EV Battery

Management
For Naan Mudhalvan
Let’s Discuss Yesterday’s
Case Study Activity
 Case Study Activity:
Nissan Leaf's Thermal Management
Evolution

Nissan’s Leaf electric vehicle has been a

pioneer in the world of sustainable mobility
since its launch in 2010.

Over the years, Nissan has made several

improvements to the Leaf’s thermal
management system to address the challenges
of battery overheating and underperformance.

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 Case Study Activity:
Nissan Leaf's Thermal Management Evolution

Key Challenges Overcoming Challenges

1. Lack of liquid cooling in the Leaf’s
battery system
2. The resulting thermal issues that arose
during charging and long-distance
driving
To overcome these challenges, Nissan integrated a
liquid cooling system into the Ariya electric
crossover, which has been performing well in
extreme heat conditions.

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 Case Study Activity:
Nissan Leaf's Thermal Management Evolution

Four takeaways from this case study are:

1. The Leaf’s battery technology is helping power

homes and businesses, while broader Nissan
EV innovation is at the heart of vehicle-to-grid
energy management services.

2. Liquid cooling may add complexity to battery

packs, but it is the best option under all weather
conditions: it allows for more precise and
effective temperature control in the most
expensive component for electric cars.
P.T.O
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 Case Study Activity:
Nissan Leaf's Thermal Management Evolution

3. The Ariya’s liquid cooling system is a good

example of how Nissan has addressed the
thermal management challenges of its
EVs.

4. The Leaf’s journey over the past decade

has laid the foundations of modern-day
electric vehicles, and it continues to inspire
sustainable mobility solutions.

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Module 4:
Battery Diagnostics
and Maintenance in
Electric Vehicles
For Naan Mudhalvan
 Module 4 Objectives

v To develop skills in diagnosing battery

issues and conducting routine
maintenance.

v To understand best practices for

extending the lifespan of EV batteries

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 Key Concepts

ü What is Battery Diagnostics and ü How is Battery Diagnostics and Maintenance Done?
Maintenance?
ü Diagnosing Battery Issues and Conducting Routine
ü Why Do We Need to Perform Battery Maintenance
Diagnostics and Maintenance?
ü Best Practices for Extending the Lifespan of EV
Batteries
ü When Do We Need to Perform Battery
Diagnostics and Maintenance?

ü Where is Battery Diagnostics and

Maintenance Done?

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Module 4
Part 1: Diagnosis and
Maintenance
 A Video: EV Battery Testing

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 What is
Battery Diagnostics and
Maintenance?

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 What is
Battery Diagnostics and Maintenance?
Definition:

Battery diagnostics and maintenance involve a systematic and thorough examination of

electric vehicle (EV) batteries to assess their performance, identify potential issues, and
implement corrective measures. This comprehensive process aims to ensure the optimal
functioning, safety, and longevity of the battery system.
Examples:

Diagnostics: Using specialised tools to measure

voltage, current, temperature, and other
parameters.

Maintenance: Implementing procedures such as

cell balancing, firmware updates, and thermal
management adjustments.
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 Why Do We Need to Perform
Battery Diagnostics and
Maintenance?

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 Why Do We Need to Perform
Battery Diagnostics and Maintenance?

1. Optimizing Performance: Regular

diagnostics and maintenance contribute to
consistent power output, preserving the
vehicle's performance.

2. Prolonging Battery Life: Timely identification

and correction of issues help extend the
lifespan of the battery, reducing the need for
premature replacements.

3. Ensuring Safety: Diagnostics uncover

potential safety concerns, allowing for
proactive interventions to prevent hazardous
situations like thermal runaway.

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 Why Do We Need to Perform
Battery Diagnostics and Maintenance?

4. Preserving Efficiency: Maintenance

activities, such as cell balancing,
contribute to preserving the efficiency of
the battery pack over time.

Examples

Performance: Comparing the acceleration and range

of an EV before and after maintenance.

Safety: Identifying and resolving issues that could lead

to overheating or other safety risks.

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 When do we need to perform
Battery Diagnostics and
Maintenance?

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 When do we need to perform Battery
Diagnostics and Maintenance?
1. Regular Intervals: Periodic diagnostics and
maintenance are recommended at regular
intervals, typically based on vehicle usage
or manufacturer recommendations.

2. After Significant Usage: After prolonged or

intensive use, especially in extreme
conditions, to address any wear and tear
and ensure sustained performance.

3. Error Codes or Alerts: Whenever the

vehicle's onboard diagnostics system
triggers error codes or alerts related to the
battery, indicating potential issues.

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 3. When do we need to perform Battery
Diagnostics and Maintenance?
4. During Scheduled Service: Incorporating battery diagnostics and maintenance into routine
service schedules ensures a proactive approach to battery health.

Examples Images

Regular Checking: Error Codes:

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 Where is
Battery Diagnostics and
Maintenance done?

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 Where is
Battery Diagnostics and Maintenance
done?
1. Service Centers: Authorised service centers
equipped with diagnostic tools and expertise
perform comprehensive battery diagnostics
and maintenance.

