Battery Management for Monitoring up to Six Lead - …...Battery Management for Monitoring up to Six...

Battery Management for Monitoring up to Battery Management for Monitoring up to

Six LeadSix Lead--Acid Batteries at the Individual Acid Batteries at the Individual

Dr. David Liu, PhDDr. David Liu, PhD

PHM Society PHM Society

BMS WorkshopBMS Workshop

September 26, September 26, 20112011

Six LeadSix Lead--Acid Batteries at the Individual Acid Batteries at the Individual

Battery and System LevelsBattery and System Levels

OverviewOverview

• Why Do We Need a Battery Fuel Gauge?

• Capabilities and Benefits of HDM BFG Technology

• BFG Application Examples

• BFG Configurations

22

• BFG Configurations

• HDM’s BFG Dual Tracking Methodology

• BFG Highlights Effects of Unhealthy Batteries on the Bank

• Re-Cap

Information is PowerInformation is Power

33

You would not drive a car

without a gas gauge…

Why would you execute a mission-critical

operation, such as “silent watch”,

without a Battery Fuel Gauge?

Capabilities of HDM BFG TechnologyCapabilities of HDM BFG Technology

• Battery Power Usage Information: Diagnostics and Prognostics– State of Charge (SOC) at 95% Accuracy

– State of Health (SOH) at 95% Accuracy

– Hours Remaining (HR) at 90% Accuracy

– Battery Voltage (V)

44

– Battery Voltage (V)

– Battery Temperature (T)

– Current (I)

– State of Life (SOL)

• Functionality– System Interface: CANBUS, RS232, Control Panel-Mounted Display

– Real-Time Data and Estimations

– Self-Calibration

– Lightweight Packaging

Benefits of HDM BFG TechnologyBenefits of HDM BFG Technology

• Operations– Alerts crew when re-charging is necessary

– Provides Hours Remaining for silent watch

– Ensures mission capacity and success

55

• Maintenance– Identifies unhealthy batteries for replacement

– Facilitates Condition-Based Maintenance (CBM)

• Cost-Efficiency– Single BFG per system vs. multiple BFGs per system

– Simple configuration reduces install, operation, and maintenance

– Powerful tool for intelligent power management systems

BFG ImplementationBFG Implementation

Mobile ApplicationMobile Application

• Customer

– Navistar Defense

• UK MOD/NATO

• Vehicle

– Husky Tactical Support Vehicle

66

– Husky Tactical Support Vehicle

• Application

– Monitors Battery SOC and SOH

Over 1500 HDM BFGs have been installed in Husky

TSVs in Afghanistan supporting the NATO troops

BFG ImplementationBFG Implementation

Stationary ApplicationStationary Application

• Customer – Raytheon Company

• System– R-Series Regenerator Hybrid

Power System

77

Power System

• Application– USMC Experimental

Forward Operating Base Phase IV Demonstration in 2010 at 29 Palms, CA

HDM BFG is critical component of intelligent Hybrid Power

System

Battery Fuel Gauge Configurations

88

Battery Fuel Gauge Configurations

Configuration 1 Configuration 1

System Level Monitoring OnlySystem Level Monitoring Only

12VDC

Battery

#3

12VDC

Battery

#1DC

Ch

a(A

lte

12VDC

Battery

#5

Interface Connection

Inline Fuse

Battery Positive Sense Wire

99

Advantage: SIMPLICITY

12VDC

Battery

#4

12VDC

Battery

#2

Lo

ad

arg

er

ern

ato

r)

12VDC

Battery

#6

Batt

Neg

Load

Neg

Interface Connection(Display, RS232, CAN-Bus)

Fuel Gauge Sensor Module

Battery Negative Connection

Load Negative Connection

Configuration 2Configuration 2

Cell Level Monitoring OnlyCell Level Monitoring Only

12VDCBattery

#3

12VDCBattery

#1

BattNeg

LoadNeg

BattNeg

LoadNeg

DC

Ch

a(A

lte

12VDCBattery

#5

BattNeg

LoadNeg

Inline Fuse


DA TA REA DING S

SO H Cell

SO C Cell

V (Voltage) Cell

1010

Advantage: PRECISION

12VDC

Battery

#4

12VDC

Battery

#2

Batt

Neg

Load

Neg

Batt

Neg

Load

Neg

Load

arg

er

ern

ato

r)

12VDC

Battery

#6

Batt

Neg

Load

Neg


(Display, RS232, CAN-Bus)




