A123 Systems AHR32113M1Ultra-B Assembly Manual Download Page 1

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USER DOCUMENTATION

Date: March 6, 2014

Document #: 493005-002

Rev 02

Battery Pack Design, Validation, and

Assembly Guide using A123 Systems

Nanophosphate

Cells

Including:

APR18650

M1-

ANR26650

M1-

AHR32113

Ultra-B

AMP20

HD-A

Summary of Contents for AHR32113M1Ultra-B

Page 1: ...MENTATION Date March 6 2014 Document 493005 002 Rev 02 Battery Pack Design Validation and Assembly Guide using A123 Systems Nanophosphate Cells Including APR18650M1 A ANR26650M1 B AHR32113M1Ultra B AM...

Page 2: ...plications of A123 s products are appropriate and safe based on conditions anticipated or encountered during use In making this document available A123 is not rendering professional or other services...

Page 3: ...ashes 5 High Voltage 5 Chapter 2 6 Transportation Storage and Disposal 6 Transporting Batteries 7 Storing Batteries 16 Battery Disposal 16 Chapter 3 17 Nanophosphate Technology and Cell Characteristic...

Page 4: ...g 55 Compliance Testing 56 Chapter 6 57 Battery Pack Assembly 57 Incoming Cell Inspection 57 Material Handling and Storage 57 Cell Welding 58 Appendix A 61 Cell Specifications 61 AMP20M1HD A 62 ANR266...

Page 5: ...oncept 34 Figure 16 Individual cell fusing strategy 35 Figure 17 Example AMP20 cell fuse pattern in cell terminals 36 Figure 18 Example of a necked down connection to the cell which can act as a fuse...

Page 6: ...ischarge currents wrt temperature and SOC 65 Table 19 AMP20M1HD A Max 10s pulse discharge currents wrt temperature and SOC 65 Table 20 ANR26650M1 B cell specifications 72 Table 21 ANR26650M1 B Max con...

Page 7: ...ith A123 Nanophosphate cells This document may not be applicable to any cells not provided by A123 Anyone involved in the design use or assembly of products that use A123 cells should read and underst...

Page 8: ...pliance testing Chapter 6 Battery Pack Assembly describes the processes for cell incoming inspections material handling and storage and cell welding Appendix A Cell Specifications describes electrical...

Page 9: ...tems com resources overview htm http www iata org whatwedo cargo dgr Pages lithium batteries aspx http www ups com media news en intl_lithium_battery_regulations pdf http www welding consultant com ht...

Page 10: ...mains potentially dangerous to personnel and property therefore anyone attempting to design or handle battery packs must first completely understand all aspects of proper battery pack design and const...

Page 11: ...nition source to vented gases can create a dangerous thermal event The battery pack must ventilate these expelled gases to the environment after the gases are vented from the cell itself Short Circuit...

Page 12: ...ies Storing Batteries Battery Disposal This document does not constitute legal advice or training This document is not intended to substitute for training that may be required by laws and industry sta...

Page 13: ...lations HMR which is found at Title 49 of the Code of Federal Regulations Sections 100 185 All of these regulations that govern the transport of rechargeable lithium ion cells and batteries are based...

Page 14: ...Perform UN testing T1 T5 T7 for batteries 3 Obtain UN compliant packaging All Class 9 Dangerous Goods DG must be shipped in UN compliant packaging 4 Package the cell or battery Follow the packaging ma...

Page 15: ...s have transportation and packaging requirements based on their storage capacity Watt hours Wh or their equivalent lithium content ELC depending on the country of origin and transportation mode For pu...

Page 16: ...grams of ELC contained in the component cells of the battery Eq 3 ELC of a cell g 0 3 x Nominal Capacity Ah of a cell Eq 4 ELC of a battery g 0 3 x Nominal Capacity Ah of a cell x Number of cells in t...

Page 17: ...nd shipping paper requirements See IATA org for details ELC less than 5 0 g per cell Medium Excepted for Road and Rail transport in the US ELC greater than 5 0 g per cell Large Class 9 Yes Requires Cl...

Page 18: ...See Figure 7 4 H of the IATA Dangerous Goods Regulations Additional requierements apply when shipping by air Cell 20 Wh Class 9 Yes Requires Class 9 markings label specification packaging and shippin...

