RECENT ADVANCES IN ENHANCED FLOODED BATTERY FOR SMART MILD HYBRID POWER TRAINS

Transcription

1 RECENT ADVANCES IN ENHANCED FLOODED BATTERY FOR SMART MILD HYBRID POWER TRAINS By Debashish Mazumdar, Ashwini Kulkarni & Achim Luelsdorf Exide Industries Ltd (EIL),R & D center, INDIA

2 CONTENTS ABSTRACT INTRODUCTION CHARACTERIZATION AND VALIDATION RESULTS AND DISCUSSION FUTURE CHALLENGES REFERENCES ACKNOWLEDGEMENT

3 ABSTRACT To serve the critical demand of battery for Smart Mild Hybrid Vehicles under tropical climate, EIL has developed Generation-2 EFB technology which passed drive cycles of SBA, NEDC and EUCAR satisfactorily. Our EFB is superior in terms of active material formulation, special grid alloy, electrolyte additives which resulted in significant increase in SBA cycle life, DCA and PSoC cyclic operation. Suppression of PCL effects due to Grid interface passivation, Negative lug thinning and Softening of PAM/NAM have been achieved. Here, we throw light on the development and evolution of EFB battery technology for major automotive players Suzuki, Nissan, VW and others in India. Keywords: EFB, mild/micro-hybrid, SHVS, PSoC, LAB

4 INDIAN SCENARIO By 2021, Estimated emission norms -113 g CO 2 /km - INDIA In Indian Scenario, Densely populated cities like Mumbai, Delhi, Bangalore, Chennai have very high pollution levels due to passenger cars, Heavy vehicles etc. Huge potential exists for mild / micro hybrids (more economical compared to fully hybrid / electric) in developing countries like INDIA Fig: Comparison of global CO2 regulations for passenger cars, in terms of NEDC CO 2 /km. [1] Market driving forces: Govt. initiatives (Subsidized schemes like FAME) Fuel economy Stringent emission norms

5 OPPORTUNITIES IN INDIA FAME (FASTER ADOPTION AND MANUFACTURING OF ELECTRIC/HYBRID VEHICLES) An INDIAN govt. Initiative Target by 2020: 6-7 million hybrid/electric vehicle sale million liters of cumulative saving. 2 Million ton reduction in pollution and green house gas emissions. Indian government has declared Tax benefits with 50 % reduction in Excise duty VEHICLE SEGMENT MINIMUM INCENTIVE MAXIMUM INCENTIVE SCOOTER MOTOR CYCLE AUTO RICKSHAW CARS LCV BUS Prices are in Indian rupees

6 RELATIVE IMPORTANCE OF BATTERY CHARACTERISTICS IN DIFFERENT MARKET CONDITION BATTERY CHARACTERIS TICS ENGINE CRANKING CAPABILITY (CCA) RESERVE CAPACITY HIGH TEMP ENDURANCE CHARGE ACCEPTANCE RECOVERY FROM DEEP DISCHARGE VIBRATION RESISTANCE RELEVANCE WITH REGARD TO OPERATING CONDITIONS EUROPE / NORTH AMERICAN MARKET SERVICE CONDITION COLD CLIMATE, PARASITIC LOAD, HIGH SPEED, LONG RUN, SMOOTH ROAD INDIAN MARKET IMPORTANCE SERVICE CONDITION IMPORTANCE HOT CLIMATE, PARASITIC LOAD, LOW SPEED, FREQUENT START- STOP, BUMPY ROADS Indian Climatic condition, Road condition and driving pattern are different from the western countries as shown in table AGM VS EFB Even though AGM gives more cycle life than EFB in mild/micro hybrid application, in Indian context EFB has more relevance In Indian tropical climatic conditions, under bonnet temperature will be high. EFB performance is less effected by the extreme temperatures compared to AGM [2] J.Valencio et al [2] EFB is also very economical as compared to the AGM technology - NOT CRITICAL - CRITICAL - VERY CRITICAL