V (Voltage) Cell

HR (H r Rem ain) Cell

I (Current) Cell

Tem p Cell


System/String/Cell Level MonitoringSystem/String/Cell Level Monitoring

12VDC

Battery

#3

12VDC

Battery

#1DC

Ch

(Alt

12VDC

Battery

#5 Inline Fuse


DATA READINGS

SOH

SOC Cell/String/System

V

Cell/String/System

Cell/System

1111

Advantage: SIMPLE, PRECISE & COST-EFFECTIVE

12VDC

Battery

#4

12VDC

Battery

#2

C L

oad

harg

er

tern

ato

r)

12VDC

Battery

#6

Batt

Neg

Load

Neg






V (Voltage)

HR (Hr Remain)

I (Current)

Temp

Cell/System

System

Cell/String/System

System

HDM’s Battery Fuel Gauge Technology:

1212

HDM’s Battery Fuel Gauge Technology:

Dual Tracking Methodology

SOC Measurement SOC Measurement

Using Dual Tracking MethodUsing Dual Tracking Method

60

80

100

SO

C (

%)

Fuel Gauge SOC

Theoretical SOC

Fuel Gauge SOH:82% (at discharging time = 0 min.)

1313

SOC Accuracy at 95%

0

20

40

0 10 20 30 40 50 60 70 80 90 100

SO

C (

%)

Discharging Time (min)

What is Dual Tracking Methodology?What is Dual Tracking Methodology?

1414

Template for Template for InitialInitial

II--SOC and VocSOC and Voc--SOC EstimationSOC EstimationSegments Voc AH SOC (%)

1 > 12.8 2 100-98

2 12.80-12.74 2 98-96

3 12.74-12.69 2 96-94

4 12.69-12.66 2 94-92

. . . .

1515

.

.

.

.

.

.

.

.

.

.

.

.

48 11.14-11.08 2 6-4

49 11.08-10.88 2 4-2

50 10.88-10.64 2 2-0

Total Segments: 1-50 Voc: >12.8 to 10.64 Total AH: 100 SOC: 100%-0%

I-SOC = AHremaining – AHdischarge

Total Initial AH

Template for Template for SelfSelf--Calibrated Calibrated

II--SOC and VocSOC and Voc--SOC EstimationSOC EstimationSegments Voc AH SOC (%)

1 > 12.8 1.8 100-98

2 12.80-12.74 1.8 98-96

3 12.74-12.69 2.1 96-93

4 12.69-12.66 2.1 93-90

. . . .

1616

.

.

.

.

.

.

.

.

.

.

.

.

48 11.14-11.08 1.6 6-4

49 11.08-10.88 1.6 4-2

50 10.88-10.64 1.8 2-0

Total Segments:

1-50

Voc:

>12.8 – 10.64

Self-Calibrated

Total AH: 90

SOC:

100%-0%

I-SOC = AHremaining – AHdischarge

Total Self-Calibrated AH

Error from CurrentError from Current--Based TrackingBased Tracking

60

80

100

SO

C (

%)

Charge/Discharge Cycling Fuel Gauge SOC

Overestimated

Accurate

Underestimated

1717

Lack of precise charge and discharge efficiency information results in accumulation of SOC estimation errors

0

20

40

0 50 100 150 200 250 300 350 400 450 500

SO

C (

%)


Error from VoltageError from Voltage--Based TrackingBased Tracking

24

25

26

27

Voc (Voltage)

Vo

c (

Vo

lts)

B (78%SOC)

A (100%SOC)

1818

Lack of voltage relaxation results in SOC errors

21

22

23

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

time(mins)

Voc (Voltage)

Voc 12Hrs Rest after Full Charge

Voc No Rest after Full Charge

Time (min)

Vo

c (

Vo

lts)

Dual Tracking MethodologyDual Tracking Methodology

60

80

100

SO

C (

%)

Combined SOC

Voltage-based SOC

(%)

Voltage-Based Tracking SOC

1919

Dual Tracking Method is optimal for all loading conditions

0

20

40

0 50 100 150 200 250

SO

C (

%)

Discharging Time (min) Discharging Time (min)

SO

C

Dual Tracking SOC


System/String/Cell Level MonitoringSystem/String/Cell Level Monitoring

12VDC

Battery

#3

12VDC

Battery

#1DC

L

Ch

ar

(Alte

rn

12VDC

Battery

#5


Inline Fuse


DATA READINGS

SOH

SOC Cell/String/System

V (Voltage)

