Engineering topics
Publications and source records attributed to Neubauer, Jeremy.
Fail-safe systems and design methodologies for large capacity battery systems are disclosed. The disclosed systems and methodologies serve to locate a faulty cell in a large capacity battery, such as a cell having an internal short circuit, determine whether the fault is evolving, and electrically isolate the faulty cell from the rest of the battery, preventing further electrical energy from feeding into the fault.
The market penetration of plug-in electric vehicles (PEVs) and deployment of grid-connected energy storage systems are both presently impeded by the high cost of batteries. Battery second use (B2U) strategies-in which a single battery first serves an automotive application, then is redeployed into a secondary market-could help address both issues by reducing battery costs to the primary repurposed PEV batteries to serve grid applications for energy storage. The authors view this as of significant importance, as our expectation is that such batteries will be both cheap and plentiful. Understanding the dynamics of B2U will be important for customers and utilities in need of storage to understand when and where such batteries will be applicable. It will also be important for suppliers of other energy storage technologies, as repurposed PEV batteries could pose a significant threat to their business model.
Fast charging is attractive to battery electric vehicle (BEV) drivers for its ability to enable long-distance travel and quickly recharge depleted batteries on short notice. However, such aggressive charging and the sustained vehicle operation that result could lead to excessive battery temperatures and degradation. Properly assessing the consequences of fast charging requires accounting for disparate cycling, heating, and aging of individual cells in large BEV packs when subjected to realistic travel patterns, usage of fast chargers, and climates over long durations (i.e., years). The U.S. Department of Energy's Vehicle Technologies Office has supported the National Renewable Energy Laboratory's development of BLAST-V-the Battery Lifetime Analysis and Simulation Tool for Vehicles-to create a tool capable of accounting for all of these factors. We present on the findings of applying this tool to realistic fast charge scenarios. The effects of different travel patterns, climates, battery sizes, battery thermal management systems, and other factors on battery performance and degradation are presented. We find that the impact of realistic fast charging on battery degradation is minimal for most drivers, due to the low frequency of use. However, in the absence of active battery cooling systems, a driver's desired utilization of a BEV and fast charging infrastructure can result in unsafe peak battery temperatures. We find that active battery cooling systems can control peak battery temperatures to safe limits while allowing the desired use of the vehicle.
Installation of fast charging infrastructure is considered by many as one of potential solutions to increase the utility and range of electric vehicles (EVs). This is expected to reduce the range anxiety of drivers of EVs and thus increase their market penetration. Level 1 and 2 charging in homes and workplaces is expected to contribute to the majority of miles driven by EVs. However, a small percentage of urban driving and most of inter-city driving could be only achieved by a fast-charging network. DC fast charging at 50 kW, 100 kW, 120 kW compared to level 1 (3.3 kW) and level 2 (6.6 kW) results in high-current charging that can adversely impact the life of the battery. In the last couple of years, we have investigated the impact of higher current rates in batteries and potential of higher temperatures and thus lower service life. Using mathematical models, we investigated the temperature increase of batteries due to higher heat generation during fast charge and have found that this could lead to higher temperatures. We compared our models with data from other national laboratories both for fine-tuning and calibration. We found that the incremental temperature rise of batteries during 1C to 3C fast charging may reduce the practical life of the batteries by less than 10% over 10 to 15 years of vehicle ownership. We also found that thermal management of batteries is needed for fast charging to prevent high temperature excursions leading to unsafe conditions.
Utilization of public charging infrastructure is heavily dependent on user-specific travel behavior. The availability of fast chargers can positively affect the utility of battery electric vehicles, even given infrequent use. Estimated utilization rates do not appear frequent enough to significantly impact battery life. Battery thermal management systems are critical in mitigating dangerous thermal conditions on long distance tours with multiple fast charge events.
The National Renewable Energy Laboratory supports energy storage R&D under the Office of Vehicle Technologies at the U.S. Department of Energy. The DOE Energy Storage Program’s charter is to develop battery technologies that will enable large market penetration of electric drive vehicles. These vehicles could have a significant impact on the nation’s goal of reducing dependence on imported oil and gaseous pollutant emissions. DOE has established several program activities to address and overcome the barriers limiting the penetration of electric drive battery technologies: cost, performance, safety, and life. These programs are; Advanced Battery Development through the United States Advanced Battery Consortium (USABC); Battery Testing, Analysis, and Design; Applied Battery Research (ABR); and Focused Fundamental Research, or Batteries for Advanced Transportation Technologies (BATT) In FY14, DOE funded NREL to make technical contributions to all of these R&D activities. This report summarizes NREL’s R&D projects in FY14 in support of the USABC; Battery Testing, Analysis, and Design; ABR; and BATT program elements. The FY14 projects under NREL’s Energy Storage R&D program are briefly described below. Each of these is discussed in depth in this report.
Abstract not provided
Fast charging is attractive to battery electric vehicle (BEV) drivers for its ability to enable long-distance travel and quickly recharge depleted batteries on short notice. However, such aggressive charging and the sustained vehicle operation that results could lead to excessive battery temperatures and degradation. Properly assessing the consequences of fast charging requires accounting for disparate cycling, heating, and aging of individual cells in large BEV packs when subjected to realistic travel patterns, usage of fast chargers, and climates over long durations (i.e., years). The U.S. Department of Energy's Vehicle Technologies Office has supported NREL's development of BLAST-V 'the Battery Lifetime Analysis and Simulation Tool for Vehicles' to create a tool capable of accounting for all of these factors. The authors present on the findings of applying this tool to realistic fast charge scenarios. The effects of different travel patterns, climates, battery sizes, battery thermal management systems, and other factors on battery performance and degradation are presented. The primary challenge for BEV batteries operated in the presence of fast charging is controlling maximum battery temperature, which can be achieved with active battery cooling systems.
