Unit 2 Battery Storage Unit: Department of Mechanical Engineering

Unit 2 Battery Storage Unit
Electric Vehicle
Prof. Praveen P. Rathod

Praveen.rathod@viit.ac.in
Department of Mechanical Engineering
BRACT’S, Vishwakarma Institute of Information Technology, Pune-48
(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
Teaching Scheme: Credits:
•TH: -- 03 hrs/week
TH:--03
•PR.: - 02 hr/week OR:-- 01
Examination Scheme:
Insem-30
Endsem-30
CE-20
Competency Skill: -20
03/29/2023
Department of Mechanical Engineering, VIIT , Pune-48
Objective`
• To understand the comprehensive overview of Electric and Hybrid

Electric Vehicles.
Learning Outcome/Course Outcome
• Describe the different electrical propulsion unit and battery storage

unit.
Department of Mechanical Engineering, VIIT , Pune-48 3

Syllabus:
• Introduction to Energy Storage Requirements in Hybrid
and Electric Vehicles, Basics – Battery Types, Battery-
Lead acid batteries, lithium batteries, Nickel-Metal
Hydride Batteries, Introduction to BMS, Fuel Cell based
energy storage, Hybridization of different energy storage
devices.
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Introduction to components used in hybrid and electric
vehicles
Electric Vehicle (EV) Configurations :
Compared to HEV, the configuration of EV is flexible.
• The energy flow in EV is mainly via flexible electrical wires rather than bolted flanges or rigid shafts.
Hence, distributed subsystems in the EV are really achievable.
• The EVs allow different propulsion arrangements such as independent four wheels and in wheel
drives.
The EV has three major subsystems: The energy source subsystem consists of
• Electric propulsion • The energy source (battery, fuel cell, ultracapacitor)
• Energy source • Energy management unit
• Auxiliary system
• Energy refueling unit
The electric propulsion subsystem comprises of:
• The electronic controller
• Power converter The auxiliary subsystem consists of
• Electric Motor (EM) • Power steering unit
• Mechanical transmission • Temperature control unit
• Driving wheels
• Auxiliary power supply
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General Configuration of a Electric Vehicle
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In modern EV’s configuration:
• Three phase motors are generally used to provide the traction force
• The power converter is a three-phase PWM inverter
• Mechanical transmission is based on fixed gearing and a differential
• Li-ion battery is typically selected as the energy source
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• EV configurations
EV configuration with clutch, gearbox and

EV configuration without clutch and gearbox
differential
EV configuration with clutch, gearbox and differential EV configuration with two EM

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• EV configuration without clutch and gearbox
configuration with in wheel motor and mechanical gear configuration with in wheel motor and no
mechanical gear
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• Electric Vehicle (EV) Drivetrain Alternatives Based on Power Source
Configuration
EV configuration with battery source EV configuration with two battery sources
EV configuration with battery and fuel cell sources EV configuration with multiple energy sources
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EV configuration with battery and capacitors EV configuration with battery and flywheel sources
sources
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Faculty Name(optional), Department of ______Engineering,
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Energy Storage ( Batteries )
Introduction
 A battery consists of two or more electric cells joined together.

