a load cell, capture valuable data
Caesar, Dan
Magazine Article
Battery Management Systems for Rechargeable Lithium Batteries Used in Aerospace StandardsAIR6897 (Current)08/20/2020
This AIR provides basic background information and guidance for design and development of BMS architectures to be used in RLBs for aerospace applications. This guidance applies to batteries that are considered “installed” equipment and are intended to be part of the original or supplemental type certification or military airframe qualification.
AE-7D Aircraft Energy Storage and Charging Committee
Information Report
Portable Emergency Lighting Systems for Flight Crew MembersARP1798B (Current)07/14/2020
The purpose of this SAE Aerospace Recommended Practice (ARP) is to recommend general design and performance characteristics for hand-held portable, emergency lighting systems (note: the portable portion of this system that contains the lamp and reflector will be identified throughout the remainder of this document simply as a “flashlight”) intended for use by crew members of commercial aircraft during any emergency situation, within or outside of the aircraft cabin, where emergency lighting is required.
A-20C Interior Lighting
Recommended Practice
Portable Emergency Lighting Systems for Flight Crew MembersARP1798B-TEST-REC (Historical)07/14/2020
The purpose of this SAE Aerospace Recommended Practice (ARP) is to recommend general design and performance characteristics for hand-held portable, emergency lighting systems (note: the portable portion of this system that contains the lamp and reflector will be identified throughout the remainder of this document simply as a “flashlight”) intended for use by crew members of commercial aircraft during any emergency situation, within or outside of the aircraft cabin, where emergency lighting is required.
A-20C Interior Lighting
Recommended Practice
Designing Battery Packs for Harsh Environment Mission-Critical DevicesTBMG-3709406/01/2020
Many portable military electronic devices are used in extreme environments and are designed to comply with the MIL-STD-810 environmental test specification. The device and battery pack need to survive high or cold temperatures, shock or vibration, or even submersion underwater. Typical devices include handheld radios, laptops and personal protection equipment.
Magazine Article
Designing Battery Packs for Harsh Environment Mission-Critical Devices20AERP06_0106/01/2020
Many portable military electronic devices are used in extreme environments and are designed to comply with the MIL-STD-810 environmental test specification. The device and battery pack need to survive high or cold temperatures, shock or vibration, or even submersion underwater. Typical devices include handheld radios, laptops and personal protection equipment. Battery packs in these devices serve a critical role, as in most cases, they are the sole source of power. The energy density in these packs is typically as high as possible, given the space available, to maximize device run times. This intensifies the need to control and protect the stored energy where a failure could result in catastrophic events such as thermal runaway. This article presents design considerations and techniques for designing and manufacturing a battery pack that operates in extreme temperatures, absorbs shock and vibration, and maintains a watertight seal.
Magazine Article
Adhesives, Sealants, and Heat Transfer Materials in Battery Systems: A Primer on Materials, Applications, and End-Use Performance RequirementsJ3178_202005 (Current)05/05/2020
This SAE Information Report introduces key concepts and properties of adhesives, sealants, and HTMs and the roles they serve in present-day battery systems applications. The basic chemistry and properties of the three types of materials are summarized along with important health and environmental information. Relevant material dispense methodologies and equipment for material dispensing is reviewed. A series of representative battery applications examples employing adhesives, sealants, and HTMs is also provided with particular attention given to end-use performance.
Battery Systems Adhesives, Sealants and Heat Transfer Matl's
Information Report
Adhesives, Sealants, and Heat Transfer Materials in Battery Systems: A Primer on Materials, Applications, and End-Use Performance RequirementsJ3178_202005-TEST-REC (Historical)05/05/2020
This SAE Information Report introduces key concepts and properties of adhesives, sealants, and HTMs and the roles they serve in present-day battery systems applications. The basic chemistry and properties of the three types of materials are summarized along with important health and environmental information. Relevant material dispense methodologies and equipment for material dispensing is reviewed. A series of representative battery applications examples employing adhesives, sealants, and HTMs is also provided with particular attention given to end-use performance.
