Basic Knowledge of EV

Battery Testing
Beny Rachmanto
Business Development Manager
HIOKI ELECTRIC INSTRUMENT, PT

Pelatihan Pengenalan Teknologi Kendaraan Listrik

Balai Besar Pengembangan Pelatihan Kerja (BBPLK) Bandung
15-24 November 2021

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Content

• Lithium Ion Battery

• Internal Resistance of Lithium Ion Battery
• HIOKI for Testing of Lithium Ion Battery Cells & Pack
• Battery Management System (BMS) Evaluation

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Training Goal

• Understand how lithium ion battery work

• Understand how to measure lithium Ion battery
• Understand the various parameters that must be considered when
arranging a battery pack
• Understand how to treat lithium ion battery properly

“You can’t manage what you can’t measure”

Peter Drucker

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Lithium Ion Battery

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Lithium Ion Battery Cross Section

CHARGER

-
Graphite
-

-
Composite Material

Cu(current collector)
Al (current collector)

Cathode Anode Sponsored by:

Separator Electrolyte
Lithium Ion Battery Variant
Lithium Nickel Cobalt Aluminum Oxide
5%
10%

NCA
[LiNiCoAlO2]

80%
Aluminum Cobalt Nickel

Lithium Manganese Oxide

LMO
[LiMn2O4]

100%

Manganese

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Lithium Ion Battery Variant
Lithium Nickel Manganese Cobalt Oxide

33% 34%
NMC
[LiNiMnCoO2]

33%
Nickel Manganese Cobalt

Lithium Iron Phosphate

5%
5%

LFP
[LiFePO4]

90%
C-LiFePO4 Graphite PVDF

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Construction of EV Lithium Ion Battery

Lithium Ion Battery

Cell 18650 21700 4680

650 mm
Module
18 mm

Pack
Pouch (0.3 – 1mΩ) Cylindrical (10 – 100 mΩ) Prismatic (0.3 – 1 mΩ)
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Lithium Ion Battery Mode

• In a proper function, a battery is a device that stores chemical energy and converts it to electrical energy.
• Within specific condition, Lithium battery can react as a different entity which can lead to fire and other
dangerous accident

Heat Source Explotion Mode

Storage Mode
Mode (Generator Mode)

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Possible Risk of Lithium Ion Cells

• Lithium-ion cells contain:

a) Oxygen chemically bound in cathode and
b) Combustible substances in other components, e.g. electrolyte solvents
• During normal operation within manufacturer specifications, Lithium-ion cells
are generally safe, as long as heat sources are absent (Note: Heat can be
created internally by e.g. damage, misuse, internal short)

Required Location
Oxygen Cathode : LMO, NMC, NCA
Environtment : Air Oxygen

Combustible Substance (liquid) Electrolyte, Separator, Carbon

Anode : Graphite
Heat Inside or Outside Cell
Raw image source: High Speed Training

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Mechanism That Causes Battery Fires

Quality failures can lead to consequential errors of varying severity

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Internal Resistance of Lithium Ion
Battery

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Internal Resistance of Battery

The drop is caused because voltage falls in proportion to the product of current and internal resistance

How much power can be extracted momentarily from the battery is determined by the
internal resistance

“As the number of charging and

discharging of the battery increases,
the internal resistance increase and
discharge capacity decrease”

• Lead Acid Battery => Internal Resistance is significant change => Possible to apply in battery maintenance
• Lithium Ion battery => Internal Resistance is not significant change => Checking battery IR uniformity

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Deterioration Of Lithium Ion Battery

Large Charge / Discharge currents generate

significant amounts of heat

If the resistance of the battery pack is

different, some of the batteries will heat up
excessively

Lowering the capacity and accelerating

deterioration The characteristics of a battery vary greatly with its
internal resistance value. High internal resistance causes
increased energy loss, resulting in degraded battery
performance. In addition, heat generation in the battery
during use accelerates the degradation process
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Lithium Ion Battery Internal Resistance

e- e-
Battery Internal
Cathode Anode
Resistance Li+ Li+ Li+ Li+ Li+ Li+

e- e-
Diffusion Resistance Li+
e-

Charge Transfer Resistance

(Reaction Resistance)

Electrolyte Resistance
(Liquid Resistance)

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Lithium Ion Battery Equivalent Circuit

e- e- 1
𝑋𝑐 =
Cathode Anode
2𝜋𝑓𝐶
Li+ Li+ Li+ Li+ Li+ Li+
=
e- e-
0 Hz 1 kHz

C
R1
Low Freq, R tot = R1 + R2
High Freq, Rtot = R1

R2
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Equivalent Circuit
Nyquist / Cole cole Plot

