Recent advancements in lead battery performance and...
Transcript of Recent advancements in lead battery performance and...
Recent advancements in lead battery performance and new
demonstration work of ALABC 1618 Program
Alistair Davidson Direction Products and Sustainability, ILA
Boris Monahov Program Manager ALABC
AABC Mainz 1 February 2017
The Advanced Lead Acid Battery Consortium
70 members22 battery manufacturers28 lead producers13 suppliers7 research & testing
4 / 17
AUTOAdvanced lead
batteries (12 and
48V) continue to
be capable of
delivering
required
performance /
fuel & CO2
benefits at lower
cost than
alternatives
AUTO
OEM vehicle
development
programs aimed
at meeting future
emission targets
to include 12V
micro hybrid and
48V mild hybrid
lead batteries
ESS
Advanced lead
batteries
continue to
deliver required
performance with
lower lifetime
cost than
alternatives
ESS
Lead batteries
specified as
product of
choice in
utilities and
domestic
energy storage
sector
WORK PROGRAMs
TECHNICAL R&D TECHNICAL COMMS
LEAD BATTERIES REMAIN PRODUCT OF CHOICE
Automotive Use of Lead Batteries
•Lead batteries essential for 12V Start Stop/micro hybrid Applications.
–Performance markedly enhanced by:
• basic research
• variety of innovations developed by production engineers, academic institutions and the
ALABC research program
–most technical parameters of modern lead and lead-carbon batteries are now
markedly enhanced or can be enhanced to match the requirements of OEMs
• improved dynamic charge acceptance
• reduced water loss at normal and elevated temperatures
• higher cold cranking power
• extra-long cycle life at high rate partial state of charge
• steady performance at elevated temperatures
Lead Batteries in 48 V applications
•ALABC has been involved in a number of successful demonstration
projects over the years with Honda, Hyundai/Kia, Ford
•Lead batteries provide excellent option for 48 V applications
• Cost effective CO2 reduction.
–99% recycling
–reliability and safety benefits
•Further information requested by OEM partners
–Would like further battery performance data under real world driving
conditions.
–Would like realistic cost estimates for battery packs under high volume
assumptions.
Generation 1: High Voltage Hybrid Projects
•Objectives
–Demonstration of lead battery endurance in mild hybrids
–Understanding hybrid vehicle battery requirements and challenges, optimize batteries
•Outcomes
–100,000 track miles on Honda Insight Mk 1 Furukawa Ultrabatteries
–150,000 road miles on Honda Civic Hybrid East Penn Ultrabatteries
–Good basis for further projects
Honda Insight with Ultrabatteries, Europe Honda Civic Hybrid with Ultrabatteries, USA
Up to 1 kWh the UB: as good as NiMH in Energy Power, Volume, Life
Generation 2: the 12/48 V Midsize Vehicle Projects
•Objectives
–Building 12/48V hybrids with lead-carbon batteries, optimize engine + battery system
–Demonstration of a commercially attractive alternative to other battery chemistries
•Outcomes
–Generation of significant interest (lots of requests from OEMs for PbA 48V hybrid
–Potential for further projects to exploit in production
Passat 1.4 gasoline Passat 1.4 gasoline Optima 1.7 Diesel Focus 1.5 Diesel
Meeting CO2 targets sustainably and at affordable price
Examples of field recorded data sets
Module and system voltage evolution during one test cycle
Examples of field recorded data sets
Capacity charged and state of charge during a test cycle
Examples of field monitored module temperature
Cell temperature is easily maintained below 40oC (max 40oC)
12/48 V Metrics – comparison of test vehicle parameters
The Test Vehicles and Their Batteries Offer Strong, Affordable Solutions
Key lessons from mild hybrids with lead-carbon batteries
1. The vehicle benefits from calibrating for each battery type (Orbital, Ultrabattery)
2. The NEDC test puts a premium on the charge acceptance around 20-25°C.
Lead-carbon batteries perform much better at only slightly higher temperature
(27°C+)
3. The best performance with lead-carbon batteries is achieved between 35 and
40°C without any deleterious effects on life
4. The best balance between charge acceptance and available energy appears to
be around the 40% SOC point
5. The benefits of improved cell design (Ultrabattery) have been very significant.
6. Customers today want to buy complete packs, not battery modules.
Communication with OEMs – Next Program
•Although there is interest, particularly from some OEMs, some more test
results are needed to address some questions that have been raised.
•The main question is:
“Though the performance is good on the relatively intense test running
shown, will the performance be maintained in more typical running?”
•A proposed new test aims to provide evidence of satisfactory operation on
an agreed test cycle more representative of typical driving. This has been
developed in discussion with an OEM and Millbrook Proving Ground.
Proposed Cycle (18 steps in 9.4 hours)
km km/hdrive (min)
park (min)
total hours
urban 6.4 32 12 0.2
park 15 0.5
rush hour 7 16.2 26 0.9
park 60 1.9
urban 6.4 32 12 2.1
urban 6.4 32 12 2.3
park 30 2.8
road 20 50 24 3.2
park 120 5.2
urban 6.4 32 12 5.4
park 60 6.4
road 20 50 24 6.8
park 15 7.0
urban 6.4 32 12 7.2
urban 6.4 32 12 7.4
park 30 7.9
rush hour 7 16.2 26 8.4
park 60 9.4
SUM PER DAY 92.4 172
Data Capture
•Key channels (all recorded at 10Hz when running):
–Module voltages and temperatures
–String current
–Battery charge
–Hybrid operating state (if available)
–Vehicle speed, engine RPM, throttle and brake positions
•Key off data recorded at low rate for battery
•Sampled data sent back to test manager over GPRS, monitored daily
•Full data collected every two weeks on SD card
Procedure
•Two week data collection, then rapid review
•Test will be continued for the next two week period if everything is
performing well, until it is felt that satisfactory performance has been
demonstrated to OEMs.
•Test will be stopped if any substantial performance shortfall is found
•Results will be made available to key partners, including raw test data.
Conclusions
• Past ALABC Demonstration Programs have demonstrated benefits of lead batteries at both 12V and 48V level.
• A number of OEMs seriously considering lead batteries for 48 V applications, but have requested further data under real world driving conditions.
• ALABC revaluating past data to show how optimisation of operating conditions (e.g temperature), vehicle calibration and cell design can maximise performance of Pb batteries.
• Will conduct new project using our current demo vehicles to collect data showing optimised performance under OEM recommended typical driving conditions. (To be presented at US AABC in San Francisco in June).