Cell/String/System

Cell/System

2020

Advantage: SIMPLE, PRECISE & COST-EFFECTIVE

12VDC

Battery

#4

12VDC

Battery

#2

Lo

ad

rge

rn

ato

r)

12VDC

Battery

#6

Batt

Neg

Load

Neg






V (Voltage)

HR (Hr Remain)

I (Current)

Temp

Cell/System

System

Cell/String/System

System

BFG Detection of Unhealthy Battery: Cycle 1BFG Detection of Unhealthy Battery: Cycle 1

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30 35

SO

C (

%)

Battery 1

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30 35

SO

C(%

)

Battery 3

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30 35

SO

C (

%)

Battery 2

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

60

70

80

90

100

SO

C (

%)

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5% 50

60

70

80

90

100

SO

C (

%)

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%50

60

70

80

90

100

SO

C (

%)

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

2121

HDM BFG identifies

weak battery during

discharge cycle 1

0

10

20

30

40

50

0 5 10 15 20 25 30 35

SO

C (

%)

AH Discharged

Battery 4

Theoretical - 5%

0

10

20

30

40

50

0 5 10 15 20 25 30 35

SO

C (

%)

AH Discharged

Battery 6

0

10

20

30

40

50

60

70

80

90

100

0 20 40 60 80 100

SO

C (

%)

AH Discharged

Battery System6 Batteries Combined

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

0 5 10 15 20 25 30 35

SO

C (

%)

AH Discharged

Battery 5

Theoretical - 5%

Battery5

BFG Accuracy Established: Cycle 3BFG Accuracy Established: Cycle 3

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30 35

SO

C (

%)

Battery 1

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30 35

SO

C (

%)

Battery 2

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

70

80

90

100

Battery Monitor

Theoretical SOC

Theoretical + 5%70

80

90

100Battery Monitor SOC

Theoretical SOC

Theoretical + 5%70

80

90

100

SO

C (

%)

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25 30 35 40

SO

C (

%)

Battery 3

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

2222

HDM BFG achieves

95% accuracy by

discharge cycle 3

(i.e. no adjustments needed)0

10

20

30

40

50

60

70

80

90

100

0 20 40 60 80 100

SO

C (

%)

AH Discharged

Battery System6 Batteries Combined

Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

60

70

0 5 10 15 20 25 30 35

SO

C (

%)

AH Discharged

Battery 4

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

60

70

0 5 10 15 20 25 30 35 40

SO

C (

%)

AH Discharged

Battery 6

Theoretical + 5%

Theoretical - 5%

0

10

20

30

40

50

60

70

0 5 10 15 20 25 30 35

SO

C (

%)

AH Discharged

Battery 5

Theoretical + 5%

Theoretical - 5%

Effects of Unhealthy Battery on Bank 1*Effects of Unhealthy Battery on Bank 1*String # Battery # Individual Battery Voltage @

End Point

Discharge Current

From To

SOC

%

SOH

%

1

1 11.3V

12A 19A

10 73

2 11.5V 16 78

2

3 11.4V

10A 18A

12 71

4 11.4V 12 73

5 10.8V 0 50

2323

* Battery Bank 1: Optima Batteries

• String 3: Divergence of voltage and reduction in discharge current cause over-current stress on Strings 1 and 2

• Premature termination of discharge cycle, resulting in 19% loss in usable capacity

3

5 10.8V

18A 4A

0 50

6 12.0V 36 78

Sum

1 - 3

Sum

1 - 6

System Battery End Voltage:

22.8V

System Discharge Current:

~41A ~41A 0% 68%

Effects of Unhealthy Battery on Bank 2*Effects of Unhealthy Battery on Bank 2*String # Battery # Individual Battery Voltage @

End Point

Discharge Current From

To

SOC

%

SOH

%

1

1 11.3V

33A 49A

14 77

2 11.4V 19 80

2

3 10.6V

33A 6A

0 55

4 12.1V 51 93

5 11.2V 12 75

2424

* Battery Bank 2: Hawker Batteries

• String 2: Divergence of voltage and reduction in discharge current cause over-current stress on Strings 1 and 3

• Premature termination of discharge cycle, resulting in 17% loss in usable capacity

3

5 11.2V

34A 45A

12 75

6 11.5V 22 87

Sum

1 - 3

Sum

1 - 6

System Battery End Voltage:

22.7V

System Discharge Current:

100A 100A 0% 62%

Weakest Battery Threshold Weakest Battery Threshold

vs. Conventional Threshold at 21Vvs. Conventional Threshold at 21VString

#

Battery

#

Battery Voltage Discharge Current Charge Current

@ End Point 1

(Bat 3 SOC=0%)

@ End Point 2 (Bat

Voltage=21V)

@ 100%

SOC

@ End

Point 1

@ End

Point 2

@ Low SOC

1

1 11.3V 9.9V

36A 51A 20A 20A2 11.4V 11.1V

3 10.6V 9.6V

2525

By extending the system run-time (e.g. by 30 minutes), would be at the expense of the weakest battery

2

3 10.6V 9.6V

30A 6A 65A 3A4 12.1V 11.5V

3

5 11.2V 9.7V

36A 45A 17A 19A6 11.5V 11.3V

Sum

1 - 3

Sum

1 - 6

22.7V 21.0V 102A 102A 102A Set @ 42A

60

70

80

90

100

SO

C (

%)

Battery System Battery Monitor SOC

Theoretical SOC

Theoretical + 5%

Theoretical - 5%

System-Level Monitoring During Complete Charge-Discharge Cycles

2626

0

10

20

30

40

50

0 200 400 600 800 1000 1200 1400 1600 1800 2000

SO

C (

%)

AH Discharged/Charged

• SOC accuracy reaches 90-95% during the charge portion of the cycle within 3 cycles

Single BFG at 95% AccuracySingle BFG at 95% Accuracy

for up to 6 Individual Batteriesfor up to 6 Individual Batteries

• Provides breadth and depth necessary for Cost-Effective

Battery Management Systems and CBM

• User Level

– Ensures power system reliability and performance

2727

– Ensures power system reliability and performance

• Maintenance Level

– Enables precision pinpoint of unhealthy batteries for CBM

• Incorporates theoretically scalable algorithm, for banks

greater than 6 batteries (i.e. important for larger, stationary

energy storage systems)

Thank You!

Contact Information:

Dr. David Liu, VP of R&D: [email protected]

2828

Dr. David Liu, VP of R&D: [email protected]

HDM Systems, Inc.226 Lincoln StreetAllston, MA 02134Tel: 617.562.4054Fax: 617.562.4013

Web: www.HDM-Sys.com

AppendixAppendix

2929

AppendixAppendix

20

40

60

80

100

SO

C (

%)

Initial Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries, 24V in Series, 10A/40A Alternating Loads)

Fuel Gauge SOC

Theoretical SOC

Fuel Gauge SOH: 95% at Discharge Time = 0

20

40

60

80

100

SO

C (

%)

2nd Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries, 24V in Series, 10A/40A Alternating Loads)

Fuel Gauge SOCTheoretical SOC

Fuel Gauge SOH: 89%

at Discharge Time = 0 min.

SOC Measured by DualSOC Measured by Dual--Tracking Method:Tracking Method:

Partial Discharge Partial Discharge –– Cycle 1 to Cycle 4Cycle 1 to Cycle 4

3030

0

0 20 40 60 80 100


0

0 20 40 60 80 100Discharging Time (min)

0

20

40

60

80

100

0 20 40 60 80 100

SO

C (

%)


3rd Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries, 24V in Series, 10A/40A Alternating Loads)

Fuel Gauge SOC

Theoretical SOC


0

20

40

60

80

100

0 20 40 60 80 100

SO

C (

%)


4th Discharge Cycle (100% to 0% SOC) (2x55AH 12V Batteries, 24V in Series, 5A/40A Alternating Loads)

Fuel Gauge SOC

Theoretical SOC


SOC accuracy reaches 90-95% after four partial discharge cycles

50

60

70

80

90

100

SO

C (

%)

Battery H2

50

60

70

80

90

100

SO

C (

%)

Battery System

Partial Charge and Discharge Cycles Partial Charge and Discharge Cycles

of Battery Bankof Battery Bank

3131

SOC accuracy reaches 90-95% after four partial charge and

discharge cycles

0

10

20

30

40

50

0 50 100 150 200

SO

C (

%)


0

10

20

30

40

50

0 100 200 300 400 500 600

SO

C (

%)


BFG: Water Submersion Test

3232

BFG was submersed in water at 25°C for three

hours, and was tested for operational performance

Battery Management for Monitoring up to Six Lead - …...Battery Management for Monitoring up to Six...

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