Design of a Li-ion battery: component selection, cell installation, connections, control, protection, isolation, thermal management, mechanical design. From the book "Li-ion Batteries and Applications" by Davide Andrea

1. Li-ion batteries
and applications
Baterías de iones de litio
y aplicaciones
Davide Andrea
Elithion Inc.
Volume 1: Batteries
Ch 6: Battery design
Volúmen 1: Baterias
Cap. 6: Diseño de la batería

2. Chapter 6.1
Battery design - Introduction
Diseño de la batería - Introducción
Ch 6.1: Battery design - Introduction

3. Ch 6.1: Battery design - Introduction
Definition
Definición
A battery has:

One current

One State of Charge

One protector switch (or a set of switches, for
charging and discharging separately)

Two power terminals (or more, for charging
and discharging separately)

4. Ch 6.1: Battery design - Introduction
Battery use classification
Clasificación de las baterías en función de su uso

Energy

Power

Buffer

5. Ch 6.1: Battery design - Introduction
Battery design checklist, 1
Lista de verificación de diseño de baterías, 1

Should I design a battery?

Establish application requirements

Produce battery specifications

Propose 2~3 solutions, select one

6. Ch 6.1: Battery design - Introduction
Battery design checklist, 2
Lista de verificación de diseño de baterías, 2

Main component selection

Cell mounting design

High power design

Low power design

Thermal design

Mechanical design

7. Ch 6.1: Battery design - Introduction
Application requirements
Requerimientos de aplicacion

The application

Desired life (years), number of cycles

Nominal battery voltage

Profile of the current during a cycle

Required energy density

Cost for first article, cost in quantity

8. Ch 6.1: Battery design - Introduction
Create battery specifications
Crear especificaciones de batería

Nominal capacity at the start of life

Actual capacity at the end of life

Initial range of SoC

Final range of SoC

Cell chemistry

Maximum value of MPT

9. Chapter 6.2
Battery design - Component selection
Diseño de la batería - Selección de componentes
Ch 6.2: Battery design - Component selection

10. Ch 6.2: Battery design - Component selection
Cell format, BMS suggestions
Formato de celdas, sugerencias de BMS.

11. Chapter 6.3
Battery design - Cell installation and
interconnection
Diseño de la batería - instalación e interconexión de
celdas
Ch 6.3: Battery design - Cell installation

12. Ch 6.3: Battery design - Cell installation
Small cylindrical cells
Celdas cilíndricas pequeñas

13. Ch 6.3: Battery design - Cell installation
Small cylindrical, series string
Celdas cilíndricas pequeñas, cadenas de series

14. Ch 6.3: Battery design - Cell installation
Small cylindrical, parallel-first
Celdas cilíndricas pequeñas, parallelo-primero

15. Ch 6.3: Battery design - Cell installation
Small cylindrical in a frame
Celdas cilíndricas pequeñas en un marco

16. Ch 6.3: Battery design - Cell installation
Small cylindrical voltage sensing
Detección de voltaje, celdas cilíndricas pequeñas

17. Ch 6.3: Battery design - Cell installation
Small cylindrical enclosure
Cerramiento para celdas cilíndricas pequeñas

18. Ch 6.3: Battery design - Cell installation
Large Prismatic cells
Celdas prismáticas grandes

19. Ch 6.3: Battery design - Cell installation
Large Prismatic arrangement
Arreglo de celdas prismáticas grandes

20. Ch 6.3: Battery design - Cell installation
Large Prismatic retention
Retencion de celdas prismáticas grandes

21. Ch 6.3: Battery design - Cell installation
Large Prismatic enclosure
Contenedor de celdas prismáticas grandes

22. Ch 6.3: Battery design - Cell installation
Pouch cells
Celdas de bolsa

23. Ch 6.3: Battery design - Cell installation
Pouch arrangement
Arreglo de celdas celdas de bolsa

24. Ch 6.3: Battery design - Cell installation
Pouch cell stack
Pilas de celdas de bolsa

25. Ch 6.3: Battery design - Cell installation
Pouch cell modules
Módulos de celdas de bolsa

26. Ch 6.3: Battery design - Cell installation
Small prismatic, large cylindrical
Celdas prismáticas pequeñas, grandes celdas cilíndricas

