Simple electrode assembly engineering:Toward a multifunctional lead-acid battery

Electrochemical energy storage is a promising technology for the integration of renewable energy.Lead-acid battery is perhaps among the most successful commercialized systems ever since thanks to its excellent cost-effectiveness and safety records.Despite of 165 years of development,the low energy density as well as the coupled power and energy density scaling restrain its wider application in real life.To address this challenge,we optimized the configuration of conventional Pb-acid battery to integrate two gas diffusion electrodes.The novel device can work as a Pb-air battery using ambient air,showing a peak power density of 183 mW cm^(−2),which was comparable with other state-of-the-art metal-O_(2)batteries.It can also behave as a fuel cell,simultaneously converting H_(2)and air into electricity with a peak power density of 75 mW cm^(−2).Importantly,this device showed little performance degradation after 35 h of the longevity test.Our work shows the exciting potential of lead battery technology and demonstrates the importance of battery architecture optimization toward improved energy storage capacity.

Electric-controlled pressure relief valve for enhanced safety in liquid-cooled lithium-ion battery packs

The liquid-cooled battery energy sto rage system(LCBESS) has gained significant attention due to its superior thermal management capacity.However,liquid-cooled battery pack(LCBP) usually has a high sealing level above IP65,which can trap flammable and explosive gases from battery thermal runaway and cause explosions.This poses serious safety risks and challenges for LCBESS.In this study,we tested overcharged battery inside a commercial LCBP and found that the conventionally mechanical pressure relief valve(PRV) on the LCBP had a delayed response and low-pressure relief efficiency.A realistic 20-foot model of an energy storage cabin was constructed using the Flacs finite element simulation software.Comparative studies were conducted to evaluate the pressure relief efficiency and the influence on neighboring battery packs in case of internal explosions,considering different sizes and installation positions of the PRV.Here,a newly developed electric-controlled PRV integrated with battery fault detection is introduced,capable of starting within 50 ms of the battery safety valve opening.Furthermore,the PRV was integrated with the battery management system and changed the battery charging and discharging strategy after the PRV was opened.Experimental tests confirmed the efficacy of this method in preventing explosions.This paper addresses the safety concerns associated with LCBPs and proposes an effective solution for explosion relief.

Battery pack capacity estimation for electric vehicles based on enhanced machine learning and field data

Accurate capacity estimation is of great importance for the reliable state monitoring,timely maintenance,and second-life utilization of lithium-ion batteries.Despite numerous works on battery capacity estimation using laboratory datasets,most of them are applied to battery cells and lack satisfactory fidelity when extended to real-world electric vehicle(EV)battery packs.The challenges intensify for large-sized EV battery packs,where unpredictable operating profiles and low-quality data acquisition hinder precise capacity estimation.To fill the gap,this study introduces a novel data-driven battery pack capacity estimation method grounded in field data.The proposed approach begins by determining labeled capacity through an innovative combination of the inverse ampere-hour integral,open circuit voltage-based,and resistance-based correction methods.Then,multiple health features are extracted from incremental capacity curves,voltage curves,equivalent circuit model parameters,and operating temperature to thoroughly characterize battery aging behavior.A feature selection procedure is performed to determine the optimal feature set based on the Pearson correlation coefficient.Moreover,a convolutional neural network and bidirectional gated recurrent unit,enhanced by an attention mechanism,are employed to estimate the battery pack capacity in real-world EV applications.Finally,the proposed method is validated with a field dataset from two EVs,covering approximately 35,000 kilometers.The results demonstrate that the proposed method exhibits better estimation performance with an error of less than 1.1%compared to existing methods.This work shows great potential for accurate large-sized EV battery pack capacity estimation based on field data,which provides significant insights into reliable labeled capacity calculation,effective features extraction,and machine learning-enabled health diagnosis.

