清华大学 锂电池管理系统

Battery

Management

SystemECG

of

Tsinghua

UniversityDr.

Languang

Lu2010-9-1Contents•

Automotive

battery

status

anddevelopment

trend•

Battery

current

major

problems•

Key

Technology

of

batterymanagement

system•

Battery

management

Systemin

Tsinghua

UniversityPlug-in

Plug-inAPUAPU(Fuel-

cell)

Vehicle

battery

power

system

and

its

requirements

Green

Power-train

SystemDivided

by

topology

：parallel,

SeriesDivided

by

deep

ofhybrid:

start/stop,

micro,mild,

strong,

plug-in,BEV.

The

Keycomponent

of

the

GreenPower-train

is

Battery.For

different

deep

ofhybrid

system,

thebattery

performancerequirements

(specificenergy,

specific

power)are

different

.Series

Hybrid

Bus

(60Ah)：the

maximum

discharge

C

rate

is

8C，the

rated

dischargerate

is

about

5CParallel

Hybrid

Bus

（40Ah）：

the

maximum

discharge

C

rate

is5C，

the

rateddischarge

rate

is

about

2.3CPlug-in（30km）Hybrid

Bus（140Ah）：

the

maximum

discharge

C

rate

is

3C，

therated

discharge

rate

is

about

2CPlug-in（60km）Hybrid

Bus（280Ah）：

the

maximum

discharge

C

rate

is

1.7C，the

rated

discharge

rate

is

about

1.1CHybrid

passenger

car：

the

maximum

discharge

rate

is

greater

than

10C，

the

rateddischarge

rate

is

greater

than

5CShort

low-speed

urban

micro-car

（<60km/h)：the

maximum

discharge

rate

is

about

1CShort

high-speed

urban

micro-car（>80km/h):

the

maximum

discharge

rate

is

about

3Cyear200820092010201220202030Annualownershipinhybridvehicles50005000015000050000025000005000000Annualalternativefuel（thousandtons）54617548838327663AnnualCO2reducedemissions（thousandtons）1514554915261199323986Number

of

vehicle（k）2005201020152020202520302035HEV-year

goal

of

Chinese

6000

5000

4000

3000

2000

1000

0

yearfrom：

International

hybrid

electric

vehicle

technologydevelopment

and

application

of

large-scale

seminars

，2008-12-9~10Rechargeable

batteries

cost

Nickel

metal

hydride,

nickel

cadmium

batteries

to

stabilize

thepriceLithium

ion

battery

prices

decrease,

the

price

has

been

lower

thanthe

nickel-metal

hydride

batteries,

in

future

it

will

be

able

to

reach2RMB/wh（in

china

the

price

of

energy

LiFePO4

battery

is2.8

RMB/wh

now）Cost

analysis

of

different

power-systemsMicro-HEV

system

strong-HEV

systemStart/stop

system

Mild-HEV

systemMini-EV

systemFull-EV

system

PHEV

systemAnalysis

showed

that

：In

the

current

oil

prices,

battery

price

.

With

the

lithium-ion

batteries•Start-stop、Micro-HEV

and

Mild-HEV

are

Profit，Therefore,

the

industrialization

of

these

kind

hybrid

could

be

undertaken•

Strong-HEV、PHEV

are

in

the

state

of

Maintain

principal•Mini-EV

Is

still

not

profitableDepends

on

the

extension

of

battery

life,

the

price

reduction

and

oil

prices

rise(but

the

mini-EV

base

on

Lead-acid

batteries

is

profit.•

Full-EV

profit

is

depends

on

the

battery

technology

leapAnalysis

base

on

the

following

supposes：（1）

Vehicle

service

life

of

200,000

kilometers（2）the

start-stop、micro-HEV、Mild-HEV、strong-HEV、PHEV、Mini-EV、Full-EV

fuel

saving

is

6%、12%、15%、20%、60%、100%、100%

respectively（3）

Conventional

vehicle

fuel

consumption

is

6L/(T*100km）（4）

the

battery

capacity

of

start-stop、micro-HEV、Mild-HEV、strong-HEV、PHEV、Mini-EV、Full-EV

is：0.18、0.36、0.5、1、3.6、16、36kWh/T

respectivelyCommonly

used

car

power

lithium

ion

battery

at

present

Three

elements

（LiCoxNiyMn1-x-yO2）Li-ion

Battery(the

United

States,

Europe

and

Japanese)