Repurposing Li-ion batteries at the end of useful life in electric drive vehicles could eliminate owners' disposal concerns and offer low-cost energy storage for certain applications.
Abstract not provided
This report documents completion of the July 2013 milestone as part of NREL’s Vehicle Technologies Annual Operating Plan with the U.S. Department of Energy. The objective was to perform analysis on range extension techniques for battery electric vehicles (BEVs). This work represents a significant advancement over previous thru-life BEV analyses using NREL’s Battery Ownership Model, FastSim,* and DRIVE.* Herein, the ability of different charging infrastructure to increase achievable travel of BEVs in response to real-world, year-long travel histories is assessed. Effects of battery and cabin thermal response to local climate, battery degradation, and vehicle auxiliary loads are captured. The results reveal the conditions under which different public infrastructure options are most effective, and encourage continued study of fast charging and electric roadway scenarios.
Battery technology is critical for the development of innovative electric vehicle networks, which can enhance transportation sustainability and reduce dependence on petroleum. This cooperative research proposed by Better Place and NREL will focus on predicting the life-cycle economics of batteries, characterizing battery technologies under various operating and usage conditions, and designing optimal usage profiles for battery recharging and use.
This report describes the activities of the Energy Storage group over FY2012.
Battery wear in plug-in electric vehicles (PEVs) is a complex function of ambient temperature, battery size, and disparate usage. Simulations capturing varying ambient temperature profiles, battery sizes, and driving patterns are of great value to battery and vehicle manufacturers. A predictive battery wear model developed by the National Renewable Energy Laboratory captures the effects ofmultiple cycling and storage conditions in a representative lithium chemistry. The sensitivity of battery wear rates to ambient conditions, maximum allowable depth-of-discharge, and vehicle miles travelled is explored for two midsize vehicles: a battery electric vehicle (BEV) with a nominal range of 75 mi (121 km) and a plug-in hybrid electric vehicle (PHEV) with a nominal charge-depleting rangeof 40 mi (64 km). Driving distance distributions represent the variability of vehicle use, both vehicle-to-vehicle and day-to-day. Battery wear over an 8-year period was dominated by ambient conditions for the BEV with capacity fade ranging from 19% to 32% while the PHEV was most sensitive to maximum allowable depth-of-discharge with capacity fade ranging from 16% to 24%. The BEV and PHEV werecomparable in terms of petroleum displacement potential after 8 years of service, due to the BEV?s limited utility for accomplishing long trips.
Battery electric vehicles (BEVs) offer the potential to reduce both oil imports and greenhouse gas emissions, but high upfront costs discourage many potential purchasers. Making an economic comparison with conventional alternatives is complicated in part by strong sensitivity to drive patterns, vehicle range, and charge strategies that affect vehicle utilization and battery wear. Identifying justifiable battery replacement schedules and sufficiently accounting for the limited range of a BEV add further complexity to the issue. The National Renewable Energy Laboratory developed the Battery Ownership Model to address these and related questions. The Battery Ownership Model is applied here to examine the sensitivity of BEV economics to drive patterns, vehicle range, and charge strategies when a high-fidelity battery degradation model, financially justified battery replacement schedules, and two different means of accounting for a BEV's unachievable vehicle miles traveled (VMT) are employed. We find that the value of unachievable VMT with a BEV has a strong impact on the cost-optimal range, charge strategy, and battery replacement schedule; that the overall cost competitiveness of a BEV is highly sensitive to vehicle-specific drive patterns; and that common cross-sectional drive patterns do not provide consistent representation of the relative cost of a BEV.
Accelerated market penetration of plug-in electric vehicles and deployment of grid-connected energy storage are restricted by the high cost of lithium-ion batteries. Research, development, and manufacturing are underway to lower material costs, enhance process efficiencies, and increase production volumes. A fraction of the battery cost may be recovered after vehicular service by reusing thebattery where it may have sufficient performance for other energy-storage applications. By extracting post-vehicle additional services and revenue from the battery, the total lifetime value of the battery is increased. The overall cost of energy-storage solutions for both primary (automotive) and secondary (grid) customer could be decreased. This techno-economic analysis of battery second useconsiders effects of battery degradation in both automotive and grid service, repurposing costs, balance-of-system costs, the value of aggregated energy-storage to commercial and industrial end users, and competitive technology. Batteries from plug-in electric vehicles can economically be used to serve the power quality and reliability needs of commercial and industrial end users. However, thevalue to the automotive battery owner is small (e.g., $20-$100/kWh) as declining future battery costs and other factors strongly affect salvage value. Repurposed automotive battery prices may range from $38/kWh to $132/kWh.
In a laboratory environment, it is cost prohibitive to run automotive battery aging experiments across a wide range of possible ambient environment, drive cycle and charging scenarios. Since worst-case scenarios drive the conservative sizing of electric-drive vehicle batteries, it is useful to understand how and why those scenarios arise and what design or control actions might be taken tomitigate them. In an effort to explore this problem, this paper applies a semi-empirical life model of the graphite/nickel-cobalt-aluminum lithium-ion chemistry to investigate impacts of geographic environments under storage and simplified cycling conditions. The model is then applied to analyze complex cycling conditions, using battery charge/discharge profiles generated from simulations ofPHEV10 and PHEV40 vehicles across 782 single-day driving cycles taken from Texas travel survey data.
This Annual Merit Review presentation describes the application of the Battery Ownership Model for strategies for optimal battery use in electric drive vehicles (PEVs, PHEVs, and BEVs).