Page 19: ...A packaging and quantity restrictions PI 965 Requirement PI 965 Lithium Ion Cells and Batteries Section 1A Class 9 Section 1B Cell 20 Wh and Max Cell 8 pkg Section 1B Batt 100 Wh and Max Batt 2 pkg Se...

Page 20: ...cking if necessary Telephone number for additional information No Yes Yes Yes Yes Air waybill No No Lithium ion batteries in compliance with Section II of PI 965 if using an air waybill Lithium ion ba...

Page 21: ...d to 5 0 2 4 5 0 2 6 1 5 0 2 12 1 Inner packaging required to enclose battery Yes inner pack completely encloses then packed with equipment Yes inner pack completely encloses then packed with equipmen...

Page 22: ...uding circuit boards Cargo Aircraft only label must be on all shipments that are only allowed on Cargo Aircraft Note Competent Authority Approval is required to ship by air for at least the following...

Page 23: ...er A123 s Nanophosphate products can pulse at high discharge rates to deliver unmatched power by weight or volume Safety A123 s Nanophosphate technology is designed to be highly abuse tolerant while m...

Page 24: ...ains relatively flat during the discharges and the delivered Ah capacity does not change significantly no matter what the rate of discharge Figure 1 AMP20 cells discharge curves Discharge data for APR...

Page 25: ...tance becomes Figure 2 shows how temperature affects the cell s terminal voltage during a one hour discharge Figure 2 AMP20 cells discharge curves at various temperatures Discharge data for APR18650 A...

Page 26: ...ell life will be degraded or the cell will be rendered inoperable Cells must not be charged or discharged outside the operating temperature range as stated in the A123 Systems Safety Data Sheet SDS wh...

Page 27: ...charge 1C discharge rates Figure 4 shows how the cells lose capacity over time sitting at 100 State of Charge SOC in various temperatures Within three months the cells lose 3 of their initial capacity...

Page 28: ...ck Design This chapter includes the following sections Design Overview Configuration of Cells in a Battery Pack Battery Pack Structural Design Cell Protection Battery Pack Control Monitoring and Manag...

Page 29: ...rotect them This step requires knowledge of electrical mechanical and thermodynamic requirements and properties of the cells application and the materials used in the pack 3 The third step is to desig...

Page 30: ...ht voltage and currents to interface properly in the application Once a configuration of cells is chosen the designer must insure that the resulting ratings of the pack are compliant with the systems...

Page 31: ...x 3 3V 6 6V nominal Four cells in series 4 x 3 3V 13 2V nominal Connect strings of series cylindrical cells using their current collection tabs in a manner similar to that illustrated in the figure to...

Page 32: ...parallel Two cells in parallel 2 x 19 5Ah 39Ah nominal for AMP20 cells Four cells in parallel 4 x 19 5Ah 78Ah nominal for AMP20 cells Connect groups of parallel cylindrical cells using their current c...

Page 33: ...copper or copper alloy straps welded to the copper tabs and aluminum straps welded to the aluminum tabs For A123 cylindrical cells cell interconnections straps should be neither soldered on the cells...

Page 34: ...st possible service life the prismatic cell needs to be mounted with some amount of pressure on its two broad faces This pressure must be evenly distributed and be compliant to the regular expansion c...

Page 35: ...heir initial thickness Over the course of the cell s lifetime as it ages during regular service its thickness will grow to be 3 5 greater than initial thickness The graphs in Figure 8 show how much th...

Page 36: ...er which may be used between the AMP20 cells Using this chart one can choose the initial deflection 16 such that the regular expansion of the cell during its cycling keeps the pressure between 4 and 1...

Page 37: ...nd plate exerting pressure on the very end of the cell stack The more flexible this is the more variation in pressures one will see on the end cell s face The best way to determine this variation is b...

Page 38: ...example a poor choice of materials for the enclosure combined with insufficient cooling and controls may cause the battery pack to overheat AMP20 Cell Vents During abusive conditions such as Overcharg...

Page 39: ...ked together face to face there are two options to cool the AMP20 cells 1 Using tabs as thermal conductors to draw the heat out of the cells The tabs are conductors of electricity and therefore therma...