27. Chapter 6.4
Battery design - BMS installation
Diseño de la batería - Instalación de BMS
Ch 6.4: Battery design - BMS installation

28. Ch 6.4: Battery design - BMS installation
BMS power
Alimentación del BMS

29. Chapter 6.5
Battery design - Sensing
Diseño de la batería - Detección
Ch 6.5: Battery design - Sensing

30. Ch 6.5: Battery design - Sensing
Cell voltage sensing
Detección de la tensión de las celdas

31. Ch 6.5: Battery design - Sensing
Current sensing
Detección de la corriente

32. Ch 6.5: Battery design - Sensing
Resistive current sensing
Detección de la corriente, método resistivo

33. Ch 6.5: Battery design - Sensing
Hall Effect current sensing
Sensor de corriente, método Hall effect

34. Ch 6.5: Battery design - Sensing
Two current sensors
Dos sensores de corriente

35. Chapter 6.6
Battery design - Communication links
Diseño de la batería - Enlaces de comunicacion
Ch 6.6: Battery design - Communication links

36. Ch 6.6: Battery design - Communication links
Wired buses
Buses cableados

37. Ch 6.6: Battery design - Communication links
Standard buses, physical layer
Buses estandar, estrato físico

38. Ch 6.6: Battery design - Communication links
Bad communication example
Ejemplo de mala comunicación

39. Ch 6.6: Battery design - Communication links
CAN, RS485
CAN, RS485

40. Chapter 6.7
Battery design - Control
Diseño de la batería - Control
Ch 6.7: Battery design - Control

41. Ch 6.7: Battery design - Control
Control inputs
Entradas de control

42. Ch 6.7: Battery design - Control
Switch driven control input
Interruptor conectado a una entrada de control

43. Ch 6.7: Battery design - Control
Control outputs
Salidas de control

44. Ch 6.7: Battery design - Control
Open drain outputs
Salidas con drenador abierto

45. Chapter 6.8
Battery design - Protection
Diseño de la batería - Proteccion
Ch 6.8: Battery design - Protection

46. Ch 6.8: Battery design - Protection
Protection is required
La protección es necesaria
THE BMS MUST BE ABLE
TO SHUT OFF THE BATTERY CURRENT COMPLETELY!

47. Ch 6.8: Battery design - Protection
Protector switch topologies
Topologías de interruptor de protección

48. Ch 6.8: Battery design - Protection
Single switch topology
Topología de un solo interruptor

49. Ch 6.8: Battery design - Protection
Dual switch single port topology
Topología de doble interruptor, puerto único

50. Ch 6.8: Battery design - Protection
Dual port topology
Topología de doble puerto

51. Ch 6.8: Battery design - Protection
Switch components
Componentes para un interruptor

52. Ch 6.8: Battery design - Protection
Single port MOSFET topology
Topología MOSFET con puerto único

53. Ch 6.8: Battery design - Protection
Dual port MOSFET topology
Topología MOSFET de doble puerto

54. Ch 6.8: Battery design - Protection
Single port contactor topology
Topología contactor con puerto único

55. Ch 6.8: Battery design - Protection
Dual port contactor topology
Topología contactor de doble puerto

56. Chapter 6.9
Battery design - Precharge
Diseño de la batería - Precarga
Ch 6.9: Battery design - Precharge

57. Ch 6.9: Battery design - Precharge
Current with no precharge
Corriente sin precarga

58. Ch 6.9: Battery design - Precharge
Current with no precharge
Corriente sin precarga

59. Ch 6.9: Battery design - Precharge
Pulse duration with no precharge
Duración del pulso sin precarga

60. Ch 6.9: Battery design - Precharge
Precharge plot
Gráfica de precarga

61. Ch 6.9: Battery design - Precharge
Precharge circuit
Circuito de precarga

62. Ch 6.9: Battery design - Precharge
Complete contactor circuit
Circuito de contactores completo

63. Ch 6.9: Battery design - Precharge
Precharge responsibility
Responsabilidad de precarga

64. Ch 6.9: Battery design - Precharge
Post-discharge
Descarga después de apagar

65. Chapter 6.10
Battery design - Battery isolation and
ground faults
Diseño de la batería - Aislamiento de la batería y
fallas a tierra.
Ch 6.10: Battery design - Isolation