7 INTRODUCTION EXIDE CONSERVO DIN70-ISS BATTERY IN SUZUKI CIAZ: INDIA s FIRST DIESEL SMART HYBRID VEHICLE HYBRID TECHNOLOGY USED IN SUZUKI CIAZ : SHVS (Smart hybrid vehicle by suzuki) FUNCTIONALITIES OF SHVS 12V SYSTEM: CRANKING IDEAL START-STOP POWER ASSIST REGENERATIVE BRAKING DIN70-ISS: Gen 2 - ISS Battery

8 ISS BATTERIES (Gen-2) UNDER SUPPLY DIN 70 ISS Battery Customer\Vehicle Model DOI MSIL CIAZ Hybrid MSIL ERTIGA Hybrid Sept 15 DIN 55 ISS MSIL-Baleno (Export- Europe) Dec 15 N55 ISS MSIL-Baleno (Export- Japan) Dec 15 AUTOMOTIVE SBU - TALOJA

9 OPPORTUNITIES IN INDIA CONSIDERING THE SUCCESS STORY OF MSIL, ALL MAJOR CAR MANUFACTURERS OF INDIA HAVE ANNOUNCED HYBRID VEHICLE LAUNCH PROGRAMME

10 ISS BATTERIES (Gen-2) UNDER SUPPLY EXIDE CONSERVO N55-ISS BATTERY IN 48V RETROFIT KITS BY M/S ALTIGREEN PROPULSION LABS Altigreen technologies makes mild hybrid Retrofit kits, which won many international awards like IDTechEx Europe 2016 award for the Most Significant Innovation in Electric Vehicles. Altigreen had joined the list of Top 20 Automotive Tech Solutions of 2016 by CIO Review, USA. N55 : Gen 2 - ISS Battery FUNCTIONALITIES SUPPORTED BY N55 BATTERY : IDEAL START-STOP POWER ASSIST REGENERATIVE BRAKING

11 ON GOING PROJECTS NEW PRODUCT DEVELOPMENT - OEM Sl. No. Project Battery Type Present Status 1 TOYOTA ISS DIN60 2 TOYOTA ISS DIN 75 3 NISSAN ISS DIN 70 4 FIAT ISS DIN 70 5 HONDA ISS 12V 60AH 6 TML ISS 115D31L Technical specifications of battery and test standards are received Samples have been submitted to few OEM for their preliminary test and validation 7 M&M ISS 85D26R 8 M&M ISS 115D31R 9 CATERPILLAR ISS DIN 90

12 EFFECTS OF PSoC APPLICATION ON THE BATTERY Fig: The impact of HRPSoC on Battery capacity [3] Fig: SEM images of NAM, a) healthy state b) sulfation State [3] Under PSoC condition, Battery is subjected to various critical conditions. With increase in cycles it may lead to the different types of failure as shown in the figure as discussed in Jun furukawa et al [5] Fig: Failure modes of the lead acid batteries

13 Why ISS Vehicles Require Advanced Battery? Parameter Why different? (Hybrid Vehicle Feature) Modifications Charge acceptance To attain full state of charge (SOC) during short period between stops (Break Energy Regeneration) Negative plate recipe Advanced corrosion resistant Ca Alloy Advanced Paste Technology CCA To achieve frequent and fast restarting of vehicle at lower SOC. (Idle Engine Start/Stop) Negative plate recipe Advanced corrosion resistant Ca Alloy Advanced Paste Technology Water Consumption To retain maintenance free characteristic. (Idle Engine Start/Stop, Break Energy Regeneration) Optimization of Carbon content and adequate ratio with other expanders High endurance- Higher Cycle Life Many-fold use of battery in Hybrid vehicle than in Conventional vehicle (Idle Engine Start/Stop, Break Energy Regeneration, Power Assist) Advanced corrosion resistant Ca Alloy Special additive in Electrolyte

