TC21X STANDARDIZATION ACTIVITIES FOR START-STOP BATTERIES

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1 TC21X STANDARDIZATION ACTIVITIES FOR START-STOP BATTERIES Jörn Albers, Torsten Hildebrandt, Jürgen Bauer Johnson Controls Power Solutions EMEA, CENELEC TC21X

2 Agenda Different levels of standardization European standardization of Secondary Cells and Batteries Family of EN Standards Battery Requirements of cars Start-Stop New project group pren Main working topics of pren New test procedures Classification of types and labels Alignment between pren and pren Update Timing of pren and pren Conclusions 2

3 Different levels of standardization IEC - International Electrotechnical Commission International Committee for Electrotechnical Standardization Responsible for standardization in the electrotechnical engineering field Technical Committee TC21 (Secondary Cells and Batteries) and SC21A (Secondary cells and batteries containing alkaline or other non-acid electrolytes) CENELEC - European Committee for Electrotechnical Standardization European Committee for Electrotechnical Standardization Responsible for standardization in the electrotechnical engineering field Technical Committee TC21X (Secondary Cells and Batteries) National standardization committees National committee for electric standardization Member of IEC / CENELEC Different working groups to mirror IEC / CENELEC technical committees 3

4 European standardization of Secondary Cells and Batteries CENELEC Technical Committee 21X Secondary Cells and Batteries Technical committee that handles standardization tasks of Secondary Cells and Batteries - Mirror committee to IEC TC21 Chairman Mr. Douady (Exide) / Secretary Mr. Hildebrandt (Johnson Controls) WG 1 Safety Requirements WG 3 Starter Batteries WG 5 Lithium LEV pren pren

5 Family of EN standards for lead acid start starter batteries UPDATE Part 1: General requirements and methods of test Part 2: Dimensions of batteries and marking of terminals Part 3: Terminal system for batteries with 36 V nominal voltage Part 4: Dimensions of batteries for heavy vehicles Part 5: Properties of battery housings and handles NEW Part 6: Batteries for Micro Cycle Applications NEW Part 7: General requirements and methods of tests for motorcycle batteries 5

6 Battery Requirements of cars with Start-Stop The battery has to withstand much more cycling: Discharge during STOP phase Engine re-crank in START phase Recharge while driving Regeneration of braking energy in addition to Start-Stop: Battery operation at partial state of charge Recharge at higher voltages than usual No full recharge to 100% SoC New set of requirements that are not covered by set of test procedures defined in the current EN Lack of field experiences and knowledge about long term failure modes Discharge Discharge Recharge 6

7 New project group pren A new project has been started in February 2011 at CENELEC TC21X - WG1 to setup the new standard: EN Lead acid starter batteries, Part 6: Batteries for micro-cycle applications This project raised an huge interest in battery and automotive industry that caused very good participation levels in over 10 joint working meetings. RENAULT EXIDE FORD MOLL FIAT ROMBAT JAGUAR LANDROVER AUDI FIAMM VW VIPIEMME YUASA BANNER VOLVO BMW GS YUASA PSA PEUGEOT CITROEN Johnson Controls 7

8 Main working topics of pren Ability of a battery to provide the power to restart the engine after frequent stop phases, recovering state of charge and aging effects due to shallow load pulses. Dynamic charge acceptance Ability of a battery to adsorb current peaks at different state of charge levels after charging or discharging operation. Micro cycling Battery for micro cycle application Classification of types and labels Ability of a battery to deliver energy under high cyclic conditions in a partially discharged state of charge Endurance Classification is needed that any kind of end user is able to select the adequate battery for the micro-cycle application 8

9 pren Test procedures Micro Cycling Micro Hybrid Test (MHT) Micro cycling MHT simulates Start-Stop applications Starts at SoC of 85% DoD of 2% C nom, fixed relative to battery size Test in water bath to avoid temperature excursions 10 sec of rest time after 300A DCH pulse Rest phases of 12h after each 100 cycles Maximum of 8000 cycles N = 1 Start PAU 10 s CHA (1+t DCH ) s 14,0 V / 100 A DCH t DCH s 48 A DCH 1 s 300 A N = N + 1 N < 100? U(1s) 9,5 V? Yes Yes No No End N = 1 PAU 12 h tt DDDDDD [ss] = (0,02 CC nnnnnn 0,083 AAh) 48 AA

