Workshop “Solutions to electromobility challenges” Hosted by CIDETEC Energy Storage with the support of CRF Core Temperature Estimation for Cylindrical Cell Battery Module Subhajeet Rath TNO, The Netherlands GV-06-2017 iModBatt and GHOST projects have received funding from the European Union’s Horizon2020 Programme for research and innovation under Hotel ARIMA, Paseo de Miramón, 162, 20014 Grant Agreements No. 770054 & 770019 San Sebastián, Spain, 18th October 2019
HIFI-ELEMENTS Introduction • Three-year EU project involving 16 partners • Objective – Develop, Validate and Publish a standardization of model interfaces for common e-drive components – Implementation of a model/data management tool and a co- simulation tool for MiL and HiL environments • End Goal – Reduction of development and testing effort – Decrease in vehicle energy consumption – Increase in validation test coverage Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 2
HIFI-ELEMENTS Task 2.3 • Partners: RICARDO, CIDETEC, VUB and TNO • Development and Validation of a scalable and flexible battery pack model • Battery Pack Model – Electrical model – Ageing model – Thermal model – BMS model Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 3
HIFI-ELEMENTS Task 2.3 High Level Schematics Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 4
HIFI-ELEMENTS Task 2.3 High Level Schematics Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 5
Thermal Model • Temperature evolution for input operating condition • Model – Battery Model – Cooling Model • BMS Output – Avg, Min and Max battery cell temperature ( 𝑈 𝑏𝑤 , 𝑈 𝑛𝑏𝑦 , 𝑈 𝑛𝑗𝑜 ) – Battery coolant pressure difference ( ∆𝑄 𝑔 ) – Battery heat loss ( 𝑅 𝑑𝑝𝑝𝑚𝑏𝑜𝑢 ) – Battery coolant pressure drop coefficient ( 𝜂 ) Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 6
Thermal Model Battery Model TNO Battery Module Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 7
Thermal Model Battery Model TNO Battery Module (Top View) Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 8
Thermal Model Battery Model TNO Battery Module (Top View) Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 9
Thermal Model Battery Model Top View Cell 9 Side View Cell 9 Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 10
Thermal Model Battery Model • State 𝑞 , 𝑈 𝑞 𝑑 , 𝑈 𝑡 , ⋯ , 𝑈 𝑑 𝑡 – 𝑈 , 𝑈 , 𝑈 𝑈 𝑜 𝑑𝑓𝑚𝑚 𝑜 𝑑𝑓𝑚𝑚 1 1 𝐶 • Input – 𝑅 1 , ⋯ , 𝑅 𝑜 𝑑𝑓𝑚𝑚 , 𝑈 𝑏 , 𝑅 𝑈 , 𝑅 𝐶 • Parameter – 𝐷 𝑑 , 𝐷 𝑡 , 𝐷 𝑞 , 𝑆 𝑑𝑡 , 𝑆 𝑡𝑡 , 𝑆 𝑡𝑏 , 𝑆 𝑡𝑞 , 𝑆 𝑈𝑏 , 𝑆 𝐶𝑏 Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 11
Thermal Model Cooling Model Cooling Plate (Module) Cooling Plate (Model) Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 12
Thermal Model Coolant Model • State – 𝑅 𝑈 , 𝑅 𝐶 , ∆𝑄 𝑔 • Input 𝑞 , 𝑈 𝑞 , 𝑈 𝑔 – 𝑈 𝑈 , 𝑊 𝐶 𝑗𝑜𝑚𝑓𝑢 • Parameter – 𝐵 𝑝 , 𝜍, 𝑑 𝑞 , 𝑆 𝑞𝑔 , 𝜂 Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 13
Thermal Model Battery Model Cooling Model 𝑞 , 𝑈 𝑞 State: 𝑅 𝑈 , 𝑅 𝐶 State: 𝑈 𝑈 𝐶 𝑞 , 𝑈 𝑞 Input: 𝑅 𝑈 , 𝑅 𝐶 Input: 𝑈 𝑈 𝐶 Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 14
Model Calibration • Parameters to identify: 𝐷 𝑑 𝐷 𝑡 𝐷 𝑞 𝑆 𝑑𝑡 𝑆 𝑡𝑡 𝑆 𝑡𝑏 𝑆 𝑡𝑞 𝑆 𝑈𝑏 𝑆 𝐶𝑏 𝑆 𝑞𝑔 𝜂 • Calibration Test – Cell Calorimetry Test – Cell Heating Test – Pressure Drop Test – 3D FEM Simulation Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 15
Model Calibration Cell Calorimetry Test • Test conducted at CIDETEC • Accelerating Rate Calorimeter (ARC) • Measure temperature rise for known heat addition Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 16