XC 𝑍= 𝑅 2 + (𝑋𝐿 − 𝑋𝐶)2

XC f1

Z f1

R f1
R
C
R1
R1 R2 Drawing a Nyquist or Cole-Cole plot
with an impedance spectrum
R1 +R2
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R2
Nyquist / Cole cole Plot & Bode Plot

Bode plot
Drawing a Nyquist or Cole-Cole plot C
with an impedance spectrum R1

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R2
Possibility of Battery Deterioration

-X Simple equivalent circuit for a battery

C1
Higher Lower
R1

0 R
R1 R2 R2

-X
R1varied -X R2varied

0 R
0 R
R2
R1 Sponsored by:
R2constant R1constant
 Checking Battery Deterioration Level

Equivalent Circuit

C
R1

R2

R1：Liquid Resistance (Electrolyte Resistance)

R2：Reaction Resistance (Charge Transfer)
C ：Double Layer Capacitor

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Internal Resistance Measurement
DC Method (DC IR)
Internal
Resistance (1) Measure point 1 (V1, I1)
Measurement Current I1: 4× to 6× the 10-hour discharge
rate
Voltage V1: Voltage 20 s after discharged at
Current I1 (with discharging to stop within
25 s)

AC Method DC Method
(2) Measure point 2 (V2, I2)
After letting battery sit 2 to 5 min.
without auxiliary charging after point
Issue with DC IR 1 measurement is complete.
• Measurement takes more time.
• Measurements are less reproducible. Current I2: 20× to 40× the 10-hour
• Battery charges rate changes. discharge rate
• Large charging and discharging equipment is required. Voltage V2: Voltage 5 s after
discharged at current I2
• The line must be capable of supplying large amounts of power
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Internal Resistance Measurement
AC Method (AC IR)

Internal
Resistance
Measurement

AC Method DC Method

Two standards on LIB performance testing, IEC 61960-3/JIS C8711 (for compact equipment) and IEC 62620/JIS
C8715-1 (for industrial equipment), describe how to measure internal resistance using the AC method (AC-
IR). The method is also used in manufacturing processes for automotive LIB cells, which are required to
deliver high levels of performance and safety Sponsored by:
Internal Resistance Measurement

1. Using Digital Multimeter (DMM) for the measurement ?

measurement
Is
Current

voltage
generated

DCV
Vx Rx circuit

➢ DC current does not pass through the internal resistance of the battery and therefore cannot be
measured accurately.
➢ Effect of thermo electric force
➢ The application of DC current causes the battery to be charged or discharged.
➢ The internal resistance of the battery is low (mΩ) and must be measured using the four-
terminal method. Sponsored by:
Internal Resistance Measurement
2. Four-terminal measurement method

DMM BT Series & RM Series (4 Terminal)

Contact
resistance
R0: DUT
2-terminal method：measurement value
r1～r4: wiring
contains wiring & contact resistance resistance
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HIOKI Sollution For Lithium Ion
Battery Test

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HIOKI Sollution For Battery Testing

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BT4560 Battery Impedance Analyzer

Feature
Measurable battery
5V
Low-frequency AC-IR measurement* voltage
frequency 0.1Hz － 1050Hz
Impedance Ranges 3mΩ, 10mΩ, 100mΩ
Testing current of 1.5 A at the 3mΩ range measurement Accuracy ±0.4%rdg. ±8dgt.
Resolution 0.1μΩ
Ranges 5V
Voltage measurement function equivalent
Voltage
to 6-digit DMM (± 0.0035% rdg) Accuracy ±0.0035%rdg.±5dgt.
measurement
Resolution 10μV
Ranges -10.0℃ － 60℃
Highly tolerant of contact and wire Temperature
resistance to provide stable measurements measurement ±0.5℃（10.0℃ －
Accuracy
40.0℃）
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BT4560 Battery Impedance Analyzer
Cole-Cole /Nyquist plot render screen Measurement screen

Cole-Cole plots can be generated using the included desktop application.

