Lithium-ion cell thermal and chemical modeling a methodology to support battery pack cooling
design
ANTUNES Benoît
Powertrain Engineer at Faurecia Clean Mobility, France
GT conference – 07&08/2019, Frankfurt, Germany
CONCLUSION & NEXT STEP5
2
CONTEXT1
METHODOLOGY APPLIED TO A PRISMATIC CELL2
THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3
COOLING LOCATION STUDY FOR A PRISMATIC CELL4
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda
3
Faurecia Clean Mobility use its knowledge
in thermal management & ultra-light weigth material in
order to equipped innovent zero emission vehicle
Battery Pack Design
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context
4
Faurecia Clean Mobility use its knowledge
in thermal management & ultra-ligth weight material in order to equipped innovent zero emission vehicle
Top Cover
Battery Pack + integratedfunctions
Full Battery System
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context
5
Faurecia Clean Mobility use its knowledge
in thermal management & ultra-ligth weight material in order to equipped innovent zero emission vehicle
Top Cover
Battery Pack + integratedfunctions
Full Battery System
FCM technical proposal :
lightweight solution with integrated functions
(crash, thermal management, EMC)
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context
6
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context
From the cell to the full battery pack
→ Understand Lithium « cell behavior »
→ Extend knowhow to the « Pack »
Cell level
Module level
Battery Pack level
Which tools are used in ordre to support battery pack activities ?
Taitherm and StarCcm+ : Use in 3D desing
GT-SUITE/AutoLion : Thermal & Electrical cell profile
7
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Context
From the cell to the full battery pack
→ Understand Lithium « cell behavior »
→ Extend knowhow to the « Pack »
Cell level
Module level
Battery Pack level
Which tools are used in ordre to support battery pack activities ?
Taitherm and StarCcm+ : Use in 3D desing
GT-SUITE/AutoLion : Thermal & Electrical cell profile
CONCLUSION & NEXT STEP5
8
CONTEXT1
METHODOLOGY APPLIED TO A PRISMATIC CELL2
THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3
COOLING LOCATION STUDY FOR A PRISMATIC CELL4
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda
9
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
Model building methodology
Because it is difficult to find this kind of
information on Google
I’m feeling lucky
10
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
Model building methodology
1D Electrochemical
model
Get a battery pack
Cell tomography
Cell teardown
Battery pack teardown
Get cell specifications & Dimensions
3D Thermal model
11
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
Segment C vehicle : PHEV (Plug in Hybrid Electrical Vehicle)
Teardown
Cell characteristics,
→ Cell shape & chemistry : Prismatic, NMC 111→ Cell capacity : 25 Ah
More information is needed
Tomography & Destructive analysis is needed ☺
SegC 90 kW
12
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
Lithium cell teardown objectives :
→ Get internal geometry of the cell
→ Get internal material of the cell
CAD Electrodes and coating dimensions
ANODE
CATHODE
Tomography
☺
☺
Now, enough data are available in order to build models
13
Model Building from extracted data
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
1D Electrochemical model 3D Thermal model
GTsuite – AutoLion StarCcm+ – Full thermal model
Data from teardown analysis
(Electrode types and dimension)
Data from teardown analysis
(Components dimensions and thermal properties)
14
Model Building from extracted data
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
1D Electrochemical model 3D Thermal model
GT-SUITE – AutoLion StarCcm+ – Full thermal model
Data from teardown analysis
(Electrode types and dimension)
Data from teardown analysis
(Components dimensions and thermal properties)
☺
☺
15
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
1D Electrochemical model 3D Thermal model
GTsuite – AutoLion StarCcm+ – Full thermal model
Data from teardown analysis
(Electrode types and dimension)
Data from teardown analysis
(Components dimensions and thermal properties)
Model Building from extracted data
16
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Methodology applied to a prismatic cell
1D Electrochemical model
Heat generation
3D Thermal model
External conditions
(Cooling, warm-up, …)
Outputs : inside and outside the casing
- Maximum temperature
- Temperature gradients
- Flux
…
No temperature feedback
Model Building from extracted data → Open loop model (first draft)
CONCLUSION & NEXT STEP5
17
CONTEXT1
METHODOLOGY APPLIED TO A PRISMATIC CELL2
THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3
COOLING LOCATION STUDY FOR A PRISMATIC CELL4
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda
18
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
Model validation methodology
Experimental data
3D Thermal model
Validation by Results&Data comparaisons
Supply1D Electrochemical
model
CALIBRATION
Experimental Tests
19
1D Electrochemical model validation → Set Up
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
DOE parameter list :
- Cathode capacity loading
- Anode N/P ratio
- Cathode/Anode first charge/discharge capacity
- Collector contact resistance
Parameter optimization by genetic algorythm
(DOE GT-SUITE)
From Experimental adiabatic discharge at 1C rate
20
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
1D Electrochemical model validation → Results
Vs.
