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J Electr Eng Technol Vol. 8, No.

6: 1431-1438, 2013 ISSN(Print) 1975-0102


http://dx.doi.org/10.5370/JEET.2013.8.6.1431 ISSN(Online) 2093-7423

Performance Assessment of a Lithium-Polymer Battery for HEV


Utilizing Pack-Level Battery Hardware-in-the-Loop-Simulation System

Sekyung Han† and Jawhwan Lim*

Abstract – A pack-level battery hardware-in-the-loop simulation (B-HILS) platform is implemented.


It consists of dynamic vehicle models using PSAT and multiple control interfaces including real-time
3D driving and GPS mode. In real-time 3D driving mode, user can drive a virtual vehicle using actual
drive equipment such as steering wheel and accelerator to generate the cycle profile of the battery. In
GPS mode, actual road traffic and terrain effects can be simulated using GPS data while the trajectory
is displayed on Google map. In the latter part of the paper, several performance tests of an actual
lithium-polymer battery pack are carried out utilizing the developed system. All experiments are
conducted as parts of actual development process of a commercial battery pack adopting 2nd
generation Prius as a target vehicle model. Through the experiments, the low temperature performance
and fuel efficiency of the battery are quantitatively investigated in comparison with the original nickel-
metal hydride (NiMH) pack of the Prius.

Keywords: HILS, Battery, Simulation, HEV, NiMH, LiPO

1. Introduction To overcome the problem, the authors have developed a


battery HILS (B-HILS) system on behalf of SK Innovation,
MODEL-BASED quantitative simulation schemes such one of the major battery-manufactures in South Korea. B-
as rapid prototyping and hardware-in-the-loop-simulation HILS enables the integrated test of a pack-level battery by
(HILS) are being widely accepted by many industrial establishing a closed control loop with a vehicle model.
engineers as a vital tool to enhance the efficiency of a Currently, many vehicle models are available in various
complex system design [1]-3]. Especially, HILS helps to types [7-17] We deployed a quasi-steady vehicle model, the
reduce the integration time by enabling the component Power-train System Analysis Toolkit, or PSAT, from
designer to perform the test in an actual control loop with Argonne National Laboratory (ANL) for our system [9].
the target device in it. The control loop consists of the PSAT is built upon Simulink environment with model-
actual target device and interacting models. The engineer based design. It contains numerous types of commercial
thus can verify the operation of the target device before it vehicle models and enables user to build a custom model
is actually integrated to the system. For this reason, HILS by assigning appropriate components through its
is being utilized in various fields including the automotive configuration tool. We customized PSAT for our own purpose
industry [4-6]. by directly cooperating with the PSAT team in ANL.
Traditionally, vehicle power-train has been considered as Neeraj in ANL and H. Dai et al have developed the
an exclusive area for the vehicle manufacturers. Recently, similar platforms [18, 19]. Their platforms, however,
however, as the electrification of vehicles proceeds, electric accept only a fixed offline drive cycle and focus mainly on
propulsion components, especially battery, are mainly the verification of the battery management system (BMS)
developed in a separated company. Moreover, since the functions. In contrast, our B-HILS provides multiple
development phase usually overlaps with that of the interfaces to feed the drive profiles. For example, the 3D
platform components, the battery manufacturers have little driving mode enables user to drive a virtual vehicle with
choice but to rely on the stand-alone test with offline actual drive equipment such as steering wheel and
profiles, such as standardized cycle pattern and/or the drive accelerator. The corresponding profiles are then fed into
cycles obtained from similar electric vehicles, during the the B-HILS, eventually cycling the battery. In the GPS
development of the battery. The integrated test is often mode, the drive profile is generated from GPS data logged
deferred until the relevant components become available. during an actual driving on the road. Through this mode, a
Consequently, many unexpected troubles continue delaying real traffic situation and a specific terrain effect can be
the overall development period. applied in the battery test.
† Corresponding Author: Dept. of Electronic and Control Engineering,
Our B-HILS has been actually utilized in developing
Hanbat National University, Korea.(sk.han@hanbat.ac.kr) various commercial battery packs. In this paper, we
* System Integration & Test Department, Battery System R&D, SCE- introduce several case study results regarding a Lithium
KSK-continental, Korea.( jaehwan.lim@sk-continental.com)
polymer (LiPo) battery pack, which has been developed for
Received: November 8, 2012; Accepted: August 7, 2013

