This report describes recommended abuse testing procedures for rechargeable energy storage systems (RESSs) for electric vehicles. This report serves as a revision to the FreedomCAR Electrical Energy Storage System Abuse Test Manual for Electric and Hybrid Electric Vehicle Applications (SAND2005-3123).
Lithium ion batteries for use in battery electric vehicles (BEVs) has seen considerable expansion over the last several years. It is expected that market share and the total number of BEVs will continue to increase over coming years and that there will be changes in the environmental and use conditions for BEV batteries. Specifically aging of the batteries and exposure to an increased number of crash conditions presents a distinct possibility that batteries may be in an unknown state posing danger to the operator, emergency response personnel and other support personnel. The present work expands on earlier efforts to explore the ability to rapidly monitor using impedance spectroscopy techniques and characterize the state of different battery systems during both typical operations and under abusive conditions. The work has found that it is possible to detect key changes in performance for strings of up to four cells in both series and parallel configurations for both typical and abusive response. As a method the sensitivity for detecting change is enhanced for series configurations. For parallel configurations distinct changes are more difficult to ascertain, but under abusive conditions and for key frequencies it is feasible to use current rapid impedance techniques to identify change. The work has also found it feasible to use rapid impedance as an evaluation method for underload conditions, especially for series strings of cells.
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Journal of Power Sources
Robust, safe, and reliable grid-scale energy storage continues to be a priority for improved energy surety, expanded integration of renewable energy, and greater system agility required to meet modern dynamic and evolving electrical energy demands. We describe here a new sodium-based battery based on a molten sodium anode, a sodium iodide/aluminum chloride (NaI/AlCl3) cathode, and a high conductivity NaSICON (Na1+xZr2SixP3−xO12) ceramic separator. This NaI battery operates at intermediate temperatures (120–180 °C) and boasts an energy density of >150 Wh kg−1. The energy-dense NaI-AlCl3 ionic liquid catholyte avoids lifetime-limiting plating and intercalation reactions, and the use of earth-abundant elements minimizes materials costs and eliminates economic uncertainties associated with lithium metal. Moreover, the inherent safety of this system under internal mechanical failure is characterized by negligible heat or gas production and benign reaction products (Al, NaCl). Scalability in design is exemplified through evolution from 0.85 to 10 Ah (28 Wh) form factors, displaying lifetime average Coulombic efficiencies of 99.45% and energy efficiencies of 81.96% over dynamic testing lasting >3000 h. This demonstration promises a safe, cost-effective, and long-lifetime technology as an attractive candidate for grid scale storage.
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Objective Statement: Development and demonstration of on-board diagnostics to determine battery state of stability and trigger a battery control system response to eliminate a impending safety related failure issues
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Objectives are: Serve as an independent abuse test laboratory for DOE and USABC; Abuse testing in accordance with the USABC abuse testing manual; Successful testing of all deliverables from developers under USABC contracts; Revise the USABC abuse testing manual; Test the propensity towards propagation of cell failure through multiple cell batteries; Provide mechanical testing support to develop and validate mechanical models for EV batteries; and, Evaluate the effect of cell age on abuse response.
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Journal of Power Sources
Traditionally, safety and impact of failure concerns of lithium ion batteries have dealt with the field failure of single cells. However, large and complex battery systems require the consideration of how a single cell failure will impact the system as a whole. Initial failure that leads to the thermal runaway of other cells within the system creates a much more serious condition than the failure of a single cell. This work examines the behavior of small modules of cylindrical and stacked pouch cells after thermal runaway is induced in a single cell. Cylindrical cells are observed to be less prone to propagate owing to the limited contact between neighboring cells. The electrical connectivity is found to be impactful as the 10S1P cylindrical cell module did not show failure propagation through the module, while the 1S10P module had an energetic thermal runaway consuming the module minutes after the initiation failure trigger. Modules built using pouch cells conversely showed the impact of strong heat transfer between cells. In this case, a large surface area of the cells was in direct contact with its neighbors, allowing failure to propagate through the entire battery within 60-80 s for all configurations (parallel or series) tested.
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