Electric Vehicle Battery Systems Manual – PDF DOWNLOAD

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Electric Vehicle Battery Systems Manual – PDF DOWNLOAD

TABLE OF CONTENTS:

Electric Vehicle Battery Systems Manual – PDF DOWNLOAD

TABLE OF CONTENTS........................................................................  5
ACKNOWLEDGMENTS..........................................................................  9
1 ELECTRIC VEHICLE BATTERIES............................................................. 11
	ELECTRIC VEHICLE OPERATION........................................................... 12
		Electric Vehicle Components...................................................... 13
		Electronic Drive Systems......................................................... 13
	BATTERY BASICS....................................................................... 14
	INTRODUCTION TO ELECTRIC VEHICLE BATTERIES........................................... 14
		The Pb-Acid Battery.............................................................. 16
		The NiMH Battery................................................................. 18
		The Li-ion Battery............................................................... 20
		The Li-Polymer Battery........................................................... 23
	FUEL CELL TECHNOLOGY................................................................. 24
	CHOICE OF A BATTERY TYPE FOR ELECTRIC VEHICLES....................................... 28
2 ELECTRIC VEHICLE BATTERY EFFICIENCY.................................................... 33
	EFFECTS OF VRLA BATTERY FORMATION ON ELECTRIC VEHICLE PERFORMANCE.................... 33
	REGENERATIVE BRAKING................................................................. 34
	ELECTRIC VEHICLE BODY AND FRAME...................................................... 34
	FLUIDS, LUBRICANTS, AND COOLANTS..................................................... 35
	EFFECTS OF CURRENT DENSITY ON BATTERY FORMATION...................................... 35
		Effects of Current Density on VRLA Battery Formation............................. 36
		Effects of Current Density on NiMH Battery Formation............................. 36
		Effects of Electrode Oxidation on NiMH Battery Formation......................... 37
		Effects of Elevated Temperatures on VRLA Battery Formation....................... 38
		Effects of Temperature on NiMH Battery Formation................................. 39
		Activation and Formation of a NiMH Battery....................................... 39
		End of Formation of a VRLA Battery............................................... 40
		Failure Modes of VRLA............................................................ 41
	EFFECTS OF EXCESSIVE HEAT ON BATTERY CYCLE LIFE...................................... 45
	BATTERY STORAGE...................................................................... 45
		Storage of a VRLA Battery........................................................ 46
		Storage of an NiMH Battery....................................................... 47
	THE LITHIUM-ION BATTERY.............................................................. 49
	TRACTION BATTERY PACK DESIGN......................................................... 51
3 ELECTRIC VEHICLE BATTERY CAPACITY...................................................... 53
	BATTERY CAPACITY..................................................................... 53
	THE TEMPERATURE DEPENDENCE OF BATTERY CAPACITY....................................... 54
	STATE OF CHARGE OF A VRLA BATTERY.................................................... 56
		Practical State-of-Charge Calculation............................................ 59
	CAPACITY DISCHARGE TESTING OF VRLA BATTERIES......................................... 61
	BATTERY CAPACITY RECOVERY............................................................ 63
	DEFINITION OF NIMH BATTERY CAPACITY.................................................. 64
		NiMH Battery Voltage During Discharge............................................ 66
		Effect of Temperature on Discharge............................................... 68
	LI-ION BATTERY CAPACITY.............................................................. 68
	BATTERY CAPACITY TESTS............................................................... 70
	ENERGY BALANCES FOR THE ELECTRIC VEHICLE............................................. 74
		Road Inclination Losses.......................................................... 76
		Vehicle Acceleration Power Losses................................................ 76
		Transmission Inefficiencies...................................................... 76
		Power Losses Due to System Controller/Engine Inefficiency........................ 77
		Power from Regenerative Braking.................................................. 78
		Power from a System Controller/Engine............................................ 78
4 ELECTRIC VEHICLE BATTERY CHARGING...................................................... 79
	CHARGING A SINGLE VRLA BATTERY....................................................... 79
	CHARGE COMPLETION OF A SINGLE VRLA BATTERY........................................... 79
		Temperature Compensation......................................................... 80
		Overcharging of the VRLA Battery................................................. 81
		Equalization Charging of a Single VRLA Battery................................... 81
		Recharging a Series String of VRLA Batteries..................................... 81
		Multistep Algorithm for Charging a Series String of VRLA Batteries............... 82
	TEMPERATURE COMPENSATION DURING BATTERY CHARGING..................................... 82
	CHARGING NIMH BATTERIES.............................................................. 84
	RATE OF CHARGE EFFECT ON CHARGE ACCEPTANCE EFFICIENCY OF TRACTION BATTERY PACKS...... 84
		Temperature Sensing of Traction Battery Packs.................................... 84
		Temperature-Based Termination Methods............................................ 88
	ENVIRONMENTAL INFLUENCES ON CHARGING................................................. 90
	CHARGING METHODS FOR NIMH BATTERIES.................................................. 91
		Advances in NiMH Charging........................................................ 95
	CHARGING TECHNOLOGY.................................................................. 97
		Charging Stations................................................................ 97
		Coupling Types................................................................... 99
		Charging Methods................................................................. 99
		Building Standards...............................................................100
		Electrical Safety................................................................100
		Ventilation......................................................................101
	BATTERY PACK CORRECTIVE ACTIONS......................................................101
		Connection Resistance............................................................101
		Thermal Runaway..................................................................102
		Cell/Unit Internal Impedance/Conductance.........................................102
		Equalizing Charge................................................................103
		Ripple Current...................................................................104
		Battery Charging Parameters......................................................104
5 ELECTRIC VEHICLE BATTERY FAST CHARGING.................................................105
	THE FAST CHARGING PROCESS............................................................105
	FAST CHARGING STRATEGIES.............................................................108
	THE FAST CHARGER CONFIGURATION.......................................................111