 It is the chemical reaction between the electrodes and the electrolyte which generates DC electricity.
 The ‘lead acid’ battery is the most well known rechargeable type.
 The first electric vehicle using rechargeable batteries preceded the invention of the rechargeable lead
acid by quarter of a century.
 number of combinations have been developed as commercial rechargeable electric batteries suitable
for use in vehicles.
Overview of Batteries
From the electric vehicle designer’s point of view the battery can be treated as a ‘black box’ which has a
range of performance criteria.
03/29/2023
Range of performance criteria for battery pack
 specific energy
 energy density
 specific power
 typical voltages
 amp hour efficiency
 energy efficiency
 commercial availability
 cost, operating temperatures
 self-discharge rates
 number of life cycles
 recharge rates
The designer also needs to understand how energy availability varies with regard to:
 ambient temperature
 charge and discharge rates
 battery geometry
 optimum temperature
 charging methods
 cooling needs.
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Battery Parameters
• Cell and battery voltages
Simple equivalent circuit model of a battery. This battery is composed of six cells
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Battery Parameters
Charge (or Ahr) capacity :The electric charge that a battery can supply is clearly a most crucial parameter.
Energy stored :The energy stored in a battery depends on its voltage, and the charge stored.
Energy in Whr =V X Ahr
Specific energy:Specific energy is the amount of electrical energy stored for every kilogram of battery mass.
Energy density: Energy density is the amount of electrical energy stored per cubic metre of battery volume.
Specific power:Specific power is the amount of power obtained per kilogram of battery.
Ahr (or charge) efficiency: In an ideal world a battery would return the entire charge put into it, in which case
the amp hour efficiency is 100%.
Energy efficiency:it is defined as the ratio of electrical energy supplied by a battery to the amount of electrical
energy required to return it to the state before discharge.
Self-discharge rates: Most batteries discharge when left unused, and this is known as self-discharge.
Battery temperature, heating and cooling needs: Although most batteries run at ambient temperature, some
run at higher temperatures and need heating to start with and then cooling when in use
Battery life and number of deep cycles: Most rechargeable batteries will only undergo a few hundred deep
cycles to 20% of the battery charge.
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Primary and Secondary Cells
• Primary cells are one time cells while secondary are

rechargeable
• If the reactions are reversed the cells are deemed as

secondary or rechargeable
Discharging
+
+
charging
+ →𝐴
+ →C
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Battery Landscape
Battery Cell Types

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Characterization of a battery
• All elements are associated with a standard potential based on its tendency to donate or accept electrons
• The reaction takes place at each of the electrodes are commonly referred to as half cell reactions. The oxidation
and reduction reaction at the anod and cathod has a STANDARED ELECTRODE POTENTIAL associated with
them.
• The maximum possible voltage that can be obtained from a cell is the difference between the electrode
potentials of the cathode and anode.
Ecell =Ecathode – Eanode
• Gibs free energy for the reaction provides an estimate of how much theoretical energy per mole is available for
a cell with this electrochemical configuration.

Structure of Common Battery

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Lead Acid Batteries
The best known and most widely used battery for electric vehicles is the lead acid battery. Lead acid batteries are widely
used in IC engine vehicles and as such are well known. However for electric vehicles, more robust lead acid batteries
that withstand deep cycling and use a gel rather than a liquid electrolyte are used. These batteries are more expensive to
produce.
When a lead-acid battery is discharged, the electrolyte divides into H2 and SO4. The H2 will combine with
some of the oxygen that is formed on the positive plate to produce water (H 2O),and thereby reduces the amount of
acid in the electrolyte. The sulfate (SO4) combines with the lead (Pb) of both plates, forming lead sulphate (PbSO 4)

Lead Acid Batteries
As a lead-acid battery is charged in the reverse direction, the action described in the discharge is reversed. The lead sulphate
(PbS04) is driven out and back into the electrolyte (H2SO4). The return of acid to the electrolyte will reduce the sulphate in the
plates and increase the specific gravity. This will continue to happen until all of the acid is driven from the plates and back into
the electrolyte

Nominal battery parameters for lead acid batteries

Lead Acid Battery Advantages
•Mature technology.
•Relatively cheap to manufacture and buy (they provide the lowest cost per unit
capacity for rechargeable cells)
•Large current capability.
•Can be made for a variety of applications.
•Tolerant to abuse.
•Tolerant of overcharging.
•Wide range of sizes and specifications available.
Disadvantages
• It has low specific energy, poor weight to energy ratio.

• It can be charged slowly i.e. fully saturated charge takes 14 to 16 hours.
• It must be stored in charged condition in order to prevent sulfation.
• It has limited cycle life.

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Lithium Batteries
In 1980s rechargeable lithium cells have come onto the market.
It has increased energy density in comparison with other rechargeable batteries.
It is a well-established feature of the most expensive laptop computers and mobile phones that lithium rechargeable
batteries are specified, rather than the lower cost NiCad or NiHM cells that we have been considering earlier.
The lithium batteries are of following types:
Lithium polymer batteries :
• The lithium polymer battery uses lithium metal for the negative electrode and a transition metal
intercalation oxide for the positive.
• In the resulting chemical reaction the lithium combines with the metal oxide to form a lithium metal
oxide and release energy.
Lithium batteries come in a variety of forms, including lithium iron phosphate, lithium titanate, lithium nickel
manganese cobalt, lithium manganese oxide, and lithium nickel cobalt aluminum oxide.

