Is there really anything wrong with it? Generation II 2007 Toyota Prius 311,000 miles

Transcription

1

2 Is there really anything wrong with it? Generation II 2007 Toyota Prius 311,000 miles

3 Always make sure that the HV Disconnect is removed! Always use the proper protective equipment! 1,000 volt gloves

4 Battery Limiting and Energy Capacity Pack Power Drive Test (Five Cycles)

5 Compare your results with these percentages SOC%: Less than 5% outstanding Less than 10% could be serviced (talk about this) Less than 15% evaluate service Less than 20% evaluate service Always compare pre-soc to post SOC Compare V-Block high to V-Block low Battery SOC should never fall below 13 volts SOC% - State of Charge percentage

6 Inverter test using a PICO Scope and Fluke amp clamps

7

8 HV Gloves required beyond this point!

9

10 Removing the series of protective covers

11 No Gloves required while connecting the test leads! Take care to make sure no leads are crossed

12 Start with a Power Test!!! This doesn t look good!!!

13 Second Energy test!!! New leads connected.

14 Start a timed charging process It is vital to keep a close eye on the battery temps through out these processes as to not cause a thermal incident!!

15 Three phase charging: 2.5 amps for 2 hours 1.5 amps for 1 hour 1 amp for 1 hour Proper cooling is essential during this time, the more cooling the better!! Max temp should never exceed 50 degrees Celsius.

16 That looks much better, all cells are balanced!! After the cycling of the pack it is wise to redo the Power and Energy test!!

17 Before: 36mpg After: 48mpg

18 NICKEL-METAL HYDRIDE CONSTRUCTION Nickel-metal hydride (NiMH) is very similar in construction to a NiCd, in that it uses a positive electrode made of nickel hydroxide and potassium hydroxide electrolyte. The big difference is in the materials used in the negative electrode, which is a hydrogen storage alloy such as lanthanium-nickel or zirconium-nickel instead of cadmium. Like the NiCd, the nominal voltage of a NiMH battery cell is 1.2 volts.

19 NICKEL-METAL HYDRIDE CONSTRUCTION Interior of a NiMH battery. NiMH batteries are known as alkaline batteries because of the alkaline nature of their electrolyte.

20 A NiMH cell. The unique element in a nickel-metal hydride cell is the negative electrode. Note that the electrolyte does not enter into the chemical reaction and is able to maintain a constant conductivity regardless of the state-ofcharge of the cell. NICKEL-METAL HYDRIDE CONSTRUCTION

21 NICKEL-METAL HYDRIDE CONSTRUCTION Chemical reactions inside a NiMH cell. Charging and discharging both involve an exchange of hydrogen ions (protons) between the two electrodes.

22 A prismatic NiMH cell. Prismatic cells are built with flat plates and separators similar to conventional lead acid batteries. NICKEL-METAL HYDRIDE CONSTRUCTION

23 NICKEL-METAL HYDRIDE CONSTRUCTION A prismatic NiMH module from a Toyota Prius HV battery pack. The battery posts are located on the left and right sides of the module. A self-resealing vent is located on the top right for venting hydrogen gas if the module overheats.

24 NICKEL-METAL HYDRIDE CONSTRUCTION

25 NICKEL-METAL HYDRIDE Toyota Prius Panasonic Prismatic Battery Modules

26 NICKEL-METAL HYDRIDE Ford Escape Batteries Sanyo Cylindrical Battery

27 NICKEL-METAL HYDRIDE Honda Civic

28 LITHIUM-ION A battery design that shows a great deal of promise for and applications is lithiumtechnology. Batteries have been used extensively in consumer electronics since A cell is so named because during battery cycling, lithium ions move back and forth between the positive and negative electrodes. Has approximately twice the specific energy of nickel-metal hydride (NiMH).

29 ZINC-AIR The zinc-air design is a mechanically rechargeable battery. This is because it uses a positive electrode of gaseous oxygen and a sacrificial negative electrode made of zinc. The negative electrode is spent during the discharge cycle, and the battery is recharged by replacing the zinc electrodes.

30 SODIUM SULPHER Sodium is an element that shows good promise as a negative electrode material for batteries. Like lithium, sodium has a low atomic mass and can produce a relatively high voltage when used in a battery. Sulfur can work well as a positive electrode, and sodium and sulfur are both plentiful and cheap. Unfortunately, sodium (like lithium) is highly reactive and had to be used with a special electrolyte called beta alumina.

31 SODIUM-METAL-CHLORIDE The sodium-metal-chloride battery is quite similar in construction to the sodium-sulfur battery. The major difference is that the positive (sulfur) electrode is replaced with one made from either nickel-chloride or a combination of nickel-chloride and ferrouschloride. This type of battery utilizes two different electrolytes; first the beta alumina similar to the sodium-sulfur design, then another layer of electrolyte between the beta alumina and the positive electrode.

32 Battery Comparison

33 Li O 2 and Li S batteries with high energy storage

34 HV Battery SOC The state-of-charge (SOC) of a NiMH battery cannot be measured using cell voltage alone. Instead, SOC is determined using a complex calculation based on battery temperature, output current, and cell voltage. Accurate SOC measurements are critical for maximizing NiMH battery performance and service life.

35 Ken Mays Automotive Technology - COCC Dr. Michael Fisher, Dean - COCC Thank You