Thermal & Electrochemical Simulation of Battery Pack Systems Steve Hartridge Director, Electric & Hybrid Vehicles

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1 Thermal & Electrochemical Simulation of Battery Pack Systems Steve Hartridge Director, Electric & Hybrid Vehicles

CD-adapco Battery Modeling Technology Micro-structure Electrochemistry Virtually test SEM produced electrode geometry Conduct

construction Use the provided database of materials to construct virtual cells and test their performance Provides previously

Electrochemistry analysis of complex power systems Study detailed spatial effects at cell, module & pack level Interface Module &

2 CD-adapco Battery Modeling Technology Micro-structure Electrochemistry Virtually test SEM produced electrode geometry Conduct design studies on new concepts Cell Design Tool Build physics based models of electrode pairs and couple them to the cells physical construction Use the provided database of materials to construct virtual cells and test their performance Provides previously unseen spatial effects within electrodes Design next generation electrodes Pouch Module & Pack Analysis Flow, thermal & Electrochemistry analysis of complex power systems Study detailed spatial effects at cell, module & pack level Interface Module & Pack analyses with complex power train system models Embed physics based or empirical models in to power train systems models Overall System Design Battery

Concentration of Li in active parts of electrode Uses the arbitrary geometry handling power and massively parallel architecture of

3 Micro-structure Electrochemistry A genuinely unique tool which predicts the spatial distribution of ions and potential within an arbitrary, multi-phase microstructure region Electric Potential in solid and electrolyte regions Salt concentration in electrolyte Concentration of Li in active parts of electrode Uses the arbitrary geometry handling power and massively parallel architecture of STAR-CCM+ Easy set up of the initial states of the electrode based on OCV and state of charge Primary use is the design of next generation battery electrodes

Micro-structure Electrochemistry Case Study A VARTA LIC 18650 WC LiCO2 battery was segmented by FIB-SEM and reconstructed**.

*Presented at Solid State Electrochemistry Workshop 2013 held at Heidelberg **Hutzenlaub et al. 2012 Three-Dimensional model development for lithium intercalation electrodes, J.

4 Micro-structure Electrochemistry Case Study A VARTA LIC WC LiCO2 battery was segmented by FIB-SEM and reconstructed**. A 21 million cell finite volume mesh was created including active material, secondary conductive phase and electrolyte fluid phase*. *Presented at Solid State Electrochemistry Workshop 2013 held at Heidelberg **Hutzenlaub et al Three-Dimensional model development for lithium intercalation electrodes, J. Power Sources 185(2) Three-dimensional electrochemical Li-ion battery modelling featuring a focused ionbeam scanning electron microscopy based three-phase reconstruction of a LiCoO2 cathode, Hutzenlaub et.al. Electrochimica Acta Primary use is the design of next generation battery electrodes

5 Micro-structure Electrochemistry Case Study A design study using DEM Active Material 3 Phases Problem Binders Use STAR-CCM+ CAD tool to improve binder s network realism Primary use is the design of next generation battery electrodes

Sizing program Numerically build the cell and understand important metrics Covers all Battery form factors Stack, wound prismatic & wound

6 Cell Design Tool A comprehensive design environment which links a physics based electrochemistry model with a sizing program, enabling the electrochemical and physical design of a cell to be studied Electrochemistry model numerous derivatives with increasing fidelity Sizing program Numerically build the cell and understand important metrics Covers all Battery form factors Stack, wound prismatic & wound cylindrical Parameterization of a battery cell creating either an contemporary electrochemistry model or equivalent circuit model Example Model

7 Cell Design Tool Sizing Example Cylindrical Cell Default High Power NCA/Graphite cell, 1.04 Ahr, Increased Energy NCA/Graphite cell, 1.28 Ahr(23% up)

Cell Design Tool Validation Result Discharge Response Sanyo LiNi0.33Mn0.33Co0.33O2 18650 cell (2.05Ahr) Cells disassembled and physically characterized C/5 to 2C discharge rate Errors within 6.

8 Cell Design Tool Validation Result Discharge Response Sanyo LiNi0.33Mn0.33Co0.33O cell (2.05Ahr) Cells disassembled and physically characterized C/5 to 2C discharge rate Errors within 6.5% over total discharge Errors within 2.8% over 60% SOC window Sakti, et. Al, A validation study of lithium-ion cell constant c-rate discharge simulation with Battery Design Studio, International Journal of Energy Research 2012

Cell Design Tool - Validation Result Figure shows the prediction of cell voltage using a detailed electrochemical model, over a complete drive cycle.

9 Cell Design Tool - Validation Result Figure shows the prediction of cell voltage using a detailed electrochemical model, over a complete drive cycle. The lower graph compares simulation (red line) with experimental (green points) result. The upper graph is the instantaneous error between the two lines. Average prediction error over the 30 minute drive cycle is 8mV Thanks to Dave Howell, DoE for their co-funding of the CD-adapco CAEBAT project and NREL for their project involvement

Cell Design Tool Process Cell Description Geometric Description of cell Material

Stoichiometry for active Electrolyte selection Cell Calibration Data OCV curve HPPC

rate/differing temperatures Cell Parameter Estimation Stoichiometry at formation to