A hierarchical enhanced data-driven battery pack capacity estimation framework for real-world operating conditions with fewer labeled data

Battery pack capacity estimation under real-world operating conditions is important for battery performance optimization and health management,contributing to the reliability and longevity of batterypowered systems.However,complex operating conditions,coupling cell-to-cell inconsistency,and limited labeled data pose great challenges to accurate and robust battery pack capacity estimation.To address these issues,this paper proposes a hierarchical data-driven framework aimed at enhancing the training of machine learning models with fewer labeled data.Unlike traditional data-driven methods that lack interpretability,the hierarchical data-driven framework unveils the“mechanism”of the black box inside the data-driven framework by splitting the final estimation target into cell-level and pack-level intermediate targets.A generalized feature matrix is devised without requiring all cell voltages,significantly reducing the computational cost and memory resources.The generated intermediate target labels and the corresponding features are hierarchically employed to enhance the training of two machine learning models,effectively alleviating the difficulty of learning the relationship from all features due to fewer labeled data and addressing the dilemma of requiring extensive labeled data for accurate estimation.Using only 10%of degradation data,the proposed framework outperforms the state-of-the-art battery pack capacity estimation methods,achieving mean absolute percentage errors of 0.608%,0.601%,and 1.128%for three battery packs whose degradation load profiles represent real-world operating conditions.Its high accuracy,adaptability,and robustness indicate the potential in different application scenarios,which is promising for reducing laborious and expensive aging experiments at the pack level and facilitating the development of battery technology.

动力电池PACK智能制造复合型人才定向培养研究

分析了新能源汽车核心能量源——动力电池PACK制造的现状,根据当前动力电池PACK智能制造人才培养的现状,对动力电池PACK智能制造复合型人才定向培养路径进行了研究,为其他跨专业领域的复合型人才培养提供启示。

Analysis on the capacity degradation mechanism of a series lithium-ion power battery pack based on inconsistency of capacity

The lithium-ion battery has been widely used as an energy source. Charge rate, discharge rate, and operating tem- perature are very important factors for the capacity degradations of power batteries and battery packs. Firstly, in this paper we make use of an accelerated life test and a statistical analysis method to establish the capacity accelerated degradation model under three constant stress parameters according to the degradation data, which are charge rate, discharge rate, and operating temperature, and then we propose a capacity degradation model according to the current residual capacity of a Li-ion cell under dynamic stress parameters. Secondly, we analyze the charge and discharge process of a series power battery pack and interpret the correlation between the capacity degradations of the battery pack and its charge/discharge rate. According to this cycling condition, we establish a capacity degradation model of a series power battery pack under inconsistent capacity of cells, and analyze the degradation mechanism with capacity variance and operating temperature difference. The comparative analysis of test results shows that the inconsistent operating temperatures of cells in the series power battery pack are the main cause of its degradation; when the difference between inconsistent temperatures is narrowed by 5 ℃, the cycle life can be improved by more than 50%. Therefore, it effectively improves the cycle life of the series battery pack to reasonably assemble the batteries according to their capacities and to narrow the differences in operating temperature among cells.

Lifetime and Aging Degradation Prognostics for Lithium-ion Battery Packs Based on a Cell to Pack Method

Aging diagnosis of batteries is essential to ensure that the energy storage systems operate within a safe region.This paper proposes a novel cell to pack health and lifetime prognostics method based on the combination of transferred deep learning and Gaussian process regression.General health indicators are extracted from the partial discharge process.The sequential degradation model of the health indicator is developed based on a deep learning framework and is migrated for the battery pack degradation prediction.The future degraded capacities of both battery pack and each battery cell are probabilistically predicted to provide a comprehensive lifetime prognostic.Besides,only a few separate battery cells in the source domain and early data of battery packs in the target domain are needed for model construction.Experimental results show that the lifetime prediction errors are less than 25 cycles for the battery pack,even with only 50 cycles for model fine-tuning,which can save about 90%time for the aging experiment.Thus,it largely reduces the time and labor for battery pack investigation.The predicted capacity trends of the battery cells connected in the battery pack accurately reflect the actual degradation of each battery cell,which can reveal the weakest cell for maintenance in advance.

Research on thin grid materials of lead-acid batteries

A detailed investigation on Pb-Ca-Sn alloys was made in order to choose suitable grid alloys materials for thin plate lead-acid batteries. The electrochemical performances of alloys were investigated by electrochemical corrosion experiment, scanning electron microscope (SEM), and cyclic voltammetry (CV) test. The results indicate that Pb-Ca-Sn-Bi-Cu alloys can be used to make the grids used for thin grid lead-acid batteries, the content of bismuth has primary effects on the corrosion resistance of grid alloys, the composition of alloys plays an important role on batteries performance, and appropriate scale of elements can be choosed to obtain optimal electrochemical performance. The lead-acid batteries using this kind of grid show good performance by cycle life test.

