Transcript Slide 1

High Voltage Battery System
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Contents
1. General
2. System Components
3. Battery Management System
4. Diagnosis
5. Cautions
2
General
3
Types of Rechargeable Battery
Lithium Type
Lithium-ion
Alkali Type
Acidity Type
Nickel-cadmium
Lead-acid
Representative
secondary battery
Li-ion Polymer
Ni-MH
HEV Battery
 Nickel-Metal Hydride
Gel/Solid electrolyte
Organic solution electrolyte
Lithium metal
 Lithium-ion
 Lithium-ion Polymer
General
4
Alkaline Battery
Alkali Type
 Cell voltage : 1.2V
 Self discharge rate: 10~30%
Nickel-cadmium
(Ni-Cd)
Nickel-Metal Hydride
 Memory effect: YES
 Application : Walkman,CD player
 Performance : Ni-MH 〉Ni-Cd
(Ni-MH)
Ni-MH Capacity: about 1~5 kWh
(Normal battery : about 0.3~1.0 kWh)
General
5
What is memory effect
Effect which cause to hold less charge because battery
remember the smaller capacity
If 80% discharged and then
fully charged,
→ only 80% capacity can be
used
If 64%(80% of 80%)
discharged and then fully
charged,
→ only 64% capacity can be
used
General
6
Nickel-Metal Hydride Battery (Ni-MH)
Most of HEV → Using Ni-MH Battery
Prius
Insight
General
7
Lithium-ion Polymer Battery (NiPB)
Lithium type
 Cell voltage: 3.75V
Lithium-ion
(Li-ion)
Representative
secondary battery
 Self discharge rate: 5% or less
 Memory effect: NO
 Application: Laptop, Digital camera,
Cellular phone, etc
 Performance: High Voltage,
Lithium-ion Polymer
(LiPB)
High energy density
General
8
TF Optima Hybrid High Voltage Battery
Lithium-ion
polymer battery
World’s first lithium-ion polymer battery for HEV
General
9
System Layout
Electric energy
Control data(CAN)
HEV Power-train
(engine+motor+transmission)
Engine/
motor
power
distribution
HCU
High Voltage Battery System
Battery
SOC,
variable output
Motor power
distribution
cooling fan speed
control
battery
current, voltage, temp.
cooling fan
battery module
MCU
AC Power
DC Power
cooling
(air cooled)
PRA
BMS
Components
10
High Voltage Battery System Components
High voltage battery
 Lithium-ion polymer battery
 270V / 5.3Ah, 72Cells in series
 Enhance safety
-Prevent overcharging
BMS*
 Voltage, Current, Temperature sensing
 SOC* estimation, Power-cut, Cooling control,
Relay control, Cell balancing, Diagnosis
Cooling system
 Maintain proper temperature
- Equipped with BLDC* cooling fan
- Increase air flow & Reduce noise
Power Relay Ass’y(PRA)
 Relay ON/OFF control
 Battery current check
BLDC: Brushless DC, BMS: Battery Management System, SOC: State of charge
Components
11
Location of High Voltage Battery
Inside of trunk
Cover opened
Inside of steel cover
High voltage battery module assembly
Components
Composition of High Voltage Battery
Cell
Module
3.75V
8Cells ⇒ 1Module
(8 X 3.75V ⇒ 30V)
Module
Assembly
9Modules ⇒ 1Module Assembly
(9 X 30V ⇒ 270V)
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Components
13
Operation of High Voltage Battery (Li-ion)
Charge
(+) Polarity
(-) Polarity
Discharge
Organic electrolyte
Mn(Cobalt)
Lithium
Oxygen
Graphite
Lithium-ion
charge
LiCoO2 + Co
Discharge
Li1-xCoO2 + LixCo
Components
14
Location of Power Relay Assembly
High Voltage Battery
System
Components
15
Composition of Power Relay Assembly
Pre-charge Resistance(?)
Pre-charge Relay
High voltage Relay (+) (-)
Capacitor
Components
16
Power Relay Circuit
Pre-charge
relay
Pre-charge
resistance
LDC
Inverter(+)
Main Relay (+)
Capacitor
Inverter(-)
Main Relay (-)
Equipped with Pre-charge circuit
to protect electrical components
Components
Power Relay Operating Sequence
K1 : Pre-charge relay
K2 : Main relay (+)
K3 : Main relay(-)
17
Components
Relay Control
18
Components
Pre-charge Relay Control
19
Components
20
Cooling Fan & Duct
Cooling Duct
Cooling Blower
Components
21
BMS Hardware
Item
Spec
Remark
CPU
16bit
XC167 (Infineon)
Battery Cell
Voltage Sensing
72 Cells
Exclusive sensing chip
Cell Balance
150mA@4V
Bucking
Current Sensing
-200 ~ 200A, 10Bit
-
Temp Sensing
11 ch
Battery 5 + External
Device 1 + Aux. Battery
1ch
Insulation
Resistance
Sensing
0.01~1㏁
-
Cooling Fan
Control
FCTL (relay control)
FSPEED (PWM output)
VF (speed monitoring
input)
BLDC Motor
Relay Control
3 ch
Pre / Main (+)/(-)
Interlock
1 ch
Safety plug
CAN Comm.