10 Cell Design Tool Process Cell Description Geometric Description of cell Material properties of coatings Voltage vs. Stoichiometry for active Electrolyte selection Cell Calibration Data OCV curve HPPC tests at differing rates/differing temperatures Constant current at low C rate/differing temperatures Cell Parameter Estimation Stoichiometry at formation to match capacity Temperature dependent diffusion co-eff Kinetic rate constant SEI resistance to match voltage drop in HPPC test Cell Validation

Cell Design Tool Aging Prediction Created a 20Ah cell with LiFePo cathode/graphite anode Run a 1 year aging simulation Compare Initial with aged cell

11 Cell Design Tool Aging Prediction Created a 20Ah cell with LiFePo cathode/graphite anode Run a 1 year aging simulation Compare Initial with aged cell performance Solvent Diffusion Model for aging of lithium-ion battery cells, H. P loehn, P. Ramadass, R. White. J Electrochemistry Soc. 151 (3) A456-A462 (2004)

Cell Design Tool > Module & Pack Analysis Cell Design Tool

to the cells physical construction Use the provided database

performance Electrochemist/Cell Designer Pouch Materials

Electrochemistry analysis of complex power systems Study

12 Cell Design Tool > Module & Pack Analysis Cell Design Tool Build physics based models of electrode pairs and couple them to the cells physical construction Use the provided database of materials to construct virtual cells and test their performance Electrochemist/Cell Designer Pouch Materials Database Prismatic Module & Pack Analysis Flow, thermal & Electrochemistry analysis of complex power systems Study detailed spatial effects at cell, module & pack level Thermal Analyst/application expert

Cylce, Discharge (Current, Power,etc) Model

Heat ElectroChemical Solver Equivalent Circuit

13 Coupled Physics Module & Pack Analysis Thermal/Fluidic Solver Input Program: Drive Cylce, Discharge (Current, Power,etc) Model Parameters: Properties + Experiments Battery Heat ElectroChemical Solver Equivalent Circuit Or Physics Based Battery Temperature Output SOC (%) Voltage (V) Heat Generation (W) Concentration Solid Diffusion Coefficient (m 2 /s) Etc Pouch Prismatic Cylindrical

14 Module & Pack Analysis Pouch LCO cells Tab Connector 120 US06 Charge Depleting Drive Cycle Periodicity Applied 21 Ahr LCO 3.8V Nominal Cooling Voltage Plates Opposite Tab Design Liquid Cooling Compression Performance PadsPrediction:RCR Model Current (A) Flow rate (kg/s) 0 0 Time (s) Cooling Channels Flow Rate Time (s) Conditions Current Density in Tab Connectors (A/m 2 )

Module & Pack Analysis German Autos OEM Project (Daimler, Porsche & GM Europe) managed by ASCS, Stuttgart 84 cell off-road hybrid pack Liquid cooled cold

validated implementations for the virtual development process of electrified vehicles S. Fell, E. Schneider, M. Lindner, R. Immel, J.

15 Module & Pack Analysis German Autos OEM Project (Daimler, Porsche & GM Europe) managed by ASCS, Stuttgart 84 cell off-road hybrid pack Liquid cooled cold plate thermal control Equivalent circuit cell model Transient electrical/thermal boundary conditions Pack Voltage Li-ion battery simulation strategies and validated implementations for the virtual development process of electrified vehicles S. Fell, E. Schneider, M. Lindner, R. Immel, J. Kremser SIMVEC Berechnung, Simulation und Erprobung im Fahrzeugbau 2012, VDI-Berichte 2169, p ; ISSN , ISBN ; VDI Verlag GmbH, Düsseldorf 2012 Cell Temperatures

16 Module & Pack Analysis Weak Cell Left Side with weak cell Right side all strong cells Current shows <20 Amps provided by weak side Weak cell runs hotter

17 Link to system design software Matlab Simulink Overall System Design Link available at cell or module/pack level Embed certain cell models in to Simulink directly AMESim Link available at cell or module/pack level Equivalent Circuit ElectroChemical Solver Or Physics Based Inputs Outputs

Battery Simulation Industry Presenters Nissan Star Global Conference 2012 FMC

Maxell Japanese Conference 2012 Hyundai Mobis Korean Conference 2012 Carnegie

are not named Department of Energy Co-funded project with JCI & A123 $3M

18 Battery Simulation Industry Presenters Nissan Star Global Conference 2012 FMC Star Global Conference 2012 GM Europe Star Global Conference 2012 Hitachi Maxell Japanese Conference 2012 Hyundai Mobis Korean Conference 2012 Carnegie Mellon - INTERNATIONAL JOURNAL OF ENERGY RESEARCH + many users worldwide that are not named Department of Energy Co-funded project with JCI & A123 $3M project Software now available Wide spread adoption of CD-adapco battery modeling methods

Conclusions CD-adapco s Battery Solution is a Multi-physics and Multi-scales solution offering performance simulation of coupled systems involving Li-ion batteries.

19 Conclusions CD-adapco s Battery Solution is a Multi-physics and Multi-scales solution offering performance simulation of coupled systems involving Li-ion batteries. Predicts the performance of a new cell and an aged or aging cell Current development focuses on abuse conditions such as thermal runaway caused by nail penetration, internal or external short circuits Current Temperature Development also focuses on other aging mechanisms Visit the company s website:

Battery Design Studio Update

Advanced Thermal Modeling of Batteries Battery Design Studio Update March 20, 2012 13:30 13:55 New Features Covered Today 3D models Voltage dependent diffusion Let s start with brief introduction to Battery