Experiments Study on Charge Technology of Lead-Acid Electric Vehicle Batteries

The basic theory of the fast charge and several charge methods are introduced. In order to heighten charge efficiency of valve-regulated lead-acid battery and shorten the charge time, five charge methods are investigated with experiments done on the Digatron BNT 400-050 test bench. Battery current, terminal voltage, capacity, energy and terminal pole temperature during battery experiment were recorded, and corresponding curves were depicted. Battery capacity-time ratio, energy efficiency and energy-temperature ratio are put forward to be the appraising criteria of lead-acid battery on electric vehicle （EV）. According to the appraising criteria and the battery curves, multistage-current/negative-pulse charge method is recommended to charge lead-acid EV battery.

Thermal Management of Air-Cooling Lithium-Ion Battery Pack

Lithium-ion battery packs are made by many batteries, and the difficulty in heat transfer can cause many safety issues. It is important to evaluate thermal performance of a battery pack in designing process. Here, a multiscale method combining a pseudo-two-dimensional model of individual battery and three-dimensional computational fluid dynamics is employed to describe heat generation and transfer in a battery pack. The effect of battery arrangement on the thermal performance of battery packs is investigated. We discuss the air-cooling effect of the pack with four battery arrangements which include one square arrangement, one stagger arrangement and two trapezoid arrangements. In addition, the air-cooling strategy is studied by observing temperature distribution of the battery pack. It is found that the square arrangement is the structure with the best air-cooling effect, and the cooling effect is best when the cold air inlet is at the top of the battery pack. We hope that this work can provide theoretical guidance for thermal management of lithium-ion battery packs.

Modeling and Optimization of Heat Dissipation Structure of EV Battery Pack

In order to solve the problems of high temperature and inconsistency in the operation of electric vehicle（ EV） battery pack,computational fluid dynamics（ CFD） simulation method is used to simulate and optimize the heat dissipation of battery pack. The heat generation rate at different discharge magnifications is identified by establishing the heat generation model of the battery. In the forced air cooling mode,the Fluent software is used to compare the effects of different inlet and outlet directions,inlet angles,outlet angles,outlet sizes and inlet air speeds on heat dissipation. The simulation results show that the heat dissipation effect of the structure with the inlet and outlet on the same side is better than that on the different sides; the appropriate inlet angle and outlet width can improve the uniformity of temperature field; the increase of the inlet speed can improve the heat dissipation effect significantly. Compared with the steady temperature field of the initial structure,the average temperature after structure optimization is reduced by 4. 8℃ and the temperature difference is reduced by 15. 8℃,so that the battery can work under reasonable temperature and temperature difference.

PREPARATION OF LEAD-ACID BATTERY USING ELECTROPLATED RETICULATED SiC AS THE POSITIVE CURRENT COLLECTOR

The possibility of using Pb-electroplated reticulated SiC as the positive current collector for lead-acid batteries was investigated. Reticulated SiC with two aperture sizes (3 and 2mm) were tested as the substrate of positive electrode. It was found that the reticulated SiC has an excellent corrosion resistance in H2SO4 solution, and the Pb layer electroplated on reticulated SiC showed analogous electrochemical behavior to metal Pb. Preliminary test of the battery performance indicated that the utilization efficiency of the positive active mass of new designed batteries are improved compared with the conventional batteries. The improvement could be ascribed to the high specific surface area of the reticulated structured positive current collector, which was further supported by the even better performance of the battery made from a smaller aperture size (2mm) reticulated SiC as the substrate of the positive electrode.

Self-Discharge in Valve-Regulated Sealed Lead-Acid Batteries

Factors that cause the self-discharge in valve-regulated sealed lead-acid batteries are discussed and measures to inhibit the self-discharge are put forward.

Study of the Charge Acceptance of Small-Size Sealed Lead-Acid Batteries

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Research on Fuzzy PID Charging Control of Battery Pack

Battery groups are widely used in production and life. Optimal charging can not only shorten the charge time, but also improve the performance and life of the battery pack. A constant current or constant voltage charging method is commonly used. This type of method cannot adjust the charge capacity in time according to the change of charging capacity of storage battery, and the charge performance is not high. This paper designs a fuzzy PID controller. In the case of variable load and interference, the battery group can still be charged by the optimal charging current. Through the simulation results, the fuzzy PID controller works well and verifies the feasibility of the charging controller.