Page 40: ...ntain average cell temperatures of 35 C In contrast liquid cooling options employed by A123 can enable 4C peak and 2C continuous power and maintain average temperatures below 40 C These results are ex...

Page 41: ...the main fuse from blowing Likewise a fault at the module level will not cause the cell fuses to blow One can achieve this circuit protection strategy by having the individual cell fuses operate at a...

Page 42: ...to 0 2 mm copper clears in approximately one second while carrying 1800 A This and possible alternative designs should be verified using modeling software and bench testing prior to design release For...

Page 43: ...r current than that of the individual cell fuses This ensures that the module fuse blows before any of the cell fuses in response to a fault on the module terminals In addition the module fuse must in...

Page 44: ...tion can ensure safe operation of the battery pack even in fault conditions Once a prototype fusing strategy is in place the Device Verification Testing DVT process should perform the short circuit te...

Page 45: ...afety and durability of the pack the Battery Management System must monitor the voltage of each individual series cell in a battery string The voltage monitoring connections shall be in a place where...

Page 46: ...urrent is flowing in one direction and have less charge in it while current is flowing in the opposite direction So while the battery is discharging the BMS would try to balance some of the cells and...

Page 47: ...e wire for balancing current from the sensing wires eliminates a good portion of the error as shown in the following diagram Weld strap material with intrinsic resistance Rs per unit length Vcell1 Vce...

Page 48: ...ervoltage undervoltage over current and undercurrent Methods of supervising and controlling the battery pack include firmware based controls or special purpose integrated circuits Regardless of how th...

Page 49: ...can grow over time as each of the cells ages differently in response to its environment and physical construction Whether or not the BMS includes cell balancing in the pack management the BMS must at...

Page 50: ...specified by its amp hour Ah rating The chemistry of the electrode materials determines the amount of voltage potential that drives the charge out during discharge and must be overcome during recharge...

Page 51: ...voltage vs SOC at 23 C Figure 22 AMP20 cell vSOC sensitivity to OCV error 3 10 3 15 3 20 3 25 3 30 3 35 3 40 0 10 20 30 40 50 60 70 80 90 100 voltage V DOD Average DOD OCV hysteresis Averagevoltage V...

Page 52: ...current and time Based on a known starting SOC point the BMS calculates the present SOC by integrating the measured current going into and out of the battery This method is as accurate and resolved a...

Page 53: ...tegrated circuit controllers offer cell balancing protection SOC calculation and State of Health SOH estimation Some of them are fully programmable using custom firmware while others are programmed fr...

Page 54: ...harger shall cease charging when either Any one cell in the series string has exceeded its maximum recommended charge voltage or The temperature measured in the pack has gone outside the recommended r...

Page 55: ...zero This process charges the cells to 100 state of charge SOC Refer to Figure 25 for an illustration Figure 25 Battery voltage and current during recharge Recommended Fast Charge Method for Strings...

Page 56: ...extended float mode all the cells are balanced the BMS must monitor all the cell voltages throughout the float mode period If one of the cells has a higher self discharge rate than the others its term...

Page 57: ...to meet the design s current sharing specifications Voltage Limits During the end of a discharge the cell voltage will start to fall precipitously when it has less than 5 of its storable charge in it...

Page 58: ...e allowed to go under 0 5V This can cause permanent damage to the cells Discharge Cell Temperature Limits For optimum life do not continuously discharge the cells or batteries faster than the maximum...

Page 59: ...gned to pass a critical set of design validation tests This chapter summarizes the recommended minimal testing to be performed on a battery pack the performance criteria it must pass and a set of desi...

Page 60: ...ery voltage falls to 2 3 of the starting OCV Application Specific Cycle Tests Cycle the battery pack using the application s expected cycle profiles There are two application cycle testing goals One i...

Page 61: ...ectric Vehicle Applications Table 13 Abuse tests Name Description Short Circuit Tests the ability of the battery pack limit the output energy in the case of an accidental short circuit on its terminal...

Page 62: ...ds and their relevant applications Standard Type Application UL 1973 Safety US Market IEC 62133 Safety Non US Markets EU Directive 2006 66 EC EU Battery Directive EU and WW Markets FCC Part 15 Subpart...

