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EV Technology & Public Charging station

Batteries in EV

Manoj Kumar MK
NIELIT calicut
Energy Sources for Electric Vehicles

1. Batteries
2. Fuel Cells
3. Ultra Capacitors
4. Ultra high speed Flywheels
Fuel Cells
Fuel cells create electricity chemically, rather than by
combustion.
Fuel cells are different from most batteries in
requiring a continuous source of fuel and oxygen
(usually from air) to sustain the chemical reaction
they generate electricity with
very little pollution–much of
the hydrogen and oxygen
used in
generating electricity ultimat
ely combine to form a
harmless byproduct, namely
water.
Fuel Cells

5-10 kg is required for 300miles drive depends

on the vehicle.
1kg needs 11m3 volume to store the hydrogen.
 compressed hydrogen mass-volume ratio is
23Kg/m3
Fuel Cells
Constraints
 obtaining hydrogen is a challenge
The durability and cost of fuel cell systems represent the
biggest barriers.
Fuel cells are still in the ‘technology development phase’.
FCEV Architecture
Ultra capacitors

 store energy electro statically

 Less energy density, rapid energy discharge
 Large life cycle (approx. 1 million)
 Used for regenerative energy storage, Power bank etc
Ultra capacitors
Ultra capacitor packs
Ultra High Speed Flywheels
Storing as rotational energy by acceleration the fly
wheel to a high speed .
 rotational speed is reduced when energy is extracted
Batteries
• A battery is a device consisting of one or
more electrochemical cells with external connections for
powering electrical devices such as flashlights, mobile
phones, and electric cars.
• The terminal marked negative is the source of electrons
that will flow through an external electric circuit to the
positive terminal.
 Cell and Battery
 A cell is a single unit device which converts chemical
energy into electric energy.
 Voltage range is between 1.5 – 3V.
 A battery usually consists of group of cells arranged
in a series/parallel fashion so that the voltage can be
raised to desired levels.
 The best known example for a battery is a power bank
which is used to charge up smart phones.
Battery terms

1. Power capacity:
It is the energy stored in a battery which is measured
in Watt-hour

Watt-hour = V * I * hours {since voltage is kept

constant, so it is measured in Ah/ mAh}

2500 mAh it means that the battery has a capability to

deliver 2.5A/2500mA of current to the load for 1 hour
2. C –rating
C-rate is a measure of the rate at which a battery is
discharged relative to its maximum capacity. A 1C rate
means that the discharge current will discharge the entire
battery in 1 hour

Time
C rate

5C 12 min
2C 30 min
1C 1h
0.5C or C/2 2h
0.2C or C/5 5h
0.1C or C/10 10h
0.05C or C/20 20h
3. Shelf Life
There might be a situation where the batteries are kept
idle/sealed especially in the stores/shops for a long
period of time.
shelf life defines the time period a battery can be
stay powered up and should be able to use it for a
rated time period.
Shelf life is mainly considered for non-rechargeable
batteries because those are of use and throw.
For rechargeable batteries even if the shelf time is less,
we can still recharge it.
4. Nominal voltage
The nominal voltage is measured at the mid point
between full charged and fully discharged based on a
0.2C discharge
5. Battery State of Charge (SoC)
SOC is defined as the fraction of the total energy or
battery capacity that has been used over the total
available from the battery.
For example, for a battery at 80% SOC and with a 500
Ah capacity, the energy stored in the battery is 400 Ah.
A common way to measure the SOC is to measure the
voltage of the battery and compare this to the voltage of
a fully charged battery.
However, as the battery voltage depends on temperature
as well as the state of charge of the battery, this
measurement provides only a rough idea of battery state
of charge.
Battery Voltage Vs DoD
6. Depth of Discharge (DOD)

A battery's depth of discharge (DoD) indicates the

percentage of the battery that has been discharged
relative to the overall capacity of the battery.
7. Cut-off voltage
It is the voltage at which the battery can be
considered as fully discharged, after which if we still
try to discharge from it the battery gets damaged.