Lithium

manganese

(LiMn2O4

)

battery（

Japanese,

Chinese）

Lithium

iron

phosphate

（LiFePO4）battery

（Chinese,

the

United

States,

Europe

）

Lithium

manganese（

Spinel

structure）Lithium

iron

phosphate

（

olivine

structure）

Three

elements（layer

structure）Contents•

Automotive

battery

status

anddevelopment

trend•

Battery

current

major

problems•

Key

Technology

of

batterymanagement

system•

Battery

management

Systemin

Tsinghua

University

The

keyproblemsdurabilitysafety

Cell

to

Cell

variation(capacity,

Impedance)

cost

manufactureIntegration

andmanagement•Hightemperature,•overcharge•Over

discharge•High

rate

charge

or

discharge

MaterialabuseThe

main

issues

of

current

lithium

ion

battery•SOC

differentBattery

pack

Cell

to

Cell

variationcoolant-out

coolant-outcoolant

-inCoulomb

efficiency

different

of

cell

to

cell•temperature

difference

of

cell

to

cellenvironment•Capacity

different•Resistant

different

coolant

-in•Shelf

discharge

different-20~55

℃Lithium-ion

batterysafety

operating

windowLithium-ion

batterysafety

operatingwindow

is

narrowLiFePO4operatingvoltage

：2.5~3.6Voperating

temperature：Battery

technology

is

the

core

ofthe

3

key

technology

of

EV(battery,motor,

and

control)Contents•

Automotive

battery

status

anddevelopment

trend•

Battery

current

major

problems•

Key

Technology

of

batterymanagement

system•

Battery

management

Systemin

Tsinghua

UniversityKey

Technology

of

batteryCELLModule:

电源模块，包括电池

组、电池热管理系统，电池监

控信号系统、密封防水、阻燃Power

Systems：包括电源管理系统、充电机

及充电管理系统、电池组模块等。BMS：电源管理系统，对各电池或电池模块

进行管理，包括安全保护、电量及电池状

态监控及显示、电池均衡控制、充电控制。

等功能，免维护设计。

保护控制

圆柱、方形、聚合物

功率型、能量型正极：磷酸铁锂、锰酸锂、三元材料负极：石墨、硬碳、钛酸锂

CELL

BLOCK

MODULE

BMS

SYSTEM

Cell

:

单体电池Cell

Block:

单体电池串并连接体，

设计上考虑电池连接的可靠性，Specifications

and

standards

forElectric

vehicle

batterySAE

J2344,EN1987-1EN1987-2EN1987-3GB/T

18384.1,

Safety

requirements

for

electric

vehicle,

part

I:Vehicle

energy

storageGB/T

18384.2,

Safety

requirements

for

electric

vehicle,

part

II:Safety

and

fault

protection

functionsGB/T

18384.3,

Safety

requirements

for

electric

vehicle,

part

III:Danger

of

electric

shock

protectionQC/T

743-2006,

Lithium-ion

batteries

for

electric

vehicleGB

4208-93,

Enclosure

protection

class

(IP

Code)Specifications

and

standards

forElectric

vehicle

batteryGB/T

XXXXX-XXXX,

Electric

vehicle

with

lithium-ion

batterypack

and

system

testing

procedures

(draft)GB/T

XXX

,The

communication

protocol

Electric

vehiclebattery

management

system

with

non-vehicle

charger

(draft)SAE

J1742,

Road

vehicles

wiring

harness

to

connect

high-voltage

test

methods

and

general

performance

requirementsSAE

J2380,

Vibration

test

electric

vehicle

batteriesSAE

J2464,

Electric

vehicle

battery

abuse

testsETA-HTP008,

Battery

ChargingJEVS

TG

Z002,

High

voltage

components

for

electric

vehicle-related

identity

guidelinesJEVS

TG

Z001,

Operation

of

electric

vehicle

chargingguidelines

identify

the

relevantBMS

Function

definedParameters

DetectionSOC

SOH

SOFOBDSecurity

alarm

and

controlCharge

control

EMCInformation

storage

TTCAN

balanceBMS

Function

definedParameters

Detectionincluded:

bus-voltage,

current,

cell

voltage,

temperature,

leakagegas,

Insulation

,

Collision

and

ImpedanceSOC(State

of

charge)estimationbased

on

the

discharge

current,

temperature

and

voltage

conditionsSOH(State

of

Health)estimationbased

on

the

battery

degradation

and

abuseSOF(State

of

Function)estimationAccording

to

the

SOC,

SOH

and

the

environment,

estimated

theoutput

capacity

of

the

batteryIn

addition

to

diagnosticperformance,

the

contactresistance

can

be

diagnosed

andfound

loose

jointsOn-board

diagnosis

（OBD）and

predictioninclude：

Sensor

failure,

actuator

failure,

network

failure,

the

batteryitself

fault,

overvoltage

(overcharging),

undervoltage

(through

put),over-current,

ultra

high

temperature,

ultra-low

temperature,

jointsloose,

flammable

gas

concentration

in

excess

of,

insulation

failure,consistent

failure

,

temperature

rise

too

fast,

etc.Security

alarm

and

controlIncluding

thermal

control,

fault

diagnosis

to

inform

the

vehicle

controller

or

charger

through

the

network,

required

vehicle

controller

or

charger

to

process

(BMS

can

also

cut

off

power

supply

output

if

over

a

certain

limit

),

in

order

to

protect

the

battery

or

person

form

high

temperature,

overcharge,

over

discharge,

over

current,

electric

leakage.Charge

controlBMS

according

to

the

characteristics

of

its

own

battery

and

chargerpower

rating,

by

controlling

the

charger

to

recharge

the

battery.BMS

Function

definedBattery

balanceAccording

to

the

battery

cells

information,

using

a

balanced

charge,or

dissipation,

or

energy

transfer,

and

so

on

,

in

order

to

keep

eachcell

SOC

consistent

as

far

as

possible

.Network

For

the

convenience

of

On-line

calibration,

monitor,

automatic

codegeneration

and

on-line

program

download,

the

network

is

needed.Information

storageused

to

store

the

key

data,

such

as

SOC,

SOH,

accumulated

chargeand

discharge

capacity,

failure

code,

consistent

information

etc.Electromagnetic

compatibility

(EMC)BMS

must

have

good

resistance

to

electromagnetic

interference（EMS）,

because

of

the

poor

conditions

of

electric

vehicles.BMS

Function

definedThe

3

key

technologies

of

BMS

High

precision

detection

of

cell

differentialvoltage

under

high

common-mode

voltage

Cumulative

voltage

can

reach

more

than

300

V,

accuracy

level

is

a

few

mV

methods:

Resistor

divide,

Optocoupler

isolation

amplifier

,

Discrete

Transistor,

Distributed

measurement,

Coupler

relay

etc.

Precision

SOC

estimation

Many

factors

that

affect

SOC

,

such

as

the

accuracy

of

the

measurement

(current,

voltage,

temperature

etc.),

the

load

,the

operating

temperature

and

the

degradation

of

the

battery

etc.Method：

Current

integration,

OCV,

load-voltage,

Resistance,

Neural

network

modeling,

Kalman

filtering

method

etc.Balance

of

the

batteryefficiency,

costResistor

dissipation

Inductance

+

Combination

Switch

capacitorCoaxialinductorContents•

Automotive

battery

status

anddevelopment

trend•

Battery

current

major

problems•

Key

Technology

of

batterymanagement

system•

Battery

management

Systemin

Tsinghua

University电流（A）电流（A）1.

The

simulation

platform

for

EV

Driving

cycle

System

model020040080010001200-10010050

0-50200150

600时间（s）0200400100012001400-10010050

0-50200150600

800时间（s）Battery

operating

cycle2.

