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Why Do We Need a Battery Fuel Gauge? Capabilities and Benefits of HDM BFG Technology BFG Application Examples BFG Configurations HDM s BFG Dual

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Battery Management for Monitoring up to Battery Management for Monitoring up to

Six Lead

Six Lead--Acid Batteries at the Individual Acid Batteries at the Individual

Dr. David Liu, PhD Dr. David Liu, PhD PHM Society PHM Society BMS Workshop BMS Workshop Six Lead

Six Lead--Acid Batteries at the Individual Acid Batteries at the Individual Battery and System Levels

(2)

Overview Overview

• Why Do We Need a Battery Fuel Gauge?

• Capabilities and Benefits of HDM BFG Technology • BFG Application Examples

• BFG Configurations • BFG Configurations

• HDM’s BFG Dual Tracking Methodology

• BFG Highlights Effects of Unhealthy Batteries on the Bank

(3)

Information is Power Information is Power

You would not drive a car without a gas gauge…

Why would you execute a mission-critical operation, such as “silent watch”,

(4)

Capabilities of HDM BFG Technology Capabilities of HDM BFG Technology

• Battery Power Usage Information: Diagnostics and Prognostics

– State of Charge (SOC) at 95% Accuracy

– State of Health (SOH) at 95% Accuracy

– Hours Remaining (HR) at 90% Accuracy

– Battery Voltage (V) – Battery Voltage (V) – Battery Temperature (T) – Current (I)

– State of Life (SOL)

• Functionality

– System Interface: CANBUS, RS232, Control Panel-Mounted Display – Real-Time Data and Estimations

(5)

Benefits of HDM BFG Technology Benefits of HDM BFG Technology

• Operations

– Alerts crew when re-charging is necessary – Provides Hours Remaining for silent watch – Ensures mission capacity and success

• Maintenance

– Identifies unhealthy batteries for replacement – Facilitates Condition-Based Maintenance (CBM)

• Cost-Efficiency

– Single BFG per system vs. multiple BFGs per system

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BFG Implementation BFG Implementation Mobile Application Mobile Application • Customer – Navistar Defense • UK MOD/NATO • Vehicle

– Husky Tactical Support Vehicle – Husky Tactical Support Vehicle

• Application

– Monitors Battery SOC and SOH

Over 1500 HDM BFGs have been installed in Husky

(7)

BFG Implementation BFG Implementation Stationary Application Stationary Application • Customer – Raytheon Company • System

– R-Series Regenerator Hybrid Power System

Power System

• Application

– USMC Experimental

Forward Operating Base Phase IV Demonstration in 2010 at 29 Palms, CA

HDM BFG is critical component of intelligent Hybrid Power

(8)

Battery Fuel Gauge Configurations Battery Fuel Gauge Configurations

(9)

Configuration 1 Configuration 1

System Level Monitoring Only System Level Monitoring Only

12VDC Battery #3 12VDC Battery #1 D C C h a (A lte 12VDC Battery #5 Interface Connection Inline Fuse

Battery Positive Sense Wire

Advantage: SIMPLICITY 12VDC Battery #4 12VDC Battery #2 L o a d a rg e r e rn a to r) 12VDC Battery #6 Batt Neg Load Neg Interface Connection (Display, RS232, CAN-Bus)

Fuel Gauge Sensor Module

Battery Negative Connection Load Negative Connection

(10)

Configuration 2 Configuration 2

Cell Level Monitoring Only Cell Level Monitoring Only

12VDC Battery #3 12VDC Battery #1 Batt Neg Load Neg Batt Neg Load Neg D C C h a (A lte 12VDC Battery #5 Batt Neg Load Neg Inline Fuse

Battery Positive Sense Wire

D A T A R E A D IN G S S O H C e ll S O C C e ll V (V o lta g e ) C e ll Advantage: PRECISION 12VDC Battery #4 12VDC Battery #2 Batt Neg Load Neg Batt Neg Load Neg L o a d a rg e r e rn a to r) 12VDC Battery #6 Batt Neg Load Neg Interface Connection (Display, RS232, CAN-Bus)

Fuel Gauge Sensor Module

Battery Negative Connection Load Negative Connection

V (V o lta g e ) C e ll

H R (H r R e m a in ) C e ll

I (C u rre n t) C e ll

(11)