Battery Systems Adhesives, Sealants and Heat Transfer Matl's
Information Report
Thermal management of electrified vehicle by means of system simulation2020-28-003304/30/2020
With an objective of improving the range as well as other safety and comfort aspects, thermal management becomes increasingly important in the development of electrified vehicles both at the component as well as system level. The considerable increase in complexity of the thermal management system and its tighter interactions with the complete vehicle is driving an increasing trend towards system simulation compared to expensive testing. At the system level, different sub-systems interact with each other at varying extents. An example of one such strong interaction is between the coolant and AC circuits using battery chillers. Thermal management system simulation models must be capable of running such interactive systems. At the component level, ensuring the efficacy of the several components used in these intricately linked systems becomes increasingly important. An accurate prediction of temperature distribution inside the battery pack is essential to avoid damaging situations such
Shah, Sanket, Vijay, Dig, Lehocky, Marek
Technical Paper
48 V High-power Battery Pack for Mild-Hybrid Electric Powertrains2020-01-044104/14/2020
Mild hybridisation, using a 48 V system architecture, offers fuel consumption benefits approaching those achieved using high-voltage systems at a much lower cost. To maximise the benefits from a 48 V mild-hybrid system, it is desirable to recuperate during deceleration events at as high a power level as possible, whilst at the same time having a relatively compact and low cost system. This paper examines the particular requirements of the battery pack for such a mild-hybrid application and discusses the trade-offs between battery power capabilities and possible fuel consumption benefits. The technical challenges and solutions to design a 48 V mild-hybrid battery pack are presented with special attention to cell selection and the thermal management of the whole pack. The resulting battery has been designed to achieve a continuous-power capability of more than 10 kW and a peak-power rating of up to 20 kW. The pack has been built and has been subjected to a series of tests at a range of
Hall, Jonathan, Borman, Stephen, Hibberd, Benjamin, Bassett, Michael, Reader, Simon, Berger, Martin
Journal Article
Design of a Flexible Hybrid Powertrain Using a 48 V-Battery and a Supercapacitor for Ultra-Light Urban Vehicles2020-01-044504/14/2020
Global warming has put the transport sector, a major contributor of CO2 emissions, under high pressure to improve efficiency. In this context, ultra-light vehicles weighting less than 500 kg, as well as hybrid powertrains, are nowadays seen as promising development trends. The design process of the powertrain of a vehicle combining the advantages of the two concepts is presented in this paper. Through a performance study based on a simple MATLAB model, and mathematical simulation, a proposal is made. A powertrain using a battery and supercapacitor 48V dual power source network, two electric motors and clutches to switch between conventional, parallel, series and full electric modes proves to be an interesting system in terms of performance and costs. A simulation study conducted on a scenario with different outcome possibilities showed that high modularity of the system allows to achieve fuel efficiencies equivalent to approximately 3 l/100 km on the Artemis cycle. Finally, integration
El Ganaoui-Mourlan, Ouafae, Miliani, El Hadj, Carlos Da Silva, Daniel, Couillandeau, Matthieu, Gonod, Charlie, Miller, Guillaume
Technical Paper
Numerical Modeling of Lithium-Ion Battery Cells and Modules Subjected to Low Speed Indentation2020-01-045104/14/2020
Lithium-ion (or Li-ion) battery systems are being increasingly used as the main power source in new generation hybrid and electric vehicles. Their mechanical integrity under abuse loading conditions is very important for vehicle safety design. In this research, a computational study was performed to simulate mechanical tests on vehicle battery cells and modules. The tests were conducted on commercial Li-ion battery cells and entire modules at low speed using a high capacity material testing system. Based on loading and boundary conditions during the tests, finite element (FE) models using the explicit FEA solver LS-DYNA, were developed. The model predictions demonstrated reasonable agreement in terms of failure modes and force-displace response at both cell and module levels. With this newly developed numerical model for the entire battery module, a parametric study was performed to investigate the effect of small design modifications on its overall behavior subject to punch