66. Ch 6.10: Battery design - Isolation
Why isolation?
¿Por qué aislamiento?

67. Ch 6.10: Battery design - Isolation
Which batteries need isolation?
¿Qué baterías necesitan aislamiento?

68. Ch 6.10: Battery design - Isolation
Grounded applications
Aplicaciónes conectadas a tierra

69. Ch 6.10: Battery design - Isolation
Battery isolation
Aislamiento de la batería

70. Ch 6.10: Battery design - Isolation
Risks of grounded batteries
Riesgos de las baterías conectadas a tierra

71. Ch 6.10: Battery design - Isolation
Automatic ground fault detection
Detección automática de fallas a tierra
Types:

Isolation loss

Ground fault current

72. Chapter 6.11
Battery design - Chargers
Diseño de la batería - Cargadores
Ch 6.11: Battery design - Chargers

73. Ch 6.11: Battery design - Chargers
AC charger control
Control de cargadores alimentados por AC

74. Ch 6.11: Battery design - Chargers
Multiple chargers
Cargadores múltiples

75. Ch 6.11: Battery design - Chargers
Multiple charger control
Control de múltiples cargadores

76. Ch 6.11: Battery design - Chargers
Charger selection
Selección de cargador

CCCV output

Output voltage, current

Power

AC input

Control:

Not adjustable

Adjustable with screwdriver adjustments

Remotely configurable (e.g.: though the CAN bus)

Multiple chargers:

For parallel operation

For series operation

77. Chapter 6.12
Battery design - Radio noise, EMI
Diseño de la batería - Ruido radioeléctrico
Ch 6.12: Battery design - Radio noise, EMI

78. Ch 6.12: Battery design - Radio noise, EMI
Noise sources
Fuentes de ruido

Switching converters

Radio transmitters

79. Ch 6.12: Battery design - Radio noise, EMI
Switch-mode noise generation
Ruido generado por fuentes de alimentación conmutadas

80. Ch 6.12: Battery design - Radio noise, EMI
Bouncing battery
Baterías saltarinas

81. Ch 6.12: Battery design - Radio noise, EMI
Noise immunity and reduction
Inmunidad al ruido y reducción del mismo
Immunity:

Switch-mode: routing, twisting, isolation,
grounding

Transmitters: ferrite clamps
Reduction:

Shielding, enclosing, grounding

82. Chapter 6.13
Battery design - Thermal management
Diseño de la batería - Gestión térmica
Ch 6.13: Battery design - Thermal management

83. Ch 6.13: Battery design - Thermal management
Temperature plot
Gráfico de temperatura

84. Ch 6.13: Battery design - Thermal management
Thermal management techniques
Técnicas de gestión térmica

85. Ch 6.13: Battery design - Thermal management
Insulation
Aislamiento

86. Ch 6.13: Battery design - Thermal management
Passive heat transfer
Transferencia de calor pasiva

87. Ch 6.13: Battery design - Thermal management
Active heat transfer
Transferencia de calor activa

88. Ch 6.13: Battery design - Thermal management
Air path
Trayectoria del aire

89. Ch 6.13: Battery design - Thermal management
Airflow through the battery
Flujo de aire a través de la batería

90. Ch 6.13: Battery design - Thermal management
Channeled airflow
Flujo de aire canalizado

91. Ch 6.13: Battery design - Thermal management
Liquid cooling
Refrigeración líquida

92. Ch 6.13: Battery design - Thermal management
Thermal storage
Almacenamiento termico

93. Ch 6.13: Battery design - Thermal management
Heating and cooling
Calefacción y refrigeración

94. Chapter 6.14
Battery design - Mechanical design
Diseño de la batería - Diseño mecanico
Ch 6.14: Battery design - Mechanical design

95. Ch 6.14: Battery design - Mechanical design
Mechanical design
Diseño mecanico

Protect from wandering fingers

Offer an environmental protection
appropriate for the use

Be electrically insulated from the
battery

Be sufficiently rugged against expected
abuse, without adding excessive mass

96. Chapter 6.15
Battery design - Regulatory standards
Diseño de la batería - Normas regulatorias
Ch 6.15: Battery design - Regulatory standards

97. Ch 6.15: Battery design - Regulatory standards
Regulatory standards
Normas regulatorias