1431
Performance Assessment of a Lithium-Polymer Battery for HEV Utilizing Pack-Level Battery Hardware-in-the-Loop-Simulation System

a mid-size hybrid sedan. The typical vehicle model utilized Matlab [20]. It supports Simulink based control interfaces,
during the experiments is 2nd generation Toyota Prius. In and thus the PSAT signal could be directly relayed without
some cases, the results are compared with those of the an extra conversion toolkit. Through the dSpace I/O
original nickel-metal hydride (NiMH) pack of Prius. interfaces, BMS information is fed into the PSAT and the
Specifically, the experiments are performed to investigate: electric power signals are conveyed to the battery cycler.
the fuel efficiency with respect to battery size; the Fig. 1 illustrates the overall configuration of the B-HILS
performance of the battery in an extremely low temperature; systems.
the effect of BMS power restriction in a harsh driving The drive profile can be generated via multiple methods.
condition such as mountain road. The original PSAT fetches the drive profile from an offline
Rest of the paper is organized as follows. Firstly, the data file. In our B-HILS platform, real-time 3D driving
configuration of the B-HILS as well as its unique features mode and GPS mode are additionally implemented.
is introduced in Section 2. In the following section, the In the 3D driving mode, the drive profile is generated in
performance of SK’s LiPo battery is investigated using the real-time as the user drives a virtual vehicle on 3D
B-HILS system. The experiments are organized so the simulator. For the realistic driving, actual drive gears such
features of the B-HILS can be explored. Finally, the as steering wheel, accelerator and brake are provided. Figs.
achievements of this paper are summarized with 2 and Fig. 3 depict the equipment and the 3D simulator,
conclusions in Section 40. respectively. On the 3D simulator, the relative information
such as vehicle speed, battery state-of-charge (SOC), pack
voltage, battery current, maximum allowable power, and
2. Configuration of Battery HILS cell temperature is displayed. The battery parameters are
real data received from the BMS of the battery while the
The original PSAT is a pure software package. All
components are described in a software model and
connected to each other via input/output ports composing a
closed control loop. The replacement of the software
battery model in PSAT with a real battery was achieved by
directly collaborating with the PSAT team in ANL. All
required input/output ports are appropriately tuned to
interact with the real BMS signals. The requested electric
power is conveyed to a cycler to actually drive the battery.
The employed cycler is a customized product directly
imported from Hitachi for the B-HILS. It accepts the
control command via either of an analog voltage or CAN
signal.
Physical I/O interfaces are also required to interact with
the battery (BMS) and the cycler. To this end, we employed
the dSpace system that supports real-time workshop in Fig. 2. Driving gears for real-time 3D driving mode.

Fig. 3. The display of 3D driving simulator with relevant


Fig. 1. Configuration of the developed B-HILS system information.

1432
Sekyung Han and Jawhwan Lim

vehicle information is calculated value by the vehicle


model.
In GPS mode, the drive profile is generated from logged
GPS data. The GPS data is converted into vehicle speed
and altitude information and fetched into the PSAT in real-
time in accordance with the GPS timestamp. As shown in
Fig. 40, the trajectory of the drive is displayed on the
Google satellite map. The GPS mode is useful when
simulating an actual road situation such as traffic and
terrain effect on a specific road.
During the simulation, the battery is placed in a chamber
to emulate a specific temperature condition. The simulation
facilities are illustrated in Fig. 50.
The relevant information is logged and selected items Fig. 6. A dash-board interface displaying vehicle speed,
are displayed on the monitors. For example, Fig. 60 is a generator RPM, engine RPM, state-of-charge (SOC),
dash-board interface that displays vehicle speed, generator current and voltage of the battery.
RPM, engine RPM, state-of-charge (SOC), current and
voltage of the battery. The detailed data such as individual
cell voltage are logged in a file for further analysis. 3. Experiments & Case Study