The lithium ion battery
 The lithium ion battery was introduced in the early 1990
 it uses a lithiated transition metal intercalation oxide for the positive electrode and lithiated carbon for the
negative electrode.
 The electrolyte is either a liquid organic solution or a solid polymer
 Electrical energy is obtained from the combination of the lithium carbon and the lithium metal oxide to form
carbon and lithium metal oxide.

Charging of Lithium Ion Battery

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Advantages & Disadvantages of Li-ion Battery
Advantages: Lightweight lithium-ion batteries were first employed correctly in electric

vehicles in the pioneering Tesla Roadster, which was produced from 2008 to 2012.
It took about 3.5 hours to fully charge the car’s 6831 lithium ion batteries, which
weighed half a ton (1 100 pounds) and stored 53-kilowatt hours of energy when fully
charged, giving it a range of about 220 miles.
Newer Tesla have significantly better cells and far more range. A normal Tesla Model 3
has a 75-kilowatt-hour battery, which is half as much energy as a roadster, which has
just 4416 cells and has a range of 374 miles.
Disadvantages: Lithium ion batteries are only good for two to three years after they’ve
been made, and they’re susceptible to extreme temperatures. It is relatively expensive
to recharge a battery that has been entirely depleted.

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Nominal battery parameters for lithium ion batteries

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Metal Air Batteries
 Rechargeable alkali metal–air batteries are considered as the most promising for the power source of electric
vehicles (EVs) due to their high energy density.
 The metal air batteries represent an entirely different development, in the sense that the batteries cannot be
recharged simply by reversing the current.
 metal electrodes must be replaced by new ones.

The aluminium air battery
 Aluminum is combined with oxygen from the air and
water to form aluminum hydroxide, releasing electrical
energy in the process.
 This battery uses the oxidation of aluminum at the anode
and the reduction of oxygen at the cathode to form a
galvanic cell.
 In the process the aluminum is completely consumed to
produce aluminum hydroxide.
 The metal air battery has a very attractive energy density
because part of the reactants come from the air.
 They have been developed for long range power supplies
for electric vehicles.
 Aluminum–air batteries are primary cells, i.e., non-
rechargeable. Once the aluminium anode is consumed by
its reaction with atmospheric oxygen at a cathode
immersed in a water-based electrolyte to form hydrated
aluminium oxide, the battery will no longer produce
electricity.
Materials
Aluminum sheet- pie plate or foil
Paper towel-or water color paper Individual aluminum cells are housed
in old pill bottles and connected in
Charcoal Briquette or activated charcoal ground to a powderseries
.5” Copper foil tape with conductive adhesive
Salt water (saturated) with a little sodium carbonate
(washing soda)
First trial = aluminum foil, paper
Styrofoam container towel, carbon, copper and
Clip leads saltwater electrolyte. Credit:BEF

Nominal battery parameters for aluminium air batteries

Advantages of aluminum-Air Battery
• Aluminum Air Batteries do not require electricity as they do not require charging and thus are the biggest blessing for electric vehicles
and its user.
• The aluminum hydroxide solution generated in the used battery can be sent to a recycling unit to get 100% aluminum back. Aluminum
air batteries are 100% recyclable and thus safe for the environment.
• Aluminum air battery technology is safer because it uses only a water-based electrolyte that is free of toxins. and in a result, Aluminum
air batteries are EV Thermal Friendly.
Disadvantages of Aluminum-Air Battery
• These batteries have major disadvantages and challenges like they are not rechargeable.
• Once the aluminum anode is consumed by its reaction with atmospheric oxygen, the battery will no longer produce electricity. It just
stops working and has to be replaced.
• An aluminum-air battery would have to be taken to a battery swap station which is a big Disadvantage.

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The zinc air battery
 The zinc air battery is similar in many ways to the aluminum air battery but it has a much better overall performance
 specific power which is nearly ten times that of the aluminum air battery
 The structure is similar, with a porous positive electrode at which oxygen reacts with the electrolyte
 The negative electrode is solid zinc
 The energy from the battery is obtained by combining zinc with the oxygen in the air and forming zinc oxide.

