Wireless Battery Management System for Safe High-Capacity Li … · 2014-02-05 · Lawrence...

LLNL IM-764347

This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. Lawrence Livermore National Security, LLC

Wireless Battery Management System for

Safe High-Capacity Li-Ion Energy Storage

Battery Management System with

Distributed Wireless Sensors

ARPA-e AMPED Program Review

January 8th & 9th 2013

J. Farmer, J. Chang, J. Zumstein, J. Kotovsky,

E. Zhang, A. Dobley, G. Moore, F. Puglia,

S. Osswald, K. Wolf, J. Kaschmitter,

S. Eaves & T. Bandhauer

• Lawrence Livermore National Lab

• Yardney Technical Products

• Naval Post Graduate School

• Naval Facilities Engineering &

Expeditionary Warfare Center

• McClellan Nuclear Research Center

• Polystor Energy Corporation

• Eaves Devices

• Colorado State University

Lawrence Livermore National Laboratory LLNL IM-764347

2

Technology Summary & Value Proposition

Description of Technology

Safe development expedited

with realistic and controllable

YTP 7S2P battery simulator

World’s first demonstration of

wireless BMS technology by

ARPA-e AMPED LLNL-YTP Team

Passive operation

with power from RF

drive coil … tag &

sensor suite

continue to operate

even if battery

disabled

Active operation

with power from

battery posts …

single pair of

wires used to

monitor cell

voltage &

provide power

to tag and

sensor suite Bluetooth 4.0

USB Receiver


3

Technology Summary & Value Proposition

Advantage Over State-of-the-Art

Yardney Technical Product’s 2.5 kWh Li-Ion

battery pack for NASA’s Mars Science

Laboratory requires massive wiring harness

Our new vision for wireless BMS technology

• Cell-level monitoring and communication,

from the factory, to incorporation into multi-

cell pack, to reclamation and recycle

• Improved control for longer cell life and

better battery pack performance

• Early warning of catastrophic thermal event

in cell responsible for initiation … provide

sufficient reaction time for intervention

• More sensors with fewer wires

• Increased reliability and safety

New wireless BMS technology has been

realized, with the intellectual property protected

for DOE and now available for licensing


4

Milestone 1: Develop Individual Wireless Sensors & Tags Capable of Being Operated in Either Passive or Active Mode • Wireless Sensors Developed with Active & Passive Modes Demonstrated

Milestone 2: Integrate Distributed Array of Wireless Tags & Sensors with Multi-Cell Li-Ion Battery Pack; Develop BMS Capability to Communicate with Distributed Array • Integrated Sensors Into Battery Simulator & Live Battery Pack • Integration of Wireless Communications Into YTP BMS During 2014

Milestone 3: Demonstrate Wireless Tags & Sensors & Conduct Comparative Studies; Create First International Standard for Wireless BMS Systems • Demonstration of Wireless Tags & Sensors & Initial Studies Completed • Initial Work on Preparation of Standard for Wireless BMS

Milestone 4: Technology-to-Market (T2M) Plan & Analysis & Evaluate Cost Reduction Strategies Involving ASIC • Comprehensive T2M Plan Developed • Protection of Intellectual Property & Initial Licensing Discussions

Validation Plan & Performance Targets

Major Interim/End Milestones

4


5

Key Interim Learning & Results

Compelling Data & Performance

3.00

3.20

3.40

3.60

3.80

4.00

4.20

Ce

ll Te

rmin

al V

olt

age

(V

)

Passive RFID Voltage Sensors Live Li-Ion Cells During Charge-Discharge Cycling

Live Cell Voltage Board 1





20

25

30

35

40

45

Tem

pe

ratu

re (C

)Passive RFID Temperature Sensor

Localized Heating Test with Li-Ion Battery Simulator

Thermistor1_board1 Thermistor 2 Board 1Thermistor 1 Board 2 Thermistor 2 Board 2Thermistor 1 Board 3 Thermistor 1 Board 4Thermistor 2 Board 4 Thermistor 1 Board 5Thermistor 2 Board 5