Page 63: ...month at 25 C temperature Loss of greater than 3 5 per month is cause for concern and those cells should be quarantined for investigation Material Handling and Storage General Practices Minimize hand...

Page 64: ...time through the welded materials These parameters can be specified and regulated for a high quality weld every time Laser welding provides a consistent amount of heat to a controlled location which...

Page 65: ...electrodes However high current applications will require thicker straps 0 3mm Direct spot welding is less effective with these thick straps because the current cannot focused in a small enough spot...

Page 66: ...head Miyachi MDB 4000B welder coupled with the 88A EZ weld head Miyachi IS 120B inverter welding control and an IT 1040 3 transformer coupled with the 88A EZ weld head transformer requires water cool...

Page 67: ...61 Appendix A Cell Specifications This appendix includes specifications performance examples and diagrams for A123 s cells AMP20M1HD A ANR26650M1 B APR18650M1 A AHR32113M1Ultra B...

Page 68: ...ed float charge voltage 3 5V Recommended end of discharge cutoff 2 0V Recommended standard charge current 20A to 3 5V Recommended maximum charge current 60A to 3 6V Cell temperature 85 C Pulse 10s cha...

Page 69: ...outside the range of 40 C to 65 C Refer to Chapter 2 on page 6 for more information Storage Specifications Store cells in a dry location To minimize any adverse affects on battery performance it is re...

Page 70: ...ooled between cycles the cell s temperature may increase beyond the recommended maximum temperature limit The cells must be properly cooled with heat sinks or time must be allowed between cycles in or...

Page 71: ...200 185 173 161 158 158 157 153 148 147 0 0 200 106 99 93 91 91 90 88 85 85 0 10 118 52 49 45 45 45 44 43 42 42 0 20 46 21 19 18 18 18 17 17 16 16 0 30 17 8 7 7 7 7 7 6 6 6 0 40 0 0 0 0 0 0 0 0 0 0 0...

Page 72: ...20M1HD A Characterization Charts AMP20M1HD A Discharge Data at Various Rates AMP20M1HD A Discharge Data at Various Temperatures Cell Discharge Data for Various Discharge Rates 19 5 A Discharge 45 C to...

Page 73: ...P20M1HD A Cycle Life at Various Temperatures AMP20M1HD A Calendar Life at Various Temperatures Effect of temperature for 1C 1C 100 DOD cycling for AMP20 cells Capacity Loss for 100 SOC storage AMP20 c...

Page 74: ...vs SOC 3 10 3 15 3 20 3 25 3 30 3 35 3 40 0 10 20 30 40 50 60 70 80 90 100 voltage V DOD Average DOD OCV hysteresis Averagevoltage V 0 0004 0 0003 0 0002 0 0001 0 0 0001 0 0002 0 0 2 0 4 0 6 0 8 1 d O...

Page 75: ...25 0 30 0 35 0 40 0 0 10 20 30 40 50 60 70 80 90 100 Resistance mOhms SOC 60 Second Discharge DCR 20Amp Discharge All TemperaturesExcept 30 10Amp 20 C DCR 10 C DCR 0 C DCR 10 C DCR 23 C DCR 40 C DCR...

Page 76: ...70 AMP20M1HD A Dimensions and Drawing Figure 30 AMP20M1HD A cell dimensions...

Page 77: ...71 Figure 31 Notes for AMP20M1HD A cell dimensions drawing...

Page 78: ...oltage 3 3V Nominal Capacity 2 5Ah Maximum discharge current continuous A 40A Pulse discharge at 10 sec 70A Recommended standard charge 4A to 3 5 V Recommended fast charge 10A to 3 5V Recommended floa...

Page 79: ...ooled between cycles the cell s temperature may increase beyond the recommended maximum temperature limit The cells must be properly cooled with heat sinks or time must be allowed between cycles in or...

Page 80: ...0 30 1 1 1 1 1 1 1 1 1 1 0 40 0 0 0 0 0 0 0 0 0 0 0 Temp C SOC 0 10 20 30 40 50 60 70 80 90 100 85 0 0 0 0 0 0 0 0 0 0 0 65 0 40 40 40 40 40 40 40 40 40 40 30 0 40 40 40 40 40 40 40 40 40 40 25 0 40 4...