2 ch
C-CAN / H-CAN
Components
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BMS Framework
battery module
battery pack
battery system
measure
cell voltage
cell temp
current
intake temp
Insulation
resistance
BMS-Major Function
battery
control device
Key On/Off
Info
① Estimate SOC
② limit output
③ control cooling system
④ control relay
⑤ troubleshooting
⑥ cell balancing
SOC
Variable Power
Drive
mechanism
fan speed
relay
sequence
Error Code
cooling fan
high voltage
relay
lamp
(Cluster)
SOC Mgmt
Power Distribution
Battery Management System
Functions
 SOC monitoring
 Input / Output power limit calculation
 Cell balancing
 Cooling fan control
 High voltage power relay control
 Self diagnosis
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Battery Management System
24
SOC Monitoring & Power Limit Calculation
100 %
Max
Over Charge
80%
Charge Limit
65%
Normal
SOC
55%
Discharge Limit
20%
Min
Over Discharge
0%
Battery Management System
25
Cooling Fan Control
25. 00
Output
(kW)
20. 00
Discharge
15. 00
Unusable
10. 00
5. 00
Usable
Temp (℃)
0. 00
- 30미만
- 30
- 25
- 15
- 10
-5
0
5
10
15
20
25
35
45
50
55
60 이상
- 5. 00
Charge
- 10. 00
Unusable
- 15. 00
- 20. 00
Min. Storage
Temp.
-40°
Min. Charge/Discharge
Temp.
-30°
Optimal Temp: Average of 30°
Warning
Operating Temp.
Max. Charge/Discharge
Temp.
Warning
Max. Storage
Temp.
- 29° ∼ 49°
50°
55°
65°
Battery Management System
26
High Voltage Power Relay Control
HV MAIN RELAY(+)
OFF Req.
High Voltage Drive Component
인버터
MCU
IG
Key
HV MAIN RELAY(-)
ON/OFF
Req.
BMS
ECU
TCU
LDC
HCU
ON/OFF
Relay
Drive
High Voltage A/C Component
HV PRECHARGE RELAY
냉각팬
FATC
Status
AIRBAG
전원차단장치
U/ V/ W
U/ V/ W
전원Cable
배선
Power
+
Bat
t er y
배터리
Invet er인버터
Mot or
모터
--
Battery Management System
High Voltage Power Relay Control
_IG KEY
Main Relay(- )
Pre- charge Relay
INV Cap. Volt.
Main Relay(+)
Main Relay ON Status
Pre-charging Time : 200ms
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Battery Management System
28
Self Diagnosis
Input
Detect
Handling
Bat. Voltage
*Detects only when preset detection condition is
maintained for certain detection period..
1. Detection condition: voltage, current, temperature,
resistance, output, etc.
2. detection period: immediate ~ 10 sec.
*After detection, the information is transmitted
(CAN) and actuation processed.
*detection item*
1. BMS Status
- Determine Ready / Controllable / Fault
Bat. Temp.
Bat. Current
voltage
current
output
Aux. Bat. Voltage
temp
SOC
balancing
& wear and tear
current sensor
voltage sensor
temp sensor
aux. battery
fan
insulation
Fan Voltage
Insulation
Resistance
2. Limit Output
- Set limit level: 0%~100%
- Set limit slope
:immediately after occurance~1kw/100ms
3. Relay Control
- Determine relay OFF/ON
Comm (CAN)
EMS
*Diagnosis will deactivate under the following
conditions.
1. Satisfactory conditions
- Category criteria: when there is no serious
problem with the battery output and internal
structure
- Deactivation condition: when preset deactivation
condition is maintained for certain period
2. IG OFF
- Category criteria: when initialization is
necessary
- Deactivation condition: IG OFF and then
deactivate
4. Fan Control
- determine fan operation and speed
HCU
MCU
Deactivate
relay
safety switch
/ fuse
communication
5. Warning Lamp
- Service Lemp ON/OFF
- MIL ON/OFF
3. Repair at shop
- Category criteria: when there’s a significant
affect on performance or durability
- Deactivation condition: Deactivate only via GST
Tool after the inspection by a technician
Diagnosis
29
Connector check
⑩
①
22
⑪
BMS External Connector
Diagnosis
30
Connector check
③
①
⑧
Cooling Fan External Connector
④
Diagnosis
Current Data 1
TF
31
Diagnosis
Current Data 2
TF
32
Diagnosis
Current Data 3
TF
33
Diagnosis
Actuation Test
TF
34
Cautions
35
Cautions while servicing on high voltage circuit
Safety Plug
Inside of trunk
Technician must disconnect safety plug !
Cautions
How to release safety plug
Lock grip
Main fuse
36
Cautions
37
Cautions for high voltage
High Voltage Warning
Orange color means high voltage cable or components
Cautions
38
High voltage checking point
Connector
PRA
(INV + /-)
Pin
No
1
2
Level
IG OFF : 0V
IG ON : 270V (198V~309V)
 When servicing high voltage system, checking
voltage must be lower than 10V.
 Must be cautious when checking high voltage.