In this section, several experiments are carried out to


show the features of B-HILS while investigating the
performance of a SK’s commercial battery for mid-size
hybrid sedan. The target vehicle model is second
generation (2004-2009) Toyota Prius, for which the electric
specifications are summarized in Table 10 [21]. The
operation CAN code for the Prius are referred from the
open data [22].
The experiments are carried out using the lithium-
polymer (LiPo) battery from SK Innovation in comparison
with the nickel-metal hydride (NiMH) battery, which is
extracted from the target vehicle, or 2nd generation Prius.
The specification of the LiPo battery can be found in Table
20. The dimension of the LiPo battery is almost same as
Fig. 4. Trajectory of the drive in GPS mode on Google the NiMH battery, but the energy density and the power
map. capacity is far better than the NiMH. Note that the
experiments in this section are conducted as parts of SK’s

Table 1. Electric specifications of the target vehicle(2nd


generation Prius, 2004-2009)
Permanent Magnet
Motor Type
Synchronous Motor
Electric Motor Power Output 50 kW/1,200 @ 1,540 RPM
Torque 295 lb.-ft. @ 0-1,200 RPM
Battery Type Nickel-Metal Hydride
Output 201.6 V (168 1.2V cells)
Specific Power 1,300 W/kg
Capacity 6.5 amperes
Specific Energy 46 Wh/kg

Table 2. Specifications of the target battery pack for the


experiments
Battery Type Lithium Polymer Battery
Fig. 5. From the left-upper image in the clockwise Output 270 V (72 3.75V cells)
direction, temperature chamber, battery clcyler, and Specific Power 2,100 W/kg
the 72 cell lithimum-ion battery pack tested in the Capacity 7.5 amperes
latter part of the paper. Specific Energy 50 Wh/kg

1433
Performance Assessment of a Lithium-Polymer Battery for HEV Utilizing Pack-Level Battery Hardware-in-the-Loop-Simulation System

Fig. 7. Example of the test result with 3D driving interface.


Fig. 8. Ttajectory of the state-of-charge for US06 driving
All the data are gathered from the real battery
cycle during the low temperature experiment (-
through the simluiation interface.
25 °C)

commercial battery development project for hybrid vehicle.

3.1 Real-time 3D driving simulation

In general, battery experiments are conducted using pre-


determined offline cycle data. In our B-HILS, however, the
drive profile can be generated in real-time using a virtual
driving environment. Battery is cycled as the user drives a
virtual vehicle using driving gears such as steering wheel,
accelerate, and the brake shown in Fig. 2.
Some simulation data logged during the 3D driving
mode are illustrated in0. The target battery is the one
described in Table 2, with BMS and cooling system.
During the operation, BMS provides real pack information
to the PSAT via CAN communication. The typical battery
information includes pack voltage, cell temperature, pack Fig. 9. Power restriction and relevant battery parameters
current, SOC, and the maximum allowable power for the estimated during the low temperature experiment (-
battery. 25 °C)
Based on the BMS data and the drive profile, PSAT
generates the required electric power. For example, the winter morning. For the experiment, the LiPo pack in Table
allowable power limits enforce the hybrid control unit 20 is used after storing in a temperature chamber at minus
(HCU) to operate the battery within the given range. The 25 °C for 12 hours. Then, one and half cycles of the US06
impact of the power restriction is discussed in the drive cycle (around 15 minutes), which is designated to test
following section. This kind of real-time interaction is at high speeds and aggressive driving conditions [30], is
especially important in developing and verifying the BMS applied to the B-HILS. The initial SOC is set to 65%.
logic. The US06 drive cycle and the resulting SOC are
illustrated in Fig 80. As seen in Fig 70, the HCU of Prius
3.2 Case study 1: Reactivity in low temperature tries to maintain the battery SOC at around 65% under a
normal driving condition. However, the SOC during the
Usually, the internal resistance of a chemical battery low temperature experiment drops down to 30% as
increases drastically at low temperature and flowing large depicted in Fig 80. The cause of this phenomenon can be
current under this circumstance often damages the cell [23- found in Fig 9. During the first four minutes, the maximum
28]. Especially, lithium deposition (plating) as a powers for both directions are restricted to less than 5 kW.
mechanism for degradation is likely at low temperature for Apparently, it seems that the vehicle is suffering from the
the Lithium-ion batteries. Therefore, as we discussed above, shortage of the electric power; the battery is enforced to
the battery power is restricted to protect the cell by the discharge at maximum rate during this period.
BMS at low temperature [29]. As the temperature exceeds minus 10 °C, the power
In order to investigate the effect of the power restriction, limit is mitigated rapidly and the HCU operates the battery
the experiment is performed assuming the driving in a in both directions. However, it still hits the limits