10 pren Test procedures Micro Cycling Micro Hybrid Test (MHT) Micro cycling Evaluation for each 100 cycle units: Average dynamic internal resistance normalized to mean value of first unit Minimum end of discharge voltage during 300 A discharge step Requirements: Minimum U 300A > 9.5 V Increase of mean internal resistance during test < 1.5 min U(EOS)300A [V] normalized av Rdyn 1,50 1,45 1,40 1,35 1,30 1,25 1,20 1,15 1,10 1,05 1,00 12,00 11,50 11,00 10,50 10, Units 9, Units 10

11 pren Test procedures Dynamic Charge Acceptance Dynamic charge acceptance DCA procedure consists of three parts: 1) Battery pre-conditioning: 2 x RC cycles and 1 x C/20 cycle Battery preconditioning 2) Charge acceptance tests After discharge history (SoC 100% 90%) After charge history (SoC 0% 80%) Charge acceptance 3) Cycle test (simulation of real-life operation) 3 x 30 min driving per day Key-off loads simulated by resistor connected to battery during testing Test duration of part three: 5 days Start-Stop cycling 11

12 pren Test procedures Dynamic Charge Acceptance Dynamic charge acceptance Separation between different available performance classes of lead acid starter batteries Requirement: DCA 0.1 A / Ah a = conventional flooded b = mechanically enhanced flooded (EFB) c = EFB with innovative negative electrodes d = conventional AGM Further information: Eckhard Karden et al.: Test Methods for Dynamic Charge Acceptance (DCA) of Microhybrid Starter Batteries 13ELBC September

13 pren Test procedures Endurance two cycling tests Endurance 17.5 % DoD at 50% SoC: Well known VDA test (aka AK3.4 test) published for the first time in an European standard Checks if a battery can deliver energy under high cyclic conditions in a partly discharged state of charge. Water bath at 25 C 12,5 Cycling procedure: U(EOS) [V] 12,0 11,5 11,0 10,5 10,0 85th Dch Pre-Dch Unit DCH 4 I n for 2.5 h (50 % DoD) CHA 40 min with 14.4 V and I max = 7 I n DCH 7 I n for 30 Min (17.5 % DoD) CHA 18 h with U= 14.8V / 16.0 V and I max = 2 I n DCH I n until 10.5 V CHA 24 h with U= 14.8V / 16.0 V and I max = 5 I n 85 x 13

14 pren Test procedures Endurance two cycling tests Endurance 50 % DoD after deep discharge: Checks if a battery can withstand a deep discharge without losing its cycling performance. New test definition taken over from pren Update Water bath at 40 C End of discharge voltage U(2h) [V] 12 11,8 11,6 11,4 11, ,8 10,6 10,4 10, Cycle Cycling procedure: DCH 5 I n for 2 h U DCH 10.0 V CHA max 5 h with U= 14.4 V / 15.6 V and I max = 5 I n or until CR 1.08 CHA max 1 h with constant current until CR

15 pren Classification of types and labels As batteries for micro-cycle applications are special designed it is important that any user can clearly identify the adequate battery needed for the application. A classification and labeling system was defined in alignment with pren Update: Mandatory label in accordance with new pren Update All batteries passing pren must fulfill all requirements of new pren as well Micro-cycle performance level M1 M3 introduced The mandatory label can be completed with optional Start-Stop symbol W1 W5 : C1 C2 : V1 V4 : M1 M3 : Water consumption level Charge retention level Vibration level Micro-cycle performance level Classification of types and labels 15

16 pren Classification of types and labels - Example Classification of types and labels VRLA12V 70Ah 760A EN : W5-C2-V2-M3 12V 70Ah 650A EN : W3-C2-V2-M1 AGM EFB 16

17 Alignment between pren and pren Upate pren pren Update In parallel a rework of EN has been developed as well. A close cooperation between both project groups was established EN is an extension of EN Same modules of test procedures have been used in both standards to minimize test efforts concerning timing, equipment and complexity 17

18 Timing of pren and pren Both project groups have submitted a draft for Enquiry that is distributed to the national committees of the European member states: pren End of Enquiry phase October 2014 Start of formal voting August 2015 Final document available December 2015 pren End of Enquiry phase August 2014 Start of formal voting June 2015 Final document available October 2015 If there are any comments or remarks concerning these new standards please submit via your national committee! 18

19 Conclusions The standardization of test methods and requirements for lead acid Start-Stop batteries was one of the main activities of CENELEC TC21X during the last 3 years. Basic research programs have been started in the individual sub groups to derive the battery requirements from experiences with real driving profiles and existing laboratory tests. A close cooperation with EN was used to ensure that EN will be an extension to the existing and the new version of EN Both standards will represent the actual increased requirements for lead acid starter batteries. 19

20 TC21X Standardization Activities for Start-Stop Batteries Thank you for your attention. 20

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