So beyond the cut-off voltage the battery should be

disconnected from the circuit and should be charged
appropriately.
8. Cycle life
Let’s consider a battery is fully charged and it is
discharged to 80% of its actual capacity, then the
battery is said to be completed one cycle.
The number of such cycles that a battery can charge
and discharge defines the cycle life.
The more the cycle life the better will be the battery’s
quality.
SoC vs Cycle Life
9. Power Density & Energy Density

Energy density (or Specific Energy) is the amount

of energy in a given mass (or volume) .Unit is
Wh/Kg (Gravimetric) or Wh/L (Volumetric).
Determined the range

Power density (or Specific Power) is the amount

of power in a given mass. Unit is W/Kg
(Gravimetric) or W/L (Volumetric)
Determined the acceleration.
10. Power Density & Energy Density

100 Wh/Kg (Alkaline battery standard power density)

implies that for 1 Kg of chemical composition it provides
100 Wh of power capacity.
Now, mass of a AAA alkaline battery is 11.5 grams. So if
1Kg can give 100 Wh capacity, then how much a 11.5 gram
AAA batery can give?? Let’s calculate.

Wh (for 11.5 gm) = 100*11.5/1000 = 1.15 Wh

So, Battery capacity is 1.15Wh/1.5V= 0.76 Ah = 760 mAh

for AAA battery
Specific Energy (Case study)
Mobile phone Battery
Dimension - 9cm x 5cm x 0.5cm
Volume - LWH (9 x 5 x 0.5) 27cm3
1L - 1000 cm3
1cm3 - 0.001L
27cm3 - 0.027L

Power Capacity 5000mAh, 3.7V

5 x 3.7 Wh = 18.5Wh
For 27cm3 =18.5Wh
For 1L =(1/0.027) x 18.5
= 685Wh / L
11. Internal Resistance
The resistance within the battery, generally different for
charging and discharging.
also dependent on the battery state of charge.
As internal resistance increases, the battery efficiency
decreases and thermal stability is reduced as more of
the charging energy is converted into heat.
12. State of Health (SoH)

 SoH is a figure of merit of the condition of

a battery compared to its ideal conditions.

Typically, a battery's SoH will be 100% at the time of

manufacture and will decrease over time and use.

SoH is compared to a threshold (typically done

by the application in which the battery is used),
to determine the suitability of the battery to a
given application
Calculation of SoH value
The BMS may use any of the following parameters(or in
combination) to derive an arbitrary value for the SoH.
Internal resistance
Capacity
Voltage
Self-discharge
Ability to accept a charge
Number of charge–discharge cycles
Age of the battery
Temperature of battery during its previous uses
Total energy charged and discharged
Types of Batteries
Batteries are basically classified into 2 types:
 Non-rechargeable batteries (primary batteries)
 Rechargeable batteries (secondary batteries)
Types of Secondary Batteries
Lead Acid Batteries

Ni-Cd Batteries

Ni-MH Bateeries

Li-Ion batteries

Li-Titanate Batteries (LTO)

Li-Po Batteries
Lead Acid Batteries
These comes with the nominal voltage starting 2V
to24V
Power density of 35-40 Wh/Kg.
Ni-Cd Batteries
Made of Nickel and Cadmium chemical composition.
available in all standard sizes like AA, AAA, C
The nominal voltage is 1.2V
Power density of 60 Wh/Kg.
Ni-MH batteries
Preferable because of their lower environmental
impact.
Nominal voltage is 1.25 V
Power density of Ni-MH batteries is 100 Wh/Kg.
Self-discharge is very high.
Expensive than Ni-Cad batteries
Li-Ion Battery
• The positive electrode is made of Lithium cobalt oxide, or
LiCoO2.
• The negative electrode is made of carbon.
• When the battery charges, ions of lithium move through the
electrolyte from the positive electrode to the negative
electrode and attach to the carbon. During discharge, the
lithium ions move back to the LiCoO2 from the carbon
Li-ion battery Characteristics
compact in size.
Nominal voltage of
C-rating ranges from 1C to 10C
Power density of Li-ion batteries is ~265 Wh/Kg.
Lithium Resources
Li-ion batteries

Nominal Typical end- Max charge

cell voltage of-discharge voltage

3.6V 2.8–3.0V 4.2V

3.7V 2.8–3.0V 4.2V
3.8V 2.8–3.0V 4.35V
3.85V 2.8–3.0V 4.4V
Li-titanate (LTO) batteries
A lithium-titanate battery is a modified lithium-ion battery
that uses lithium-titanate nanocrystals, instead of carbon, on
the surface of its anode
 fast recharging possible
Typical Cell Voltage is 2.3V.
3000 to 7000 charge cycles
Power density of 60-110 Wh/Kg.
Li-Po batteries
it uses high conductivity polymer gel/polymers
electrolyte instead of liquid electrolyte.
comes under the Li-ion technology and a bit costly.
highly protected when compared to the Li-ion batteries.
Energy density & cycle life less compared to Li-Ion
More safety than Li Ion
Aluminum –Air Batteries
 Aluminum is very powerful.