1434
Sekyung Han and Jawhwan Lim

occasionally, especially dragging at the charge limit


frequently. This seems to arise from the aggressive
acceleration of the drive cycle. That is, the HCU
experiences shortage of the charging power more
frequently than that of the discharging power.
After around 11 minutes, as the battery temperature
exceeds 10 °C, the restrictions are drastically lessened,
especially in discharge direction. The battery power thus
stays far less than the discharge limit. It is, however, not
because the drive cycle turned mild but because the
discharge limit exceeded the inverter size. Note that the
battery in this experiment is SK’s LiPo battery, while the
vehicle model is 2nd generation Toyota Prius which comes
with the NiMH battery. From our analysis, the original Fig. 10. The trajectory of electric power
NiMH battery provides the power limits in current level.
During a normal operation, the maximum current is
allowed up to 100 A for both directions. Since the voltage
of the original pack is around 200 V, the inverter must have
been sized to fit this level, around 20 kW. Therefore, the
discharge limit stays around 20 kW despite the higher
capability of the battery power. As a result, it could be
concluded from the HIL experiment that the tested battery
is oversized for this vehicle, especially in discharge
direction. The inverter size as well as HCU logic thus
should be tuned to fully utilize the new battery.

3.3 Case study 2: Fuel efficiency vs battery size

The second experiment is to investigate the relationship


between fuel efficiency and battery size. The experiment is Fig. 11. The trajectories of accumulated energy
performed for two batteries with different power limits.
Both batteries are physically identical, but the available
power limits are configured differently by manipulating the
BMS parameters. Specifically, the power limits for the high
power battery is set to 16 kW and 20 kW for charging and
discharging, respectively, which is the same as the original
NiMH battery of the target vehicle, or Prius. The other one,
the low power battery, is configured to have half of those
of the high power battery, or 8 kW for charging and 16 kW
for discharging. The experiments are carried out at normal
temperature (25 °C) with the initial SOC of 65 %. For the
drive profile, two cycles of Urban Dynamometer Driving
Schedule (UDDS) [31] is applied. Other vehicles relative
parameters are same as the previous experiment.
Fig 100 illustrates the trajectory of the electric power
actually assigned to the batteries. As marked with circles, Fig. 12. The trajectory of SOC
the low power battery pulls out its maximum power and
drags in many places. On the other hand, the high power 10%, while that of the high power battery is only 6%.
battery operates within far less than the maximum power The results imply that the battery size may not properly
seldom hitting the limit. In fact, as shown in 0Fig. 11, the match the motor size, at least for this type of drive pattern.
energy requirement of the vehicle is almost same for the For the low power battery, the battery size seems to be
both batteries. Nevertheless, due to the lack of the power, small for the given motor since it frequently suffers the
the low power battery tends to drag at the maximum power, power shortage. Conversely, the high power battery is
and hence results in the higher deviation of the state-of- operated at around half of its power capability being rarely
charge (SOC). The SOC deviation is illustrated in Fig. 120; required the maximum power. Actually, the drive cycle
the maximum SOC deviation for the low power battery is used in this experiment (UDDS) is comparably mild since

1435
Performance Assessment of a Lithium-Polymer Battery for HEV Utilizing Pack-Level Battery Hardware-in-the-Loop-Simulation System