Experimental tests
21
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
Constante discharges – Voltage correlations
OCV curve
(C/10 → 2,5 A)
Discharge curves
(from 30 → 80 A)
1D Electrochemical model validation → Results
Vs.
Experimental tests
Vo
ltag
e (V
)V
olt
age
(V)
Time (s)
Time (s)
22
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
Constante discharges – Temperature correlations
OCV curve
(C/10 → 2,5 A)
Discharge curves
(from 30 → 80 A)
1D Electrochemical model validation → Results
Vs.
Experimental tests
Tem
per
atu
re (
K)
Tem
per
atu
re (
K)
Time (s)
Time (s)
23
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
Transient current profile – Voltage correlations
HPPC Cycle – 25°C
Full HPPC
cycle First Peak
1D Electrochemical model validation → Results
Vs.
Experimental tests
Vo
ltag
e (V
)
Time (s)
Vo
ltag
e (V
)
Time (s)
24
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
Transient current profile – Temperature correlations
1D Electrochemical model validation → Results
Vs.
Experimental tests
HPPC Cycle – 25°C
Tem
per
atu
re (
K)
Time (s)
Tem
per
atu
re (
K)
Time (s)
Full HPPC
cycle First Peak
25
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
3D Thermal model validation
– Results
Access to internal thermal behavior
Model validation by external
temperature analysis
Model vs. Experimetal
A-A Cut view of the cell
A
A
26
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Thermal and Electrochemical model validation
3D Thermal model validation
– Results
In the worst case, there is a maximal temperature
deviation about 1°C
Model vs. Experimetal – Constante discharge
Temperature sensor locations
Tem
per
atu
re (
K)
Time (s)
TC type K 0,5mm
The model match
27
CONTEXT1
METHODOLOGY APPLIED TO A PRISMATIC CELL2
THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3
COOLING LOCATION STUDY FOR A PRISMATIC CELL4
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda
CONCLUSION & NEXT STEP5
28
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Cooling location study for a prismatic cell
Cooling location scenarios
Bottomcooling
Tabscooling
Sidescooling
Get external&internaltemperature
Get temperature
gradients
Cooling location ranking at the cell level
Time (s)
Tem
per
atu
re (
K)
Tmax
Cell run dry
29
CONTEXT1
METHODOLOGY APPLIED TO A PRISMATIC CELL2
THERMAL AND ELECTROCHEMICAL MODEL VALIDATION3
COOLING LOCATION STUDY FOR A PRISMATIC CELL4
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Agenda
CONCLUSION & NEXT STEP5
30
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step
WORKFLOW ADVANTAGES,
- GT-AutoLion is able to generate cell heat source for any scenarios
- The 3D model give us cell thermal behavior in function of the cooling strategy
and increase our level of expertise
31
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step
WORKFLOW ADVANTAGES,
- GT-AutoLion is able to generate cell heat source for any scenarios
- The 3D model give us cell thermal behavior in function of the cooling strategy
and increase our level of expertise
WORKFLOW DISADVANTAGES,
- The entire model (1D + 3D) is an open loop model. The 1D model must takes
care about cell temperature variations
32
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step
- Investigate in close coupled model possibility
GT-AutoLion 3D
1D3D
33
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step
- Investigate in close coupled model possibility
- Study impact of the cooling location on cell ageing
Bottomcooling
Tabscooling
Sidescooling
Ongoing Experimental tests
GT-AutoLion 3D
1D3D
34
LITHIUM-ION THERMAL AND CHEMICAL MODELING-Conclusions & Next step
- Investigate in close coupled model possibility
- Study impact of the cooling location on cell ageing
- Extend workflow to module level
Bottomcooling
Tabscooling
Sidescooling
Ongoing Experimental tests
Cell level
Module level
GT-AutoLion 3D
1D3D
35
LITHIUM-ION THERMAL AND CHEMICAL MODELING
36