Zhu, Feng, Du, Xianping, Lei, Jianyin, Audisio, Lorenzo, Sypeck, David
Technical Paper
Evaluation of External Short-Circuit Safety of NCM/C Li-Ion Power Battery under Different State of Health2020-01-045404/14/2020
With the increasing frequency of fire incidents of electric vehicles, the safety of power batteries has attracted more and more attention. At present, the research on the safety of power batteries is mainly focused on fresh batteries. As the state of health of batteries deepens, how the safety of the battery evolves is not clear enough so far. This paper analyzes the external short-circuit safety of a NCM/C rectangular battery under different state of charges. The results show that when the cycle number is less than 800, the maximum temperature of the battery during short-circuit is below 130 °C. The main failure mode of the battery is bulging in volume or opening of the explosion-proof valve and there is no obvious regularity between the failure mode with the cycle life. However, when the cycle number reaches 1000, the battery goes into thermal runaway during the safety test. In specific, the explosion-proof valve opens, and a large amount of smoke is sprayed, and the surface
Liu, Lei, Lin, Chunjing, Yang, Peixia, Wang, Fang, Fan, Bin
Technical Paper
Revealing Lithium-Ion Battery Internal Uncertainty through a Combined Electrochemical Based Degradation Battery Model with a Markov Chain Monte Carlo Approach2020-01-045004/14/2020
The battery electrodes are porous and have complicated microstructures due to irregular sizes and shapes of pores. Electrode design parameters like porosity, thickness, particle size, and conductivity can vary from one local area to another in one cell. Even under the normal operating current, some local areas may experience over-charge/over-discharge, extensive degradation, and rapid heat generation. These local events are not easy to observe or measure at onset and can eventually lead to catastrophic failure of the whole cell if no actions are taken. Battery design parameters are treated as constant values in many electrochemical battery models. However, the uncertainty of these parameters has an adverse effect on the longevity and safety of batteries. To prevent any catastrophic failure, a battery model is needed to predict any potential over-charge/over-discharge and rapid heat generation caused by internal uncertainty. In this work, a new method is developed to simulate random
Liu, Changhong
Technical Paper
AI Enhanced Methods for Virtual Prediction of Short Circuit in Full Vehicle Crash Scenarios2020-01-095004/14/2020
A new artificial intelligence (model order reduction) / finite element coupled approach will be presented for the risk assessment of battery fire during a car crash event. This approach combines standard crash finite element for the main car body with a reduced order model for the battery. Simulation is today used by automotive engineering teams to design lightweight vehicle bodies fulfilling vehicle safety regulations. Legislation is rapidly evolving to accommodate the growing electrical vehicle market share and is considering additional battery safety requirements. The focus is on avoiding internal short circuit due to internal damage within a cell which may result in a fire hazard. Assessing short circuit risk in CAE at the vehicle level is complex as there involves phenomena at different scales. The vehicle deforms on a macroscale level during the impact event. The battery cells deform locally and damage extremely thin components such as the separator, generating short circuits at
Dumon, Alexandre, Andres, Michael, Menegazzi, Stefano, Breitfuss, Christoph, Jimenez, Cristian, Chinesta, Francisco, Daim, Fatima, Tramecon, Alain
Technical Paper
Dynamic Load Identification for Battery Pack Bolt Based on Machine Learning2020-01-086504/14/2020
Batteries are exposed to dynamic load during vehicle driving. It is significant to clarify the load input of the battery system during vehicle driving for battery pack structural design and optimization. Currently, bolt connection is mostly applied for battery pack constraint to vehicle, as well as for module assembly inside the pack. However, accurate bolt load is always difficult to obtain, while directly force measurement is expensive and time consuming in engineering. In this paper, a precise data driven model based on Elman neural network is established to identify the dynamic bolt loads of the battery pack, using tested acceleration data near bolts. The dynamic bolt force data is measured at the same time with the acceleration data during vehicle running in different driving conditions, utilizing customized bolt force sensors. A data preprocessing method synthesizing Wavelet denoising method and machine learning algorithm is designed to improve model precision under dynamic