Fig. 15. Battery data during harsh driving for original


Fig. 13. The trajectory of fuel efficiency NiMH pack

it merely represents the urban driving. Thus, additional


tests are required to exactly judge if the battery is oversized.
As a measure of the performance, we estimated the fuel
efficiency of the both experiments. From Fig. 130, the fuel
efficiency of the high power is estimated at around 31 km/l.
With the low power battery, however, the fuel efficiency
deteriorates more than 30% marking around 21 km/l.
Obviously, the proper sizing of the battery appears as a
significant factor in terms of the vehicle performance. In
practice, however, performance is not the only factor to
determine the battery size. Many other parameters such as
profitability should be considered simultaneously. Yet, the
result of this experiment is important in terms of Fig. 16. Battery data during harsh driving for SK’s LiPo
determining the physical matching of the battery with the pack
motor.
of 2nd generation Prius. The experiment was performed for
3.4 Case study 3: Harsh driving test using GPS mode two different batteries; original NiMH battery and SK’s
As introduced in section 2, our B-HILS system supports LiPo battery described in Table 2, for which the results are
a GPS mode. In this mode, actual GPS log is fetched and depicted in 0 and Fig. 16, respectively.
converted into the speed and the gradient information, from During the first 30 minutes, the vehicle climbs uphill,
which the cycle profile of the battery is generated for a and thus the battery is likely to be used for propulsion
given vehicle model. rather than the regeneration. Consequently, the SOC in
In this experiment, the GPS mode is utilized to both tests continues to decrease until the vehicle reaches
investigate the reactivity of the batteries under harsh the top of the mountain. During this period, the power
driving condition. Using a similar size vehicle with the variance of NiMH battery is higher than that of the LiPo
target model, actual drive profile was logged by the GPS battery. The cause seems to be the wider variation of the
along the route illustrated in Fig. 140 that lies on the Mt. battery voltage in NiMH due to the higher internal
Jiri, one of the steepest mountains in South Korea. The resistance. The SOC variation is, however, higher in the
GPS data is then fed into the B-HILS with a vehicle model NiMH due to the smaller energy capacity. Specifically,
from 0Table 1 and Table 2, the energy capacity of the
original Prius pack is around 1.3 kWh, while the SK’s LiPo
pack is around 2.0 kWh. For the same reason, the SOC
increase by the regeneration during the idle period,
between 30-50 minute, is higher in the NiMH battery.
A noticeable difference occurs during the downhill area.
Generally, batteries are designed to have higher capability
in discharge. Therefore, a typical battery experiences
higher stress when charged at the same power. As seen in
0Fig. 15, the absolute value of the charging power during
Fig. 14. The drive route of the test cycle the downhill is not significantly higher than the discharging

1436
Sekyung Han and Jawhwan Lim

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Stresa, Lago Maggiore, Italy, 25th-27th Apr 2007 currently an assistant professor at Hanbat National
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his B.S. degree in chemical engine-
1994.
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Conversion, vol. 25, no. 3, pp. 821-835, 2010 ogy(POSTEC) in 1999, He had worked
[29] M.C. Sart, B.V. Ratnakumar, L. Whitcanack, K. Chin, for developing the battery system for
M. Rodriguez, S. Surampudi, “Performance charac- HEV & EV in R&D center, Hyundai-motor company
teristics of lithium ion cells at low temperatures”, during 2001-2007.
IEEE Aerospace and Electronic Systems Magazine, He has accumulated vast knowledge in high voltage
vol. 17, no. 12, pp. 16-20, 2002 battery systems including battery management system in
[30] Emission Test Cycles: SFTP-US06. Available at EV/HEV, system integration of energy storage system and
http://www.dieselnet.com/standards/cycles/ftp_us06. EV utilization for smart grid. Currently, he is working in
php; Oct. 2012 SK innovation and is responsible for evaluation and
[31] Emission Test Cycles: FTP-72 (UDDS). Available at validation of battery systems.
http://www.dieselnet.com/standards/cycles/ftp72.php;
Oct. 2012

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