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Chapter 5

Summary of Battery Pack Validation

To ensure safe operating performance of a battery pack using A123 cells, the battery pack must be designed 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 design guidelines to follow while
designing the product. This chapter includes the following sections:

•

Performance Testing

•

Abuse Testing

•

Compliance Testing

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Содержание AHR32113M1Ultra-B

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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