2. Specialised Facilities: Facilities specialising

in EV maintenance and repair, equipped with
the necessary tools and trained personnel.

3. Mobile Service Units: Some diagnostic

procedures can be performed by mobile
service units, bringing convenience to the
vehicle owner.

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 Where is
Battery Diagnostics and Maintenance
done?
4. At-Home Diagnostics Kits: Developing technologies allow for simplified diagnostics
at home using user-friendly kits and smartphone applications.

Examples Images

Service Centers: Mobile Service Units:

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 How is Battery Diagnostics
and Maintenance Done?

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 How is Battery Diagnostics and
Maintenance Done?

1. Diagnostic Tools: Utilizing specialized

diagnostic tools to measure and analyze
parameters such as voltage, current,
temperature, and state of charge.

2. Software Analysis: Employing sophisticated

software algorithms to interpret data collected
during diagnostics and identify patterns or
anomalies.

3. Visual Inspection: Physically inspecting the

battery components, connections, and thermal
management systems for any signs of wear,
damage, or irregularities.

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 How is Battery Diagnostics and
Maintenance Done?
4. Cell Balancing: Implementing cell balancing procedures to equalize the charge among
individual cells, enhancing overall battery performance.

5. Firmware Updates: Updating battery management system firmware to ensure compatibility

with the latest algorithms and improvements.

6. Thermal Management Adjustments: Fine-tuning thermal management systems to optimize

temperature control and prevent overheating or overcooling.

Examples Images: Diagnostic Tools & Visual Inspection

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 Battery Diagnostics and Maintenance

Conclusion
Battery diagnostics and maintenance are critical practices for preserving the health,
efficiency, and safety of electric vehicle batteries.

By understanding the significance, timing, locations, and procedures involved, both

vehicle owners and service professionals can contribute to the longevity and
reliability of EVs, fostering a sustainable and efficient mode of transportation.

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Quiz Time!
Battery Safety and Thermal Management
 Quiz

1. What is the primary goal of battery diagnostics in electric

vehicles?

A) Adjusting Seat Positions

B) Monitoring and Controlling Battery Parameters

C) Regulating Air Conditioning

D) Controlling Window Tint

Answer: B)

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 Quiz

2. Why is routine maintenance essential for electric

vehicle batteries?

A) To Increase Tire Tread Life

B) To Enhance Interior Comfort

C) To Maximize Battery Lifespan and Performance

D) To Adjust Wiper Speed

Answer: C)

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 Quiz

3. What safety feature is essential for preventing

thermal runaway in electric vehicle batteries?

A) Air Freshener Dispenser

B) Emergency Brake System

C) Ventilation System

D) Thermal Protection

Answer: D)

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 Quiz

4. How does thermal management contribute to the

overall safety of electric vehicles?

A) Enhancing Radio Signal

B) Controlling Air Freshness

C) Preventing Overheating

D) Adjusting Seat Positions

Answer: C)

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 Quiz
5. What is the primary purpose of safety
protocols for EV batteries?

A) Adjusting Mirror Positions

B) Regulating Tire Pressure

C) Ensuring Safe Handling and Operation

D) Controlling Headlights

Answer: C)

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 Diagnosing battery issues
and conducting routine
maintenance

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 Diagnosing battery issues and conducting
routine maintenance
1. State of Charge (SoC) Imbalance

Issue: Uneven charge distribution among

individual cells can lead to reduced overall
battery capacity, inefficient energy
utilization, and potential damage to specific
cells.

Cause: Repeated charge and discharge

cycles result in variations in cell capacity
over time, especially if the battery
management system (BMS) is not
effectively balancing the cells.

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 Diagnosing battery issues and
conducting routine maintenance

2. Overheating

Issue: Elevated temperatures within the

battery pack can accelerate degradation,
reduce overall battery life, and pose safety
risks such as thermal runaway.

Cause: Intense usage, fast charging, or

exposure to high ambient temperatures can
lead to increased internal resistance and heat
generation.

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 Diagnosing battery issues and
conducting routine maintenance

3. Overcharging:

Issue: Charging the battery beyond its

recommended capacity can result in
accelerated degradation, decreased energy
storage capacity, and safety hazards such as
gas release or thermal instability.

Cause: Faulty charging equipment, incorrect

charging algorithms, or prolonged charging
sessions can lead to overcharging.

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 Diagnosing battery issues and conducting
routine maintenance
4. Deep Discharging:

Issue: Allowing the battery to discharge to

extremely low levels can lead to
irreversible damage, reduced capacity, and
diminished overall battery life.

Cause: Prolonged disuse, intentional deep

discharging, or a failure in the battery
management system can contribute to this
issue.

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 Diagnosing battery issues and
conducting routine maintenance

5. Cell Damage:

Issue: Physical or chemical damage to

individual battery cells can compromise their
structural integrity, leading to decreased
performance, potential safety hazards, and
accelerated degradation.

Cause: Impact from accidents, manufacturing

defects, or exposure to extreme conditions like
high temperatures can result in cell damage.

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Thank You!