The document summarizes a project to develop a multifunctional intelligent battery cell (MIBC) with integrated sensors. The project aims to reduce battery cell waste by enabling secondary use in stationary applications. Sensors have been integrated into demonstration battery cells to measure pressure, current, temperature and gas composition. Abuse testing shows the sensor-integrated cells perform similarly to unmodified cells in safety. Future work will optimize sensor performance and evaluate manufacturability of the MIBC design.

1. Presentation Title
(Arial Bold 30pt)
Author, Co-author Name, Organization (Arial 23pt)
Company Logo
INDIA
Theme: Disruptive Technology for Affordable and Sustainable Mobility
2-5 October, 2018
Chennai Trade Centre, India
Session No : Battery Technology (EHV4)
Battery Passport for Multifunctional
Intelligent Battery Cells and Packs for
Automotive and Stationary Applications
Matthias Popp and Michael Vogt
SGS Transportation

2. INDIA FISITA 2018
SGS Group – At a Glance
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Nº1
WORLD LEADER
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EMPLOYEES
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GLOBAL
SERVICE
LOCAL
EXPERTISE

3. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
SGS Group - Automotive Services
SOURCE
We test
materials and
parts to OEM
and industry
standards to
facilitate the
supply chain
BUILD
We verify that
manufacturer
vehicle design
and quality
meets
regulations and
gains market
access
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We audit
delivery and
aftermarket
operations to
ensure quality
and brand
guidelines
adherence
POWER
We enhance
the design,
construction
and operation
of motor
vehicles, testing
fuels, lubricants
and usability
SAFEGUARD
Our vehicle
testing centres
worldwide
verify safety
and minimise
environmental
impact
AMAZE
Annette loves
the feeling of
going for a
drive in her
new car

4. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Agenda
• Introduction & Project Overview
• Multifunctional Intelligent Battery Cells (MIBC)
• Project Results

5. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Project Motivation
• Reduction of CO2 emissions drives e-mobility and thus battery usage
• Secondary use of battery cells in stationary applications could help to reduce
carbon footprint
• Development of a smart cell with additional sensing devices for prediction of
lifetime, usability and maintenance

6. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Project MIBC: Multifunctional Intelligent
Battery Cell
• German federal funded project to research a multifunctional intelligent battery cell (MIBC)
• Project budget: 12 million EUR
• Project duration: November 2015 to January 2019
• Seven project members from different industries, universities and research institutes
funded project of

7. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
MIBC Demonstrator
• First MIBC demonstrator with external electronic
boards and sensors.
• Electronic board includes the logical device to handle
sensor data, the battery pass and the communication
interface.
• Electronic boards will be minimized for industrialization
and will be mounted on top of the battery cell
between the cell connectors.

8. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Influences on Cell Safety

9. INDIA FISITA 2018
Approach to Battery Safety
• Safety of a battery depends on several parameters
• System safety requires that all parameters are considered
• Cell safety can be investigated with dedicated tests under
abuse conditions
• Risk analysis shows that countermeasures need to be in
place to avoid harm to humans and the environment
• Functional safety standards state the procedure to develop
safety related systems e.g. BMS
)
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications

10. INDIA FISITA 2018
Project MIBC: Part of SGS
Functional Safety for ‘Active Safety’
• SGS examines the applicable standards for functional safety
(automotive and stationary apps)
• Comparison of automotive and stationary requirements to reduce
development effort during the design phase
• Assessment of the used electronic architecture which is needed for
industrialization
Battery cell Testing under Abuse Conditions
• SGS and involved project partners define abuse test cases and adapt
test cases if necessary
• Execution and analysis of tests and results for battery cells (reference
cell vs. MIBC)
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications

11. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Reference Cell Parameters
• NMC + Graphite
• Prismatic Metal Case
• All connections integrated on the top
• Capacity < 35Ah

12. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Integrated Pressure Sensor
• Integrated sensor and terminal board is glued directly to cover assembly

13. INDIA FISITA 2018
Δt = 21 minutes
overcharging
stopped
vent opens
Cell internal pressure during overcharge
• Cell is overcharged until 200% SOC at
1C until 4.4V. No pressure build up or
temperature increase is measured.
• Pressure is very sensitive to overcharge,
this is detected 21 minutes earlier than
using critical temperature of 50°C.
Pressure sensing could be used as true
redundancy to voltage sensing.
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications

14. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Current Sensor
• Sensor Principle: Magnetoresistance
• Galvanic Separation
• Low-voltage Drop
• Compensation of Stray Fields

15. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Gas Sensor
• Functional demonstrator with lithium button cell battery:
• Results during forming and over-charge of the battery cell:

16. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Additional Cell Intelligence
Digital Cell Pass
• Collection, compression and storage of critical cell parameters
• Encrypted secure access control of the data
• Sensorless temperature measurement via EIS1
SOC/SOH Estimation
• Models with U, I and T are state of the art
• Further development by inclusion of pressure sensor and reference electrode, possibly
also gas sensor
• Further expansion for performance prediction, optimized loading etc.
1 EIS: Electrochemical Impedance Spectroscopy

17. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Communication Between MIBC’s
Capacitively Coupled Ring Bus:
• Twisted Pair Cable
• Capacitive or Inductive Coupling
• Data rate: ≥ 1Mbit
• Wake up and Sleep Function
• Integrated in the MIBC Function Demonstrator
CSC
Battery
Stack
CSC
CSC
CSC
HV+
HV-
UART_MOBuC (Comm.)
Host Controller
Transceiver
CSC
trafo
RX
TX
RX
TX
RX
TX
TX
TX
RX
TX
TX
IF_HS
IF_LS
IF_HS
IF_LS
IF_HS
IF_LS
IF_HS
IF_LS
IF_HS
IF_LS
IF_HS
IF_LS
Slave n-1
Slave n+1
trafo
UART_MOT
Master to Slave
Slave to Master

18. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Why is a Wireless Communication not an Option?
• Wireless communication in battery systems was not an option for the MIBC Project.
• Limitation factors for a wireless communication are:
– Many metal components inside a battery system leads to reflections of the signal.
– Increased complexity for design, placement and integration of components (investigated
in a European funded project called Smart-LIC).
– Required special antenna geometries inherit scalable battery systems (topology, housing
etc. are different).

19. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Abuse Test Performed by SGS
• Abuse tests are first executed with reference cells (cells without integrated sensors)
• Second step is to execute abuse tests with MIBC (sensors are integrated)
• Results from first and second tests should show difference under abuse condition
and should confirm HL ≤ 4
• Test results are currently being evaluated and analyzed
• A specific set up of tests are executed:
– Over charge
– Short circuit
– Nail penetration with ceramic nail (IEC DTR 62660-4:2016)
– Crush
– Hot plate (individual OEM test spec)

20. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Abuse Tests Ref: Cell (Hot Plate)

21. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Abuse Tests Ref: Cell (Ceramic Nail)

22. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Abuse Tests MBC Demonstrator (Ceramic Nail)

23. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Abuse Tests MIBC Demonstrator (Over Charge)

24. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Safety: Automotive vs. Stationary
Automotive Requirement:
• ASIL2 C for BCU to avoid malfunction on cell level
• Lifetime: 5 years
• ISO 26262 is the relevant standard
• Important: Second edition of ISO 26262 will be published mid 2018. Scope of the
standard extends to motorcycles, heavy duty vehicles and busses
Stationary Storage Requirement (Second Use):
• SIL3 2 for BCU to avoid malfunction on cell level
• Lifetime: 10 years
• IEC 61508 is the relevant standard
• Note: IEC 62619 (Safety requirements for secondary lithium cells and batteries
for use in industrial applications) has been reworked and published in February
2017 and recommended by IEC 61508.

25. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Comparison Functional Safety Requirements
• The selected standards for functional safety include different requirements on
system: HW-, and SW-Level
• A comparison is necessary and carried out to identify the differences in detail
• Assumptions:
– Second use in a stationary app
– System is first used in an automotive environment
– System fulfills the requirements of ISO 26262
– Perspective of comparison ISO 26262  IEC 61508
• Result of comparison shows that 100 requirements are similar
• Comparison shows, that different requirements from the standards (e.g. on SW-,
HW-Level)

26. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Preliminary Results
• Tests at cell level show that the sensors integrated into the cell function in the chemical
environment (e.g. electrolyte)
• Abuse tests of MIBC cells with integrated sensors actually shows no deterioration in
safety behavior (hazard level)
• Validation of various sensors was performed successfully
– Pressure sensor and internal temperature sensor
– Sensorless temperature measurement via impedance
– TMR current sensor could be validated  no hysteresis
• Sensors are able to measure different parameters on cell level:
– Internal temperature measurement enables decreasing of safety margins
– Pressure measurement could be used as redundant signal to voltage sensing

27. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Next Project Steps
• Further testing of sensors
• Optimization of sensorless temperature determination
• Evaluation of manufacturability and cost potential

28. INDIA FISITA 2018
Battery Passport for Multifunctional Intelligent Battery Cells
and Packs for Automotive and Stationary Applications
Many Thanks
• Thank you very much for your attention
• Many thanks to all project members of MIBC
• Many thanks also to German Ministry of Education, Science, Research
and Technology (BMBF) for financial funding of the project
(Förderkennzeichen 03XP0027G)