Nominal battery parameters for zinc air batteries

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Nickel-Metal Hydride Battery (Electric Vehicle
Battery)

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• The nickel metal hydride battery is a type of nickel metal hydride battery. Another type
of electric vehicle is a hybrid vehicle, which has both a battery and a gasoline engine.
• These batteries do not require any external power to charge. When compared to
lithium-ion batteries, the charging of the battery is primarily dependent on the car’s
regenerative braking speed and wheels.
• Nickel metal batteries have a longer life cycle and are safer in intolerant situations.
• these batteries have a higher self-discharge rate, are much more expensive, and
generate significant amounts of heat in high temperatures.
• These drawbacks make nickel metal batteries a poor choice for vehicles whose batteries
must be charged from an external source.
• it dominated the hybrid vehicle market until lithium-ion technology arrived.
• They have good specific energy and specific power capacity.
• Nickel metal hydride batteries have a far longer life cycle than lead acid batteries, and
they are also much safer and more resistant to misuse.

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Advantages of nickel metal hydride battery
• Double energy density compared to lead acid battery.

• Harmless to the environment.
• Easily recyclable.
• Safe operation at high voltage.
• It can store volumetric power and energy.
• Cycle life is longer.
• The operating temperature range is long.
• It is resistant to overcharge and discharge.
Disadvantages of nickel metal hydride battery
• The reduced lifetime of around 200 to 300 cycles if discharged rapidly on high load
currents.
• High self-discharge and heat generation at high temperatures.
• Reduced usable power because of the memory effect.

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Solid-state Battery (Electric Vehicle Battery)

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• it is only in the last 10 years that progress has allowed for the adoption of
these technologies by the automotive industry in the not-too-distant
future.
• The idea is to replace the battery’s liquid electrolyte with a solid material,
which may be a plastic polymer compressed in organic granules or a
combination of the two. In theory, this technique is all positive.
• It allows for increased energy density and stability while also improving
temperature control.
• the solid state is still in the lab prototype stage, and the lithium-ion
battery has a long life ahead of it.

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Advantages of solid-state battery
• These batteries are capable of delivering 2.5 times more energy density as compared
to lithium ion batteries.
• These are comparatively more durable and safe.
• Less expensive and compact in nature.
• The recharge rate of solid state batteries is four to six times more than regular ones.
• The greater electrochemical stability of these batteries makes them more reliable.
Disadvantages of solid-state battery
• The mass production and manufacturing of these batteries are quite complex.
• Research of solid state batteries is still in progress and the perfect material for the
electrolyte with an ideal ionic conductivity is yet to be found.

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Nickel-Cadmium Battery (Electric Vehicle Battery)

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Nickel cadmium technology is recognizable to anyone who used
rechargeable batteries in the 1990s. The advantages of nickel cadmium
accumulators were numerous.
• Significant storage density.

• The lifespan of around 500 to 1000 charging cycles.
Nickel cadmium batteries, which were used in the production of

electric vehicles in the 1990s, are now prohibited due to cadmium’s
toxicity.

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Advantages of nickel cadmium battery
•Long lifetime.
•It can discharge fully without being damaged.
•It is easily recyclable.
Disadvantages of nickel cadmium battery

•Cadmium can cause pollution in case of not properly disposed of.
•It is costly for vehicular applications.

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Battery Charging
The battery charging involves:

• A battery charger
Charging a modern vehicle battery is not a simple matter of providing a constant voltage or current through the battery,
but requires very careful control of current and voltage. The best approach for the designer is to buy commercial charging
equipment from the battery manufacturer or another reputed battery charger manufacturer.
• Charge equalization
The way to prevent to fully charge the battery till each and every cell is fully charged (a process known as charge
equalization) at regular intervals.

Battery Management System
• A battery management system (BMS) is any electronic system that
manages a rechargeable battery (cell or battery pack), monitoring its
state, calculating secondary data, reporting that data, controlling its
environment, authenticating it and / or balancing it.
• A battery pack built together with a battery management system with

an external communication data bus is a smart battery pack. A smart
battery pack must be charged by a smart battery charger.