14 DESIGN PARAMETERS PARAMETER Brief Remarks ALLOY Base alloy C21 alloy (Ca,Ba,Sn,Al) Ca Sn-Ag Both alloys are Highly corrosion and creep resistant [5] POSITIVE PLATE Additives Additive A Additive E+A NEGATIVE PLATE Additives High paste Density- oxide mill particle size < 6 μm Expanded Negative grid results in thinner plates B Carbon Black- Surface Area > 800sq.m/gm Max. Particle size <125 μm C BaSO 4 - particle size < 0.8 ± 0.1 μm ASSEMBLY COS Pb-Sb alloy Effective utilization of active material Less internal resistance Carbon enhances the charge acceptance [6-7] Controls the growth and porosity of PbSo 4 crystals[8] D Vanilex-N Prevents the solidification of spongy lead [8] PAM/NAM RATIO More amount of NAM plays a role in increasing the CA PE ENVELOPE Special Grade

15 TESTS CONSIDERED FOR ISS APPLICATION 1 CHARGE 90% SOC, ROOM TEMPERATURE 2 SBA LIFE CYCLE SBA S 0101 : EUCAR POWER ASSIST PROFILE LIFE CYCLE 4 NEDC LIFECYCLE % DOD CYCLE 27 C 6 50 % DOD CYCLE 40 C

16 SBA LIFE CYCLE SBA S 0101 : 2006 SBA S 0101:2014 TEST CONDITION : 25 ± 2 º C (ROOM TEMPERATURE) Test Standard : SBA S 0101 : 2006 NEW SBA CYCLE 2014: AIR WIND VELOCITY < 2 m/s Charge 100A STEP -1 : 59 SEC 45 A 18.3 x I V 1 CYCLE STEP-2: CONSTANT 14 V, 1 SEC 60sec 300 A 300 A 45A STEP-3: CONSTANT 14 V, 60 SEC 300A 1sec 100 A 59sec 100 A Discharge STEP- 4 : AFTER 3600 CYCLES REST FOR HRS Battery is discharged to lower SOC in new SBA STEP -5 : TOPPING UP WITH WATER ONLY AFTER cycles NOT MENTIONED MENTIONED LIFE CYCLE IS STOPPED ONCE TEST BATTERY REACHES 7.2 V

17 EUCAR POWER ASSIST PROFILE EUCAR POWER ASSIST PROFILE : EUCAR TEST: STEP-1: C 2 up to 60% SOC STEP-2: Start EUCAR profile run for 10K cycles (1 unit) STEP-3: 16V/12.6A for 20 hour STEP-4: Discharge at C 2 rate upto 10.2 volts (note down C 2 capacity) STEP-5: Recharge at 16V/12.6A for 24 hrs REPEAT: Again repeat from step-1 to step -5 END CONDITION : C2 capacity 50% of initial value/ Voltage drop 8.4V FOR example, N55 ISS BATTERY C 20 = 45 AH C 2 = 25.2 AH CYCLE LIFE TEST parameters EUCAR MODIFIED OPERATING TEMPERATURE 25 ºC 40 ºC C 2 (Current, A) 12.6 A 18 A 5 C 2 63 A 90 A

18 DISCHARGE CHARGE DISCHARGE CHARGE NEDC LIFE CYCLE 150 NEDC DAY MODE 100 CURRENT (A) TIME (S) NEDC NIGHT MODE CURRENT (A) TIME (S) NEDC Test Temperature = 25 ºC Initial condition : 100%SOC NEDC(Day + Night mode) should be run up to six days (i.e.,432 cycles) Rest period for a day, then the NEDC is repeated again End condition: Voltage reaches (V) 8.0 V Or Internal resistance(ω) 10 Ω OEM requirement hybrid vehicle 4000 cycles for mild