Page 81: ...75 ANR26650M1 B Characterization Charts ANR26650M1 B Discharge Data at Various Rates ANR26650M1 B Discharge Data at Various Temperatures...

Page 82: ...76 ANR26650M1 B Cycle Life at Various Temperatures ANR26650M1 B Calendar Life at Various Temperatures Estimated capacity fade for cells for 50 and 100...

Page 83: ...Circuit Voltage vs State of Charge ANR26650M1 B Temperature Effects on OCV vs SOC For examples of temperature effects on OCV vs SOC refer to the AMP20M1HD A chart on page 69 ANR26650M1 B DCR vs SOC at...

Page 84: ...tion for Various Charge Rates For examples of capacity degradation for various charge rates refer to the AMP20M1HD A charts on page 69 ANR26650M1 B Dimensions and Drawing Figure 32 ANR26650M1 B cell d...

Page 85: ...mum discharge current continuous A 16A Pulse discharge at 10 sec 28A Internal Impedance 1kHz AC 18 m typical Internal Resistance 10A 1s DC 27 m typical Recommended standard charge 3A to 3 5V Recommend...

Page 86: ...ooled between cycles the cell s temperature may increase beyond the recommended maximum temperature limit The cells must be properly cooled with heat sinks or time must be allowed between cycles in or...

Page 87: ...7 5 7 5 7 5 7 5 7 5 4 4 4 4 0 10 5 5 5 5 5 5 3 3 3 3 0 0 3 3 3 3 3 3 2 2 2 2 0 10 2 2 2 2 2 2 2 2 2 2 0 20 1 1 1 1 1 1 1 1 1 1 0 30 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 40 0 0 0 0 0 0 0 0 0 0 0...

Page 88: ...82 APR18650M1 A Dimensions and Drawing Figure 33 APR18650M1 A cell diagram and dimensions...

Page 89: ...Maximum discharge current continuous A 200A See Max Rate tables for more detail Pulse discharge at 10 sec 25 C A 350A See Max Rate tables for more detail Peak power 10 sec watts 550W Recommended stan...

Page 90: ...cooled between cycles the cell s temperature may increase beyond the recommended maximum temperature limit The cells must be properly cooled with heat sinks or time must be allowed between cycles in...

Page 91: ...16 16 33 36 36 37 20 23 23 24 0 10 C 11 11 20 21 21 22 14 15 15 16 0 0 C 5 9 5 9 8 9 9 9 10 5 10 9 7 5 8 8 9 0 9 2 0 10 C 4 2 4 2 4 7 5 1 5 8 6 0 5 9 7 1 7 8 7 8 0 20 C 1 8 1 8 1 5 2 8 2 9 3 1 3 1 3...

Page 92: ...86 AHR32113M1Ultra B Characterization Charts AHR32113M1Ultra B Discharge Data at Various Rates AHR32113M1Ultra B Discharge Data at Various Temperatures...

Page 93: ...87 AHR32113M1Ultra B Cycle Life at Various Temperatures AHR32113M1Ultra B Calendar Life at Various Temperatures Estimated capacity fade for AHR32113 for 50 SOC storage...

Page 94: ...ure Effects on OCV vs SOC For examples of temperature effects on OCV vs SOC refer to the AMP20M1HD A chart on page 69 AHR32113M1Ultra B DCR vs SOC at Various Temperatures AHR32113 Gen 2 cell Open circ...

Page 95: ...adation for Various Charge Rates For examples of capacity degradation for various charge rates refer to the AMP20M1HD A charts on page 69 AHR32113M1Ultra B Dimensions and Drawing Figure 34 AHR32113M1U...

Page 96: ...g and controlling the battery pack BOL Beginning of Life CC Constant Current A method to charge or discharge a battery in which the current is held constant independent of the battery s terminal volta...

Page 97: ...sting ELC Equivalent Lithium Content ESS Energy Storage System iSOC Current based SOC algorithm OCV Open Circuit Voltage voltage reading of a battery when there is no current going in or out of it SDS...

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