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BT4560 Battery Impedance Analyzer
Converting measurement data into a Nyquist or Cole-Cole plot

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https://www.circuitfitting.net/multiplot
BT4560 Battery Impedance Analyzer

Toyota Prius Prismatic Battery Cell Formation BT4560 SET

Impedance Measurement Cole cole Plot Tesla New 4680

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 BT3561A/62A/63A & BT3564
Measuring battery performance and safety using internal resistance (AC-IR) and open-circuit voltage (OCV)

BT3561A
•Voltage : 6 V/60 V
•Resistance :30 mΩ/300 mΩ/3 Ω/30 Ω/300 Ω/3 kΩ Higher tolerances for Multiple Instrument
line resistance Connectivity

BT3562A
•Voltage : 6 V/60 V/100 V
•Resistance : 3 mΩ/30 mΩ/300 mΩ/3 Ω/30 Ω/300 Ω/3 kΩ
Withstand contact
with ±30 kV of LAN
BT3563A static electricity
•Voltage Range : 6 V/60 V/300 V
•Resistance : 3 mΩ/30 mΩ/300 mΩ/3 Ω/30 Ω/300 Ω/3 kΩ

BT3564
•Voltage Range : 10V to 1000V
Analog Output Contact Check
•Resistance : 0,1 μΩ to 3000 Ω
•Spark Reduction

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SUMMARY OF HIOKI BATTERY TESTER

BT3564

BT3554-50
BT3563A

BT4560

3561 BT3562A

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BT3561A
RM3545 RESISTANCE METER
Assembled batteries are used to obtain the desired current capacity and voltage.
High contact resistance⇒ High heat loss⇒ Cause of battery defects

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RM3545 RESISTANCE METER

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ALTERNATIVE = USING BT356X

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 MEASUREMENT PROCEDURES
1. Battery Intenal Resistance

a) Keeping cables and batteries away from metallic objects b) Use 4-terminal-pair method

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 MEASUREMENT PROCEDURES
2. Busbar Resistance Measurement

1. Effects of thermo-electromotive force 2. Effects of ambient temperature

J1 Rt = Rt0 ×{ 1 + αt0 × (t - t0) }

Vbat
• Since the measurement target exhibits
J1 temperature dependence, changes in the
ambient temperature will cause resistance values
to vary
• A difference of 1°C can cause a variation of
The offset voltage compensation (OVC) function can be approximately 0.4% in aluminum wire
used to achieve stable and consistent measurement Sponsored by:
Battery Management System
(BMS) Evaluation

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To achieve longer all-electric driving range
Key parts of electrified vehicles

• High Efficiency Inverter such as Motor

Inverter SiC inverter

• High Efficiency motor such as

Motor PMSM

Inverter Battery
• High energy density battery cell
Battery such as Lithium Ion Battrey

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To achieve longer all-electric driving range

Keep battery packs healthy across their lifetime

Battery Management

Monitoring conditions all the time Keep

battery packs healthy across their lifetime Battery Battery pack
Management
Protection systems for overvoltage, under- System (BMS)
voltage, overcurrent, and thermal runaway

Optimize battery cell balance

SOC estimation
Distributed architecture Centralized architecture

Fault detection Sponsored by:

Conventional BMS Validation Environments

Use actual batteries

– Time-consuming processes, or charging/discharging
– Difficult to set the voltage of individual cells as desired
– Overvoltage/under-voltage cells → Battery degradation, Fire at worst
– Relay control required for broken wire and short simulation

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Conventional BMS Validation Environments
Use multiple power supplies
• Complicated control multiple power supplies
and DMMs
• Expensive per channel
• Enormous amount of maintenance for each
unit
• Time-consuming processes
Using Battery / power supply + Resistance partial
voltage
• Time-consuming processes, setting variable
resistors
• Difficult to set verification operating condition
• Low output voltage accuracy with variable
resistors
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Why a better accuracy of simulator is required

There are 2 reasons why the performance of BMS is improving

a. To balance each cell voltage more accurately

← To reduce the deterioration of battery as much as possible

b. To accurately estimate the remaining battery charge (more accurate SOC estimation)
← To improve the accuracy of EV driving range estimation

Any power supply and electronic load cannot guarantee the accuracy which
SS7081-50 provides that can justify using SS7081-50 without them.

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 Necessity of BMS High-Precision Evaluation
For a lithium Ion Battery operating range of 10% to 90%

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Necessity of BMS High-Precision Evaluation

Without high • Measurement

accuracy of accuracy of BMS
standard side can not
instrument grasped Reduce
output battery
(monitor),
efficiency,
accelerated
If the deterioration ,
• Impossible to
measurement
grasp the causes
may lead the
accuracy on the worst case
of variation (BMS
instrument
under test
environtmental accident
change, aging
(BMS) side is
degradation
poor,

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Feature of SS7081-50

Main Feature

Integrated 12-cell power supplies, electronic

loads and DMM in to single units

Industry-leading output accuracy and

measurement accuracy

Safety and Simple simulation function

Control and simulate by using PC application

Reliable support by International Standard

Calibration Organization
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Terima kasih

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