1,080

1,090

1,100

1,110

1,120

1,130

1,140

1,150

1,160

1,170

1,180

Stra

in in

Ce

ll C

ase

(A

rbit

rary

Un

its)

Passive RFID Strain Sensor for Li-Ion Cell CaseStrain Sensor 1 Board 1

0.01

0.1

1

10

100

0 20 40 60 80 100 120

Dat

a Tr

ansm

issi

on

Err

or

(%)

Distance (ft)

Error in Random Outdoor Environment

% CrC Errors % Retransmissions

0.01

0.1

1

10

100

0 5 10 15 20 25 30 35

Dat

a Tr

ansm

issi

on

Err

or

(%)

Distance (ft)

Error in Controlled Laboratory Environment

% CrC Errors % Retransmissions

26

27

28

29

30

31

32

Ce

ll Su

rfac

e T

em

pe

ratu

re (C

)

Passive RFID Temperature SensorsEnclosure Test with Li-Ion Battery Simulator

Sim Cell Temp Board 1 Sim Cell Temp Board 2

3.00

3.20

3.40

3.60

3.80

4.00

4.20

Ce

ll Te

rmin

al V

olt

age

(V

)

Passive RFID Voltage Sensors Live Li-Ion Cells During Charge-Discharge Cycling







6

Key Interim Learning & Results

Compelling Data & Performance

Successful testing of wireless tags and

sensors with active 240-volt BMS

demonstrating no significant interference

Successful testing of wireless tags and

sensors inside active 22-kV capacitor

module successfully transmitting data to

monitoring station during charge and

discharge

Wireless tag and sensor suite

inside capacitor module

Wireless transmission of secure encrypted data,

immune to noise in harsh EM environments

Wireless tag and sensor suite

inside capacitor module

Active 240-V BMS

Live Battery Pack

Pulsed power system with 192 capacitor

modules, each consisting of twenty 22-kV

capacitors. Energy is stored for 60 seconds

and then released in 400-microsecond burst,

with a peak current in excess of 100 million

amperes, and a peak power in excess of one

terawatt — more power than the entire United

States uses in that same fraction of a second.

Current pulses are delivered via more than

150 kilometers of high-voltage cable.


7

Attribute Wired

Sensors

Wired

Multiplex

Wireless

Sensors

Number of Sensors Practical Low Increased High

Number of Wires Required for Sensors High Reduced None

Immunity to Single-Point Sensor Failure No No Yes

Continuous Cell Monitoring Over Entire Life Cycle No No Yes

Wireless Inventory Control Enabled No No Yes

Reliability Enhancement No Yes Yes

Safety Enhancement During Pack Assembly No No Yes

Safety Enhancement During Pack Operation No Yes Yes

Useful for Controlling Cell-Level Cooling No Yes Yes

QA Records Travel with Individual Cell No No Yes

Cost Low Modest Modest

Uniqueness: How Technology Differs From &

Represents Enhancement Over State-of-the-Art

Acknowledgement: The author thanks ARPA-E for the support necessary to prepare this document.

Lawrence Livermore National Laboratory is operated by Lawrence Livermore National Security, LLC,

for the U.S. Department of Energy, National Nuclear Security Administration under Contract DE-

AC52-07NA27344.

Disclaimer: This document was prepared as an account of work sponsored by an agency of the

United States government. Neither the United States government, nor Lawrence Livermore National

Security LLC, nor any of their employees make any warranty, expressed or implied, or assumes any

legal liability or responsibility for the accuracy, completeness, or usefulness of any information,

apparatus, product, or process disclosed, or represents that its use would not infringe privately

owned rights. Reference herein to any specific commercial product, process, or service by trade

name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its

endorsement, recommendation, or favoring by the United States government or Lawrence Livermore

National Security, LLC. The views and opinions of authors expressed herein do not necessarily state

or reflect those of the United States government or Lawrence Livermore National Security, LLC, and

shall not be used for advertising or product endorsement purposes.

Wireless Battery Management System for Safe High-Capacity Li … · 2014-02-05 · Lawrence...

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