Liu, Ruixue, Hou, Zhichao, Wang, Shuyu, Sheng, Deke, Liu, Yuan
Technical Paper
Recent Progress on In-Situ Monitoring and Mechanism Study of Battery Thermal Runaway Process2020-01-086104/14/2020
Lithium-ion batteries (LIBs) with relatively high energy, power density and eco-friendly characteristic are considered as a vital energy source in consumer market of portable electronics and transportation sector especially in electric vehicles (EVs). To meet the higher capacity requirements, the nickel-rich LIBs with higher capacity has been used as the commercial power batteries. However, the battery with higher energy density is more destructive, which could result in thermal runaway accidents and make the battery safety issues become more and more prominent. Thermal runaway of LIBs is one of the key scientific problems in safety issues. Until now, the inducement of thermal runaway process is complicated which perplex researchers and industry a lot. On the one hand, the internal mechanism about thermal runaway should be deeply studied. On the other hand, in-situ monitoring should be developed to supply the mechanism study and early warning. In this paper, the latest evolution about
Xuan, Tang, Wang, Xueyuan, Dai, Haifeng, Sun, Jun, Zhang, Guangxu, Zhang, Haonan
Technical Paper
Mechanical Response of Laterally-Constrained Prismatic Battery Cells under Local Loading2020-01-020004/14/2020
The crash safety of lithium-ion batteries has received great attention in recent years because of their growing popularity in electric vehicles. However, the safety issues of prismatic batteries have not been thoroughly studied; in particular, the mechanical responses of prismatic battery cells with lateral constraints under varied loading conditions still remain unclear. In this study, indentation tests are conducted to study the mechanical response of prismatic battery cells. Fixtures providing lateral constraint which simulates the real packing situation in battery module are designed. Firstly, the effects of lateral constraints on coupled mechanical and electrical responses of prismatic battery cells are analyzed and discussed. Secondly, dynamic indentation tests of prismatic cells with lateral constraints are carried out. The response of the stacked batteries under local loading is revealed. Thirdly, non-destructive X-ray computed tomography imaging technique is employed to detect
Xiao, Feiyu, Xing, Bobin, Xia, Yong
Technical Paper
Sensorless Individual Cell Temperature Measurement by Means of Impedance Spectroscopy Using Standard Battery Management Systems of Electric Vehicles2020-01-086304/14/2020
Lithium ion technology is state of the art for actual hybrid and electrical vehicles. It is well known that lithium ion performance and safety characteristics strongly depend on temperature. Thus, reliable temperature measurement and control concepts for lithium ion cells are mandatory for applications in electrical cars. Temperature sensors for all individual cells increase the battery complexity and cost of a battery management system. Normally, temperature is measured on module level in current battery packs, without observation of the individual cell temperature. Sensorless cell impedance-based temperature measurement concepts have been published and are validated in laboratory studies. Dedicated test equipment is usually applied, which is not useful for automotive series application. This work describes a practical approach to enable impedance-based sensorless internal temperature measurement for all individual cells using state-of-the art battery management system components
Haussmann, Peter, Melbert, Joachim
Technical Paper
Comprehensive 3D Thermal Modeling of Vehicle-Ready Battery Module2020-01-138504/14/2020
Thermal management of vehicle battery pack is crucial in determining the life/ageing of the battery pack, in establishing the range of the vehicle on a day to day basis and in determining the safety of the vehicle and occupants. An effective design of a thermal management system cannot be established solely through experimentation as it is time consuming and costly. Accurate computational models are required to aid in the design process. This study describes the development and validation of 3D computational model for simulating electrical and thermal characteristics of a vehicle-ready battery module. The modeling process starts with the full 3D CAD geometry of the module including the coolant channels and cold plate. As part of the study, an experimental test case was setup. This included a climate chamber for the initial soak of the module and to control ambient temperature. Coolant was pumped through channels underneath the cold plate atop which the cells sat in blocks. The cell