 High Specific Energy & Energy Density

MJ/Kg MJ/L
Petrol 46.4 34.2
Diesel 45.6 38.6
Aluminium 31.0 83.8
Li-ion 0.8 3
Working
 It is Primary Battery
 Oxygen+Water+Aluminium
 8 times more power.
 Aluminum is cheap.
 Just Burning Aluminum.
 Power comes from Oxidation
 Aluminum Hydroxide is by product
 Needs Aluminum Recycling for recharge

4Al + 3O2 + 6H2O 4Al(OH)3 + 2.71V

Aluminium-Ion Batteries
• Charge 60times faster than Li Ion
• Spontaneous overheat is not there
• Energy density ~1000Wh/Kg
 Cell Architecture in EV
Electric Vehicle Battery is Composed of “Cell → Module → Pack”

Battery Cell Basic Unit of a Li-Ion Battery made by inserting

Cathode, Anode, Separator and Electrolyte into
a rectangular Aluminium case
Battery Module A Battery assembly put into a frame by
combining a fixed number of cells to protect
from external shocks, heat or vibration.
Battery pack Final shape of the Battery system installed into
an EV. Composed of modules and various
controls/protection system including BMS,
cooling system etc.
Cell → Module → Pack
Introduction to EV Batteries
• The battery must be designed to satisfy the requirements
of the motor(s) and charging system
• efficient packaging within the vehicle’s body to
maximize capacity.
• As the main contributor to weight in an EV, designers
must also consider the battery's placement within a
vehicle as they can affect power efficiency and
vehicle handling characteristics
 EV Battery Spec….
Voltages and Capacities
A common pack is composed of blocks of 18-30 parallel
cells in series to achieve a desired voltage
Common battery capacity ranges are
• Hybrid vehicles: 0.5 to 2 kWh (100 -200V)
• Plug-in hybrid vehicles: 4 to 20 kWh (100-200V)
• Electric vehicles: 30 to 100 kWh or more.(400-800V)
Drawbacks of using higher voltage
Higher-voltage-rated components required.
Prevent the ability to use DC fast-charging stations of a
lower voltage
EV Battery Structure
Components of EV Battery

1. Battery Pack
2. Battery Management System (BMS)
3. Battery Heating / Cooling System
4. On-Board charger (OBC)
Battery Management System (BMS)
A battery management system (BMS) is any electronic
system that manages and protects a rechargeable battery

Main characteristics of BMS are,

Monitor cell voltage and temperature
Estimate battery state-of-charge (SOC) and state-of-
health (SOH)
Limit power input and output for thermal and
overcharge protection
Control the battery charging profile
Balance the state-of-charge of individual cells
Isolate the battery pack from source and load when
necessary
BMS continued…….
Cell Balancing
 Cell balancing is the process of equalizing the
voltages and state of charge among the cells when they
are at a full charge.

 No two cells are identical. There are always slight

differences in the state of charge, self-discharge rate,
capacity, impedance, and temperature characteristics
Types of Cell balancing

1. Passive Cell balancing

2. Active Cell balancing
Temperature effects of Battery
Batteries in EV operate over a wide temperature range due to
mainly.
1. Internal heat Generation (I2R)
2. Effect of surrounding environment.

 Internal temperature rises as temperature decreases.

 Higher temperature reduces life and vice versa
 Lower temperature reduce the capacity
Temperature effects of Battery
• < 50C can not be fast charged
• < 00C battery loose charge, loss in power, acceleration,
driving range
• > 300C battery performance degrades.
• > 400C can lead to serious and irreversible damage
• Higher temperature e.g 70 to 1000C thermal runaway occur.
• Ideal temperature range is 15 to 350C.
Temperature effects of Battery
Battery Thermal Management
Role of Thermal Management System is
Cooling
Heating
Insulation
Ventilation
Medium to regulate Battery Temperature
• Air Cooling & Heating
• Liquid Cooling & Heating
Air Cooling & Heating
Liquid Cooling & Heating
There are 2 types of Liquid
cooling/heating
1. Dielectric liquid (direct-contact
Liquid) such as mineral oil
2. Conducting Liquid (indirect-contact
liquid) such as mixture of ethylene
glycol and water
Liquid Cooling