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A BMS may monitor the state of the battery as represented by
various items, such as:
• Voltage: total voltage, voltages of individual cells, or voltage of
periodic taps
• Temperature: average temperature, coolant intake temperature,
coolant output temperature, or temperatures of individual cells
• Coolant flow: for liquid cooled batteries
• Current: current in or out of the battery
• Health of individual cells
• State of balance of cells
Communication
•Different types of serial communications.

•CAN bus communications, commonly used in automotive environments.
•Different types of wireless communications.

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Protection
• Over-charging
• Over-discharging
• Over-current during charging
• Over-current during discharge
• Over-voltage during charging, especially important for lead–acid, Li-ion
cells
• Under-voltage during discharging, especially important for Li-ion cells
• Over-temperature
• Charging while under low temperature
• Over-pressure (NiMH batteries)

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Battery Management Controls: Measurement & protection of an automotive REESS,
specifically the BMS and its interactions with other vehicle systems.
• Fail-Safe Response to Faulted Conditions
• Diagnostics/Prognostics
• Sensor Validity/Integrity
• Cell Voltage
• Cell Temperature
• Cell Balancing

HEV/PHEV Status Indications
System Status Charge State Low Charge Discharge Rate/Range
BMW Mini E (BEV)
Chevrolet Volt (PHEV)
Fisker Karma (BEV+)
Nissan Leaf (BEV)
Tesla Roadster (BEV) (Regen Off)
Toyota Prius (PHEV)

HEV/PHEV Malfunction Indications
High Temp. 12V Fault REESS Fault Low Power Hazard
/Other
BMW Mini E (BEV)
Chevrolet Volt
(PHEV)
Fisker Karma (BEV+)
Nissan Leaf (BEV)
Tesla Roadster (BEV)
Toyota Prius (PHEV)

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Unit 2 Battery Storage Unit

Prof. Praveen P. Rathod

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

•PR.: - 02 hr/week OR:-- 01

• To understand the comprehensive overview of Electric and Hybrid

Learning Outcome/Course Outcome

• Describe the different electrical propulsion unit and battery storage

Department of Mechanical Engineering, VIIT , Pune-48 3

EV configuration with clutch, gearbox and

EV configuration with clutch, gearbox and differential EV configuration with two EM

EV configuration with battery source EV configuration with two battery sources

 A battery consists of two or more electric cells joined together.

• Primary cells are one time cells while secondary are

• If the reactions are reversed the cells are deemed as

Battery Cell Types

Department of Mechanical Engineering, VIIT , Pune-48

Ecell =Ecathode – Eanode

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

• It has low specific energy, poor weight to energy ratio.

Faculty Name(optional), Department of ______Engineering,

In 1980s rechargeable lithium cells have come onto the market.

It has increased energy density in comparison with other rechargeable batteries.

The lithium batteries are of following types:

Lithium polymer batteries :

Department of Mechanical Engineering, VIIT , Pune-48

 The lithium ion battery was introduced in the early 1990

 The electrolyte is either a liquid organic solution or a solid polymer

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Advantages: Lightweight lithium-ion batteries were first employed correctly in electric

Faculty Name(optional), Department of ______Engineering,

Department of Mechanical Engineering, VIIT , Pune-48

 metal electrodes must be replaced by new ones.

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Disadvantages of Aluminum-Air Battery

Faculty Name(optional), Department of ______Engineering,

 The negative electrode is solid zinc

Department of Mechanical Engineering, VIIT , Pune-48

Department of Mechanical Engineering, VIIT , Pune-48

Faculty Name(optional), Department of ______Engineering,

• it dominated the hybrid vehicle market until lithium-ion technology arrived.

• They have good specific energy and specific power capacity.

Faculty Name(optional), Department of ______Engineering,

• Double energy density compared to lead acid battery.

Disadvantages of nickel metal hydride battery

Faculty Name(optional), Department of ______Engineering,

Faculty Name(optional), Department of ______Engineering,

Faculty Name(optional), Department of ______Engineering,

Disadvantages of solid-state battery

Faculty Name(optional), Department of ______Engineering,

Faculty Name(optional), Department of ______Engineering,

• Significant storage density.