Battery

performance

testing

and

modeling

LiFePO4Improved

lead-acid

batteriesNi-MHLithium

manganesebattery

test

equipment电池基本性能阻抗特性加速寿命试验

温度特性电池耐久性

温度放电倍率放电截止电压

充电倍率充电截止电压

加速应力内阻增加容量衰减Battery

performance

testing

and

modeling

Single

Cell

Testing

and

Modeling

Base

performance

test

and

analysis

performance

test

and

analysis

under

driving

cycle

Durability

test

and

analysis

Single

cell

modeling

Pack

Testing

and

Modeling

Base

performance

test

and

analysis

Cycle

test

and

analysis

Pack

network

Modeling

开路电压特性factorslevelsTemperatureADischargecut-offvoltageBDischargecurrentCChargecut-offvoltageDChargecurrentE1301.25V5C3.65V1/3C2401.5V3C3.75V1/2C3501.75V1C3.85V1C4602V1/3C3.95V1.5C预备试验内阻增加容量衰减放电截止电压

充电倍率充电截止电压

……

加速应力正交设计放电截止电压

充电倍率容量衰减率耦合关系充电截止电压

……

加速应力

℃Durability

test

method

(Orthogonal

accelerated

)

Accelerated命试验

温度放电倍率加速寿

Life

TestPreparation

test

温度

放电倍率almost

4

times

in

50

℃than

that

in

30

℃50

℃30

℃The

degradation

isBattery

pack

modelingBattery

networkmodelingTesting

procedures

in

TsinghuaUniversity3、

Battery

management

system

hardware

and

software

developmentEMC

TechnologySignals

Collection

and

storage

moduleaccording

to

the

function

in

section

2TTCAN

network

technologyCommunication

protocol

(included

the

protocol

with

charger),

on-line

calibrateand

monitor,

automatic

code

generation

and

on-line

programUnderlying

software

based

on

OSEKThermal

Management

Module(cooling

and

heating)High

voltage

management

module(leakage,

isolate,

control)SOC（each

cell）,SOH,

SOF

and

OBDEach

cell

has

its

own

ID

and

its

own

data

fileBattery

management

systemhardware

framework

数数数数Digital

CoreS12XEP100数数数数

Charging

Circuit

数数数数数数数

Toltal

V/I

Measurement

数数数数Cell

Temp.

Sensor

Arrary

数数数数数数

Cell

Voltage

Measurement数数数数数数数

General

Analog

Inputs数数数数数数数

General

Digital

Inputs数数数数数数

Internal

Power

Supply数数数数数数

Men-Machine

Interface

数数数数数

Thermal

Management数数数数数数BalanceControl

Circuit数数数数数数数

High

Voltage

SafetyControl

数数数数

Communication

Module数数数数数数

Global

Timer

Module数数数数数数数

General

Digital

Outputs数数数数数数数数数数数数数数数数数数数数数数数数数数数

数

/数

数

数

数

数

数数

数

数

数

/数

数

数

数数

数

数

数

/数

数

数

数VCx:数

数

数

数

数

数VBx:数

数

数

数

数VBx:数

数

数

数

数数数数数数数数

1数数数数数数数

2数数数数数数数

1数数数数数数数

2

IT0:数

数

数

数

数

数

数

数

数

VT0:数

数

数

数

数

数

数

数

数T1,T4:数

数

数

数

数

数

数T2,T5:数

数

数

数

数

数

数

数

数T3,T6:数

数

数

数

数

数

数

数

数TCx:数

数

数

数

数

数

数

数

数SWx:数

数

数

数

数

数

数

数数数数数数数数数数数数数数数数数数数数数数数数数

数数数数

DC/DC数

数

数数

S1:数

数

数

数

数

数

数

数

S2:数

数

数

数

数

数

S3:数

数

数

数

数

数

数

数

F1:数

数

数

数

数

数CCP数

数

数

数数

数

数

数

CAN数

数

1数

数

数

数

CAN数

数

2数数数数数数数数数数数数数数数数数数数数数数数数数数数数Battery

management

system

hardware

framework……………CAN紧急保通讯模块护开关非隔离DC/DC5V输出继电器线性稳压器3.3V输出DC/DC输出CANFLASH:

64K

BYTES码互阵

CIP-51内核信号

绝对抗干扰模块公共端AHardwareframework

of

CM(cell

monitor)

单片电压采集

内部CAN网络燃料电池电堆单片电压采集

单板硬件结构

每块单板可采集

124路单片电压信号

电源模块

控制系统用24V电源

电源滤波＋保护

CAN

接口电路

隔离

时钟电路、复位电路

隔离

RAM:

4K

BYTES

GPIO

译

硬

件

C8051F040

器

ADC0

锁

列

+

处理

值

电路

-

电路

精密隔离运放

AD202

…

燃料电池堆

…

奇数序号

…

+5V受控于译码器

+5V受控于译码器

+5V受控于译码器

光控继电器

AQW214阵列

偶数序号

+5V

+5V

+5V公共端Bpatent：ZL200510086690.8Solve

the

following3

key

issues

①

High

Cumulative

voltage

②

“common

earth”

③

The

absolute

value

of

the

signal

Error

<5mV

Number

of

channels

meet

each

cell

detectedCell

voltage

test

socAh

integrateOCVLoad-VoltageResistanceLinear

modelNeural

networkModeling

Kalman

filteringSelf

dischargeLithium

manganese

reasonThe

flat

voltage

of

Li-ionbattery,

especially

LiFePO4Highly

nonlinear

（

Iondiffusion

is

about

10-9cm2/s)Accuracy

of

the

sensors(especially

the

currentsensors

and

cell

voltagedetect)

solutionscompensated

by

differentmodelsCurrent

Sensor

Compensation

Improve

the

accuracy

of

inputby

using

the

voltage

differenceRegularity

Maintenance（balancecharge）LiFePO4

battery

Resistance

of

LiFePO4

battery△VBattery

management

system

software

copyright

V1.0，2009SRBJ5098SOC

estimation

base

on

Practical

Engineeringtest（

Large

amounts

of

data

MAP）Based

on

Ah

integrationCompensated

by

the

following

methods

Degradation

of

capacity（map）

Self

discharge（map）

Coulomb

efficiency

Full

charge

OCV（map）SOC=

SOC0

+η∫Idt

C

SOC

Diagnosis•sensors•actors•network•Cell•overvoltage•Over

current•SOC•Loose

joints•isolation•Over

or

lowtemperature•Over

temperaturerising

rate•consistentSOC

currenttemperature

time

minSOHLimitBatteryoutputcurrentcapability

SOF

Algorithmvoltage

SOC

estimation

Battery

temperature

voltage

current

isolationLeakage

gas

concentration

Signals

in

networkBattery

balance

technologyBalance

charge

(for

plug-in,

EVusing

in

battery

maintain)Dynamic

balanceWorm

gear

+

stepping

motor

to

choosethe

cell

to

be

balanced,

and

to

achievebalanced

of

the

battery

by

directly

controlof

two-way

DCDC

through

a

micro-controllerBattery

balance

technology

in

TsinghuaWith

balance

charge

the

available

capacity

withoutbalance

charge

depends

on

thesmallest

capacity

of

single

cells(depend

on“the

lowest

water

level

ofthe

glass

cup”)the

available

capacity

with

balancecharge

depends

the

minimumcapacity

of

single

cells

(depend

onthe“Minimum

volume

of

glass”）

Full

charge

of

the

battery

without

balance

chargeBalance

chargeAfter

maintaining

by

abalanced

charge,

it

do

notneed

to

balance

in

eachcharge,

because

theinconsistency

is

todeterioration

over

a

periodof

time.Available

capacityAvailable

capacityVCn/2+1

Active

balanced

subsystem

VCnBalance

current

is

largeBalance

depend

on

eachcell

SOCPatent:200910092039.x200910092039.x

VCn/2

VC0

Available

capacityPage

40Charge

control

in

BMSFast

Charge

or

Slow

charge

depend

onThe

customer

and

the

conditions

of

the

batteryBMS

Charge

control

processing：1.Communication

with

charger2.

According

to

the

battery

charger

power

class,

the

battery

condition

as

well

as

the

driver

requestT