		Fast Charging Prerequisites......................................................114
	USING EQUALIZING/LEVELING CHARGERS...................................................115
		Limitations of Fast Charging.....................................................115
		Fast Charging and Battery Overcharge.............................................117
		Fast Charging and Battery Degradation............................................118
		Fast Charging and the Electrical Utility.........................................120
	INDUCTIVE CHARGINGÛMAKING RECHARGING EASIER..........................................  0
	RANGE TESTING OF ELECTRIC VEHICLES USING FAST CHARGING...............................123
		Driving Range at the End of Day-1 Test...........................................123
		Driving Range at the End of Day-2 Test...........................................124
		Driving Range at the End of Day-3 Test...........................................124
	ELECTRIC VEHICLE SPEEDOMETER CALIBRATION.............................................124
6 ELECTRIC VEHICLE BATTERY DISCHARGING...................................................125
	DEFINITION OF VRLA BATTERY CAPACITY..................................................127
	DEFINITION OF NIMH BATTERY CAPACITY..................................................129
		Voltage During Discharge.........................................................131
		Effect of Temperature on Discharge...............................................132
		Discharge Rate...................................................................132
	DISCHARGE CAPACITY BEHAVIOR..........................................................133
		Effect of Temperature............................................................133
		Termination of Discharge.........................................................134
	DISCHARGE CHARACTERISTICS OF LI-ION BATTERY..........................................137
	DISCHARGE OF AN ELECTRIC VEHICLE BATTERY PACK........................................138
	COLD-WEATHER IMPACT ON ELECTRIC VEHICLE BATTERY DISCHARGE............................140
7 ELECTRIC VEHICLE BATTERY PERFORMANCE...................................................143
	THE BATTERY PERFORMANCE MANAGEMENT SYSTEM............................................143
		A Model of the BPMS..............................................................145
		The Typical BPMS Configuration...................................................146
	BPMS THERMAL MANAGEMENT SYSTEM.......................................................147
		Design Analysis of the Battery Thermal Management System.........................150
	THE BPMS CHARGING CONTROL............................................................151
		BPMS Charge Protector............................................................152
		Protecting the Traction Battery Pack.............................................152
		The BPMS Charge Indicator........................................................154
		Depolarization as a Process to Enhance Charging..................................156
		Smart Battery and BPMS Diagnostics Control.......................................157
	HIGH-VOLTAGE CABLING AND DISCONNECTS.................................................158
	SAFETY IN BATTERY DESIGN.............................................................160
		Electrical Safety................................................................161
		Mitigation of Intrinsic Materials Hazards........................................162
	BATTERY PACK SAFETYÛELECTROLYTE SPILLAGE AND ELECTRIC SHOCK..........................  0
	CHARGING TECHNOLOGY..................................................................165
		Charging Stations................................................................165
		Coupling Types...................................................................166
	ELECTRICAL INSULATION BREAKDOWN DETECTION............................................167
	ELECTRICAL VEHICLE COMPONENT TESTS...................................................167
		Reliability/Durability Test......................................................167
		Operating Life Test..............................................................168
		Extended Life Test...............................................................168
		Vehicle Endurance Test...........................................................168
	BUILDING STANDARDS...................................................................169
	VENTILATION..........................................................................169
8 TESTING AND COMPUTER-BASED MODELING OF ELECTRIC VEHICLE BATTERIES......................171
	TESTING ELECTRIC VEHICLE BATTERIES...................................................173
		Core Battery Performance Tests...................................................173
		The Constant Current Discharge Test..............................................174
		Peak Power Test..................................................................174
		Constant Power Test..............................................................174
		Variable Power Discharge Test....................................................174
		Federal Urban Driving Schedule Regime (Variable Power Discharge) Test............175
		Dynamic Stress Test Regime (Variable Power) Test.................................175
		Special Performance Test.........................................................175
		Partial Discharge Test...........................................................175
		Standloss Test...................................................................175
		Sustained Hill-Climb Power Test..................................................175
		Thermal Performance Test.........................................................176
		Battery Vibration Test...........................................................176
		Charge Completion on Optimization Test...........................................176
		Fast Charge Test.................................................................176
		Performance Safety and Abuse Test................................................177
	ACCELERATED RELIABILITY TESTING OF ELECTRIC VEHICLES.................................177
	BATTERY CYCLE LIFE VERSUS PEAK POWER AND REST PERIOD.................................181
		Impact of Charge Method on Battery Cycle Life....................................182
		Thermal Management of the Electric Vehicle Battery...............................182
		Battery Test Recommendations.....................................................183
		The Thermal and Electrochemical Coupled Model....................................186
	SAFETY REQUIREMENTS FOR ELECTRIC VEHICLE BATTERIES...................................198
FUEL CELL PROCESSING TECHNOLOGY FOR TRANSPORTATION APPLICATIONS: STATUS AND PROSPECTS....201
	COMPARISON OF FUEL CELL TECHNOLOGIES.................................................208
	FUEL-CELL EMISSIONS..................................................................211
	POLICY DIRECTIVES FOR CLEAN AIR ACT..................................................212
	RECOMMENDATIONS......................................................................213
VEHICLE BATTERY CHARGING CHECKLIST/LOG...................................................215
DAY 1/2/3 RANGE AND CHARGE TEST LOG......................................................217
SPEEDOMETER CALIBRATION TEST DATA LOG....................................................219
ELECTRIC VEHICLE PERFORMANCE TEST SUMMARY................................................221
BIBLIOGRAPHY.............................................................................225
INDEX....................................................................................231

ELECTRIC VEHICLE BATTERY SYSTEMS MANUAL – PDF DOWNLOAD:

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