Velivelli, Aditya, Khaleghi Rahimian, Saeed, Tang, Yifan
Technical Paper
Dynamic Simulation for LFP Pouch Batteries Coupled Mechanics-Electrics-Thermodynamics under Mechanical Abuse2020-01-133204/14/2020
The safety design of batteries, an important part in passive safety development of electric vehicle, is difficult in practical project application because of complex structure inside and Multi-physics reactions coupled mechanics-electrics-thermodynamics under mechanical abuse. An efficient computational model of batteries that can be attached to model of vehicle used for collision simulation is needed. In this work, four types of Multi-physics battery models (detailed computational model, simplified representative-sandwich model, composite layered model and simplified layered model) of pouch cell with LiFePO4 system are established in a commercial finite element software LS-DYNA (usually used for vehicle collision simulation). And the difficulties of modeling, resource demanded for calculation, accuracy of results (in mechanics, electrics and thermodynamics) in the four models are compared. In detail, based on quasi-static mechanical experiments of positive and negative current
ZHANG, Ruiyu, Wang, Tao, Deng, Chenghao, Jin, Guoqing, Xiao, Heping, Zhang, Yanbing
Technical Paper
Replacement of a 50cc Two-stroke Engine with an Electric Powertrain2019-32-062301/24/2020
As global regulations look to create a dramatic reduction in CO2 emission and other forms of pollution, companies with products that rely on engine technology must be ready to take on the electrification challenge. Applications that remain using two-stroke engine technology continue to exist due to their very high power density requirements. However, their history of higher pollution compared to four-stroke engines makes them a target to be regulated out of existence. Such high power two-stroke applications include high performance off-road motorcycles. In this type of product, electrification can solve not only pollution challenges but market challenges, such as ridership and public perception. By addressing the core problems presented by the two-stroke engine and turning challenges into opportunity, a strong attraction is created to convert a two-stroke engine motorcycle to an electric vehicle. With Automotive electric vehicle technology paving the way, the basis for cost effective
Beeker, Jesse
Technical Paper
Pulsating Heat Pipe Automotive Application2019-36-022701/13/2020
It is proposed a study to evaluate PHP (pulsating heat pipes) device application in battery thermal management systems for HEV (hybrid-electric vehicle) and EV (electric vehicle). Firstly, it is necessary to understanding Li-ion (lithium ion) batteries for HEV/EV, the electrical energy supply state-of-the-art. The analyzed aspects were battery framework and configuration; working principles and mechanisms; and market penetration and potential. Secondly, the adverse effects of temperature over such batteries were discussed. After understanding the case study, a battery modeling survey was performed in order to later evaluate BTMSs (battery thermal management systems). Well comprehended case study and battery modeling, then, it was possible to examine current automotive battery cooling and heating solutions. Finally, PHP was evaluated as a possible BTMS regarding technical and commercial aspects, explaining what would be the requisites in order to attend automobile heat dissipation
Barbosa de Oliveira, Rafael Beicker, Villalva, Sergio Gradella, Filho, Luiz Paulo Rodrigues, Windlin, Fernando Luiz, Alegre, Guilherme Henrique Mayer, Gonçalves do Santos, Rogério
Technical Paper
Innovative Fluid Allowing a New and Efficient Battery Thermal Management2019-01-225912/19/2019
With the increasing availability of fast charging stations across the globe, tighter and tighter constraints are placed on electric vehicles batteries. In order to handle the thermal stresses induced during fast charging, the improvement of the existing battery thermal management systems has become key. This article presents an innovative thermal management system for batteries. The system consists of circulating a newly developed highly advanced dielectric fluid in direct contact with the electrochemical cells of the battery pack. Experiments on our dedicated bench test and numerical simulations are reported here demonstrating the performance of this system with fluids, i.e. its ability to efficiently regulate the temperature of the battery cells even under fast charging conditions and low flow rates. Consequently, this thermal management strategy could be implemented within the next generation of battery electric vehicle (BEV) using conventional pumping systems and lead to an