19 current in Amps Current in Amps 1. CHARGE ACCEPTANCE N55 ISS DIN70 ISS CURRENT V/S. TIME FOR 1 MIN OF CHARGING CA TEST AT 90% SOC, 25 C, I MAX CHARGE = 100A Sample A Time in sec CURRENT V/S. TIME FOR 1 MIN OF CHARGING CA TEST AT 90% SOC,25 C, I MAX CHARGE = 100A Sample B Sample E Sample F Time in sec Sample A Sample B Sample E Sample F

20 sec voltage sec voltage 2. SBA LIFE TEST N55 ISS SBA LIFE TEST N55 ISS VOLTAGE AFTER 1 SEC 300A SBA life cycles achieved: N55 ISS Cycles DIN70 ISS cycles No. of cycles DIN70 ISS 12 SBA LIFE TEST DIN 70 ISS VOLTAGE AFTER 1 SEC 300A No. of cycles

21 Water loss (gms/ah) 3. WATER LOSS TEST DIN70 ISS TEST C,14.4 V, 28 DAYS REQUIREMENT: weight loss 1 gm/ah Loss of weight (gm/ah) Sample

22 4. EUCAR - Life Expectancy based on Discharge Energy Cycles achieved : cycles

23 CUT OPEN ANALYSIS AFTER EUCAR POSITIVE COULD BE ROLLED SPIDER DIAGRAM

24 FIELD RESULTS FAILURE MODE ANALYSIS Failure mode of DIN70 ISS batteries tested on fleet vehicles Sr. Kilometers completed Major Failure modes PAM softening Positive Grid corrosion Positive Grid corrosion Sedimentation Positive Grid corrosion Sedimentation Positive Grid corrosion Observation: Positive Grid corrosion is major cause of battery failure

25 FUTURE CHALLENGES EUROPEAN MANUFACTURERS ABIDING BY EN STANDARD TEST LEVEL M1 LEVEL M2 LEVEL M3 MICRO-HYBRID TEST Normalized mean R dyn increases 1.5 after 8000 cycles U(EOS) 9.5 Volts. C e 50% after 8000 cycles 17.5% DoD CYCLE TEST 9 units 15 units 18 units 50% DoD CYCLE TEST 150 cycles 240 cycles 360 cycles Dynamic charge acceptance EN , clause 7.3 Test under going, Target is to achieve I DCA 0.40

26 17.5 % DOD cycle test 17.5% DOD - TEST PROCEDURE Step-1 : Discharge the battery for x I 20, 27 C Step-2: Perform cycle A 85 times. Step-3 : Charge for 18 2 I 20, 16V, 27 C Step-4: perform the capacity test C 20 Step- 1 to 4 is counted as 1 unit SWITCH OFF CRITERION AT EACH END OF STEP IS V 10 V Cycle A Charge for 40 7 I 20, 14.4 V Discharge for 30 7 I 20 MEETING LEVEL M1 as per EN

27 REFERENCES [1] The International Council on Clean Transportation Website ( ) [2] J.Valencio, M.Fernandez, F.Trinidad, L.Sanz, Journal of power sources 187 (2009) [3] Jun yang, Chen Hu, Hao wang, kai Yang, Jing Bing Liu and Hui yan, International journal of Energy Research (2016) DOI: /er 3613 [4] Article name : What is Fame Indian scheme? ( [5] Kenji Nakano, Syuhei Takeshima and Jun Furukawa. Furukawa Review, No [6] Ellen Ebner, Daniel Burow, Alexander Borger, Michael Wark, paolina Atanassova, Jesus Valencio, Journal of power sources 239(2013) [7] Patrick T. Moseley, David A.J.Rand, Ken Peters, Journal of power sources 295 (2015) [8] Pavlov.D, Lead Acid Batteries : Science and technology, Copyright 2011, Elsevier B.V.

28 ACKNOWLEDGEMENT The Authors acknowledge the contributions made by other R&D colleagues Mr. SS Vaze, Ms. Asma Khan and Mr. Mohan Tirukoti in compiling and interpreting the test results & graphs.

29 Thank you