Model Calibration Cell Calorimetry Test • Test conducted at CIDETEC • Accelerating Rate Calorimeter (ARC) • Measure temperature rise for known heat addition • Identified Parameter – 𝐷 𝑑𝑓𝑚𝑚 = 60.5 J/K – 𝐷 𝑡 = 9.15 J/K (Material Properties) – 𝐷 𝑑 = 𝐷 𝑑𝑓𝑚𝑚 − 𝐷 𝑡 = 51.35 J/K Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 17
Model Calibration Cell Heating Test • Battery heating with asymmetric current profile • Cooling with constant flow rate Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 18
Model Calibration Cell Heating Test • Battery heating with asymmetric current profile • Cooling with constant flow rate Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 19
Model Calibration Cell Heating Test • Battery heating with asymmetric current profile • Identified Parameter – 𝐷 𝑞 = 620.10 J/K – 𝑆 𝑡𝑡 = 181.02 K/W – 𝑆 𝑡𝑞 = 14.4 K/W – 𝑆 𝑡𝑏 = 106.16 K/W – 𝑆 𝑈𝑏 = 0.18 K/W – 𝑆 𝐶𝑏 = 1.57 K/W – 𝑆 𝑞𝑔 = 0.02 K/W Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 20
Model Calibration Pressure Drop Test • Coolant circulation throught cooling plate at constant flow rate • Pressure drop recorded from Inlet to Outlet Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 21
Model Calibration Pressure Drop Test • Coolant circulation throught cooling plate at constant flow rate • Pressure drop recorded from Inlet to Outlet • Identified Parameter – 𝜂 = 37.92 Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 22
Model Calibration • Parameters to identify: 𝑆 𝑑𝑡 • Core Temperature measurement not available • Virtual Modelling of a cell with known material properties Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 23
Model Calibration 3D FEM Simulation • FEM Model of a single cell Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 24
Model Calibration 3D FEM Simulation • FEM Model of a single cell • Identified Parameter – 𝑆 𝑑𝑡 = 0.6 K/W Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 25
Model Validation • Module subjected to WLTP drive cycle • Ambient – 0 ° C – 20 ° C – 40 ° C • Measurement and Model compared – Cell 20 – Cell 27 Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 26
Model Validation Ambient 0°C Temperature Evolution Error Histogram Error [ ° C] Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 27
Model Validation Results Cell 20 Cell 27 Ambient Temperature Max Error Error Peak Max Error Error Peak 0°C 1.34° C 0.05° C 1.81° C 0.10° C 20°C 1.34° C 0.35° C 2.13° C 0.05° C 40°C 1.34° C 0.85° C 2.61° C 0.05° C Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 28
Thermal State Observer • Thermal State Observer (TSO) used in Thermal Management System – Safety – Reliability – Battery Life • Kalman Filter – Uses State-Space Thermal Model – Predicts system states from measurements – Real time capable Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 29
Thermal State Observer • TSO Tuning: – Measurement Noise: 0.5 ° C – Process Noise: 0.05 • Measurement and Prediction compared – Surface temperature compared as Core Temperature not available • Assumption: Core temperature can be predicted with a known surface temperature Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 30
Thermal State Observer Validation TSO Schematics Measured Estimated Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 31
Thermal State Observer Validation Temperature Evolution Error Histogram Error [ ° C] Workshop “Solutions to electromobility challenges”, 18 th October 2019, San Sebastian (Spain) 32
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