Transcript DESIGN AND TESTING OF A LOW-COST LEAD-CARBON REPLACEMENT BATTERY PACK FOR

DESIGN AND TESTING
OF A LOW-COST LEAD-CARBON
REPLACEMENT BATTERY PACK FOR
A HONDA CIVIC
D. Karner, T. Grey, R. Newnham
Work Conducted for the
Advanced Lead Acid Battery Consortium
And The
U.S. Department of Energy
Project Overview
• Furukawa Ultra Battery has shown promise in
mild HEV applications
• East Penn Manufacturing has licensed Ultra
Battery technology for US production
• US Department of Energy and ALABC are
interested in evaluating the East Penn Ultra
Battery in a mild HEV application
• Electric Transportation Applications has been
engaged to evaluate the East Penn Ultra Battery
in a Honda Civic HEV
Project Objectives
• Convert a Honda Civic HEV to operate using an
Ultra Battery manufactured by East Penn
• Retain an 800 pound vehicle payload
• Provide packaging favorable to battery life
• Maintain vehicle fuel economy performance
• Maintain vehicle emissions performance
• To obtain an "Experimental Vehicle" permit
• Maintain vehicle FMVSS certification
• To evaluate vehicle performance/durability
Progress
• Development and testing of Simulated Honda
Civic HEV profile (HCHEVP)
• Characterization of Ultra Batteries from
Furakawa (FUB)
 Capacity at various rates
 Discharge resistance at various SOCs
 Performance of FUB and standard lead-acid
(STLA) under HEV screening test
 Full HPPC analysis of FUB and STLA
Progress
• Preliminary optimization of HCHEVP
• Operation of FUB under HCHEVP
• Vehicle Preparation
 Design of battery compartment
 Evaluation of vehicle safety features
 Design of Battery Management System
 Analog/Digital/Analog converter
 Emulation software
Honda Civic
East Penn Ultra Battery Pack
Preliminary
packaging
with
extension, but
without
thermal
management
Development and Testing of HCHEVP
Development of simulated profile
• Battery data logged during field and dyno (UDDS,
HWFET) operation
• Information obtained on affects of air conditioning, hill
climbing, etc.
• Profile based on one pass through UDDS and HWFET
schedules
• Data from five individual passes through both profiles
used to obtain an average
• UDDS schedule = 1380 s, 7.5 miles, 19.5 mph
• HWFET schedule = 760 s, 10.2 miles, 48.5 mph
Development and Testing of HCHEVP
HCHEVP – one pass through UDDS followed by one pass through HWFET
Battery current and vehicle speed on dyno.
Development and Testing of HCHEVP
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Voltage
40
45
35
30
Voltage
40
25
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10966
11366
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Time (s)
35
30
25
0
2000
4000
6000
8000
10000
12000
14000
Time (s)
Battery voltage (STLA) over seven passes
and one pass through the HCHEVP
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12566
Development and Testing of HCHEVP
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60
40
Current
80
60
Current
40
20
0
-20
-40
20
-60
-80
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Time (s)
-20
-40
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4000
6000
8000
10000
12000
14000
Time (s)
Battery current (STLA) over seven passes
and one pass through the HCHEVP
12166
12566
Development and Testing of HCHEVP
Application of simulated profile
• 3 months of cycling provides >64,000 miles of simulated
HEV driving
• Energy/power levels of profile equivalent to that
experienced in the field and on dyno
• One pass through the HCHEVS – battery delivers and
accepts 2.89 Ah. Over the design life of the vehicle
(160,000 miles), the battery would deliver 26,000 Ah, the
equivalent of 4,000, 100% cycles
• Comparative calculations performed for a Toyota Prius
battery pack indicate the delivery of almost 6,000, 100%
cycles over the same distance.
FUB Characterization - Capacity
Discharge time (h)
7
6
5
4
Values from this
study
3
CSIRO values
2
1
0
1
10
100
Discharge current (A)
1000
Discharge
current
(A)
End- ofdischarg e
voltage (V)
Temp at endof-discharge
(C)
Capacity
(Ah)
1.33
1.33
1.33
1.33
2.19
2.19
2.19
6.65
6.65.
6.65
39.9
39.9
39.3
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
9.6
9.6
9.6
25.0
25.0
25.0
25.0
25.5
25.5
25.5
28.0
28.0
28.0
34.5
35.0
34.5
9.63
9.43
9.74
9.79
9.45
9.47
9.50
8.15
8.05
8.07
4.88
4.65
4.56
FUB Characterization – Discharge Resistance
SOC
%
90
80
70
60
50
40
30
20
10
0
Resistance of
module (ohm)
0.015
0.015
0.015
0.016
0.016
0.018
0.019
0.022
0.026
0.045
Resistance per
cell (m-ohm)
2.4
2.4
2.5
2.6
2.7
2.9
3.1
3.6
4.4
7.5
FUB Characterization – HEV Screening
(i) Discharge at 1C for 30 min (to ~ 50% SOC nominal)
(ii) Rest for 10 s
(iii) Charge at 2C for 60 s (to ~ 53% SOC nominal)
terminate test if voltage hits 17.5 V;
(iv) Rest for 10s
(v) Discharge at 2C for 60 s (to ~ 50% SOC nominal).
(vi) If voltage during (v) drops to 11.5 V (~ 40% SOC),
then recharge an additional 5% SOC over the next
100 cycles.
STLA Characterization - HEV Screening
FUB Characterization - HEV Screening
STLA Characterization - HPPC Testing
FUB Characterization - HPPC Testing
Conclusions
• Simulated HCHEVP complete and validated
• Furakawa has been characterized
• Preliminary vehicle design complete –
continuing work on thermal management
• Next steps
 Characterize EPUB modules
 Cycle full EPUB pack under HCHEVP for 3 months
(64 000 miles equivalent)