RAISIN, Jonathan, CHAMPAGNE, Nicolas
Technical Paper
Novel electrochemical capacitors with high-energy density using intercalated metal-organic framework electrodes2019-01-226012/19/2019
The energy-density improvement of capacitors while maintaining high power, long-term-cycle stability and safety is challenging. Asymmetric capacitors using non-faradaic and intercalation electrodes are proposed in order to achieve this. However the reported asymmetric capacitors with graphite-based negative electrode have a safety risk, which is an internal short circuit due to Li deposition when further high-energy density is performed. Here asymmetric capacitors consisting of intercalated metal-organic frameworks (iMOFs) negative operating potential range of 0.5-1.0 V vs. Li/Li+ that enable Li deposition reduction and activated carbon positive electrodes is proposed to construct a high volumetric energy (ca. 60 Wh L-1) and power densities with safety.
Ogihara, Nobuhiro
Technical Paper
Battery experts: solid-state EV tech could be five years out19AUTP11_1111/01/2019
Solid-state batteries are the “reach” energy-storage technology slated to take electric vehicles (EVs) - and to a lesser extent, other consumer-electronic products - to the next level. And at September's 2019 Battery Show of North America, speaker panels and presentations about solid state certainly were in abundance. Just one problem: experts at the show's Solid State Battery Feasibility roundtable discussion where brutally realistic in agreeing the technology won't meet criteria for mass-production EVs for at least five years. The reasons for the five-year wait are manifest, but the two primary factors are familiar to the automotive sector: cost and manufacturability. Nonetheless, most experts here agree that solid-state batteries for EVs certainly are not an “if,” but a “when.” One analyst estimate indicates $500 million was invested in solid-state battery ventures in 2018 alone.
Visnic, Bill
Magazine Article
Hybrid and EV First and Second Responder Recommended PracticeJ2990_201907-TEST-REC (Historical)07/29/2019
xEVs involved in incidents present unique hazards associated with the high voltage system (including the battery system). These hazards can be grouped into three categories: chemical, electrical, and thermal. The potential consequences can vary depending on the size, configuration, and specific battery chemistry. Other incidents may arise from secondary events such as garage fires and floods. These types of incidents are also considered in the recommended practice (RP). This RP aims to describe the potential consequences associated with hazards from xEVs and suggest common procedures to help protect emergency responders, tow and/or recovery, storage, repair, and salvage personnel after an incident has occurred with an electrified vehicle. Industry design standards and tools were studied and where appropriate, suggested for responsible organizations to implement. Lithium ion (Li-ion) batteries used for vehicle propulsion power are the assumed battery system of this RP. This chemistry is
Hybrid - EV Committee
Recommended Practice
Hybrid and EV First and Second Responder Recommended PracticeJ2990_201907 (Current)07/29/2019
xEVs involved in incidents present unique hazards associated with the high voltage system (including the battery system). These hazards can be grouped into three categories: chemical, electrical, and thermal. The potential consequences can vary depending on the size, configuration, and specific battery chemistry. Other incidents may arise from secondary events such as garage fires and floods. These types of incidents are also considered in the recommended practice (RP). This RP aims to describe the potential consequences associated with hazards from xEVs and suggest common procedures to help protect emergency responders, tow and/or recovery, storage, repair, and salvage personnel after an incident has occurred with an electrified vehicle. Industry design standards and tools were studied and where appropriate, suggested for responsible organizations to implement. Lithium ion (Li-ion) batteries used for vehicle propulsion power are the assumed battery system of this RP. This chemistry is
Hybrid - EV Committee
Recommended Practice
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