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Battery lifespan estimation is essential for effective battery management systems, aiding users and manufacturers in strategic planning. However, accurately estimating battery capacity is complex, owing to diverse capacity fading phenomena tied to factors such as temperature, charge-discharge rate, and rest period duration. In this work, we present an innovative approach that integrates real-world driving behaviors into cyclic testing. Unlike conventional methods that lack rest periods and involve fixed charge-discharge rates, our approach involves 1000 unique test cycles tailored to specific objectives and applications, capturing the nuanced effects of temperature, charge-discharge rate, and rest duration on capacity fading. This yields comprehensive insights into cell-level battery degradation, unveiling growth patterns of the solid electrolyte interface (SEI) layer and lithium plating, influenced by cyclic test parameters. The results yield critical empirical relations for evaluating capacity fading under specific testing conditions.
Electric vehicles (EVs) are rapidly growing in popularity, but range variability has become an important research area with significant implications for EV performance, usability, and overall market adoption. This study aims to unravel the complexities of range variability by examining the contributing factors and offering innovative strategies to mitigate these differences during pack design. Through a detailed analysis of cell parameter deviation, cell connections, battery configuration, battery pack size, and driving behavior, the research illuminates their impact on extractable energy and driving range. The study employed a comprehensive approach and conducted systematic simulation-based experimentation to identify the optimal battery pack configuration based on maximum extractable energy, minimal variability and maximum range. The results reveal insights into the relationship between discharge rate and battery pack performance, and the impact of cell parameter variations on pack energy output. This research advances the understanding of EV performance optimisation, reduces pack-to-pack variability, and extends battery pack lifespan.
Protocol for conducting advanced cyclic tests in lithium-ion batteries to estimate capacity fade
(2024)
Using advanced cyclic testing techniques improves accuracy in estimating capacity fade and incorporates real-world scenarios in battery cycle aging assessment. Here, we present a protocol for conducting cyclic tests in lithium-ion batteries to estimate capacity fade. We describe steps for implementing strategies for accounting for variations in rest periods, charge-discharge rates, and temperatures. We also detail procedures for validating tests experimentally within a climate-controlled chamber and for developing an empirical model to estimate capacity fading under various testing objectives. For complete details on the use and execution of this protocol, please refer to Mulpuri et al.1.
This study addresses the common occurrence of cell-to-cell variations arising from manufacturing tolerances and their implications during battery production. The focus is on assessing the impact of these inherent differences in cells and exploring diverse cell and module connection methods on battery pack performance and their subsequent influence on the driving range of electric vehicles (EVs). The analysis spans three battery pack sizes, encompassing various constant discharge rates and nine distinct drive cycles representative of driving behaviours across different regions of India. Two interconnection topologies, categorised as “string” and “cross”, are examined. The findings reveal that cross-connected packs exhibit reduced energy output compared to string-connected configurations, which is reflected in the driving range outcomes observed during drive cycle simulations. Additionally, the study investigates the effects of standard deviation in cell parameters, concluding that an increased standard deviation (SD) leads to decreased energy output from the packs. Notably, string-connected packs demonstrate superior performance in terms of extractable energy under such conditions.