Mathematical Model and Experiment of Temperature Effect on Discharge of Lead-Acid Battery for PV Systems in Tropical Area

This paper presents Mathematical Model and Experiment of Temperature effect on Charge and Discharge of Lead-Acid Battery performance in PV system power supply. To test temperature effect on battery discharge cycles, a temperature range of tropical area from 25 - 60 degrees Celsius in a simulator is set up for testing. This temperature range is normally practical for battery usage. This allows the battery to determine the parameters of the battery quickly and high accurate. A Mathematical Model with MATLAB Program is written and constructed as block diagram using the equations of battery the parameters. By running program, the effects of various parameters are investigated. The results showed that time of discharge the battery is longer. Then, the experiment is set up by battery VRLA 12 V 20 AH. The results confirmed the mathematical model simulations.

Comparative study of the thermal insulation performance of steel and aluminum battery packs in high-and low-temperature environments

As the only power source of pure electric vehicles,the performance of battery packs is easily affected by the temperature,and too high or too low temperature will make the performance of battery packs decline.In this study,the thermal analysis finite element modeling of a cast aluminum battery pack and steel battery pack of a pure electric vehicle is established to compare the thermal insulation performance of two kinds of battery packs under high-and low-temperature conditions.The simulation results show that the thermal insulation performance of the two kinds of battery packs meets the design requirements under high-and low-temperature conditions.The external environment of the cell and battery pack mainly transmits heat through heat conduction.Aiming at the problem that the uniform temperature performance of the steel battery pack is lower than that of the cast aluminum battery pack,several optimization solutions are put forward for the insulation design of the steel battery pack,and the optimal solution is obtained by comparing the simulation results.

New Composite Equalization Strategy for Lithium Battery Packs

In order to improve the working efficiency of the power battery pack and prolong the service life, there is a problem of inconsistency among the individual cells. Based on the centralized equalization structure of the multi-output winding transformer, a three-stage hybrid equalization control strategy is designed for equalization. The equalization scheme realizes that the high voltage single battery transfers the energy to the low voltage battery cell during the charging of the battery pack, improving not only charging efficiency and energy use loss, but also the high voltage battery transferring the power to the low voltage battery cell when the pressure difference is greater than 10 mv during the discharge. Between 5 mv and 10 mv, it performs passive equalization, reducing the output fluctuation of the power battery pack and achieving the balance purpose. During the standing time, the maximum active balancing operation within the battery pack is performed in order to achieve intra-group optimum consistency. It is proved by experiments that the equalization control method can realize the quick and effective equalization in the battery pack, and the energy balance of each single battery.

A study on equivalent circuit model of lead-acid battery for electric vehicles

A 100Ah@42V lead-acid battery package for electric vehicles are used for study. 1he hybrid pulse test is applied to the battery package to acquire enough data, by which the partnership for a new generation of vehicles （PNGV） equivalent circuit model parameters are identified by the least square method. Then, the PNGV model is verified under two conditions, i.e., the composite pulse excitation and the constant-current respectively. The corresponding maximum relative errors of output voltage are less than 3 % and 3.5 %. Results show that the present PNGV equivalent circuit model and verification method is effective, which can satisfy requirement of simulation of power system of electric vehicles.

Potentiometric Measurement of State-of-Charge of Lead-Acid Batteries Using Polymeric Ferrocene and Quinones Derivatives

Measurement of state-of-charge of lead-acid batteries using potentiometric sensors would be convenient;however, most of the electrochemical couples are either soluble or are unstable in the battery electrolyte. This paper describes the results of an investigation of poly (divinylferrocene) (PDVF) and Poly(diethynylanthraquinone) (PAQ) couples in sulfuric acid with the view to developing a potentiometric sensor for lead-acid batteries. These compounds were both found to be quite stable and undergo reversible reduction/oxidation in sulfuric acid media. Their redox potential difference varied linearly with sulfuric acid concentration in the range of 1 M - 5 M (i.e. simulated lead-acid electrolyte during battery charge/discharge cycles). A sensor based on these compounds has been investigated.