Configuration 3 Configuration 3

System/String/Cell Level Monitoring System/String/Cell Level Monitoring

12VDC Battery #3 12VDC Battery #1 D C C h (A lt 12VDC Battery #5 Inline Fuse

Battery Positive Sense Wire

DATA READINGS SOH SOC Cell/String/System V Cell/String/System Cell/System

Advantage: SIMPLE, PRECISE & COST-EFFECTIVE

12VDC Battery #4 12VDC Battery #2 C L o a d h a rg e r te rn a to r) 12VDC Battery #6 Batt Neg Load Neg Interface Connection (Display, RS232, CAN-Bus)

Fuel Gauge Sensor Module

Battery Negative Connection Load Negative Connection

V (Voltage) HR (Hr Remain) I (Current) Temp Cell/System System Cell/String/System System

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HDM’s Battery Fuel Gauge Technology: HDM’s Battery Fuel Gauge Technology:

(13)

SOC Measurement SOC Measurement

Using Dual Tracking Method Using Dual Tracking Method

60 80 100 S O C ( % )

Fuel Gauge SOC Theoretical SOC Fuel Gauge SOH:82% (at discharging time = 0 min.)

0 20 40 0 10 20 30 40 50 60 70 80 90 100 S O C ( % )

(14)

What is Dual Tracking Methodology? What is Dual Tracking Methodology?

(15)

Template for

Template for InitialInitial

II--SOC and VocSOC and Voc--SOC EstimationSOC Estimation

Segments Voc AH SOC (%)

1 > 12.8 2 100-98 2 12.80-12.74 2 98-96 3 12.74-12.69 2 96-94 4 12.69-12.66 2 94-92 . . . . . . . . . . . . . . . . 48 11.14-11.08 2 6-4 49 11.08-10.88 2 4-2 50 10.88-10.64 2 2-0

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Template for

Template for SelfSelf--Calibrated Calibrated II--SOC and VocSOC and Voc--SOC EstimationSOC Estimation

Segments Voc AH SOC (%)

1 > 12.8 1.8 100-98 2 12.80-12.74 1.8 98-96 3 12.74-12.69 2.1 96-93 4 12.69-12.66 2.1 93-90 . . . . . . . . . . . . . . . . 48 11.14-11.08 1.6 6-4 49 11.08-10.88 1.6 4-2 50 10.88-10.64 1.8 2-0 Total Segments: 1-50 Voc: >12.8 – 10.64 Self-Calibrated Total AH: 90 SOC: 100%-0%

(17)

Error from Current

Error from Current--Based TrackingBased Tracking

60 80 100 S O C ( % ) Charge/Discharge Cycling

Fuel Gauge SOC Overestimated Accurate Underestimated

Lack of precise charge and discharge efficiency information results

0 20 40 0 50 100 150 200 250 300 350 400 450 500 S O C ( % )

(18)

Error from Voltage

Error from Voltage--Based TrackingBased Tracking

24 25 26 27 V o c ( V o lt a g e ) V o c ( V o lt s ) B (78%SOC) A (100%SOC) 21 22 23 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 time(mins) V o c ( V o lt a g e )

Voc 12Hrs Rest after Full Charge

Voc No Rest after Full Charge

Time (min) V o c ( V o lt s )

(19)

Dual Tracking Methodology Dual Tracking Methodology

60 80 100 S O C ( % ) Combined SOC Voltage-based SOC (% )

Voltage-Based Tracking SOC

0 20 40 0 50 100 150 200 250 S O C ( % )

Discharging Time (min) Discharging Time (min)

S

O

C

(20)

Configuration 3 Configuration 3

System/String/Cell Level Monitoring System/String/Cell Level Monitoring

12VDC Battery #3 12VDC Battery #1 D C L C h a r (A lte rn 12VDC Battery #5 Interface Connection Inline Fuse

Battery Positive Sense Wire

DATA READINGS SOH SOC Cell/String/System V (Voltage) Cell/String/System Cell/System

Advantage: SIMPLE, PRECISE & COST-EFFECTIVE

12VDC Battery #4 12VDC Battery #2 L o a d rg e r n a to r) 12VDC Battery #6 Batt Neg Load Neg Interface Connection (Display, RS232, CAN-Bus)

Fuel Gauge Sensor Module

Battery Negative Connection Load Negative Connection

V (Voltage) HR (Hr Remain) I (Current) Temp Cell/System System Cell/String/System System

(21)

BFG Detection of Unhealthy Battery: Cycle 1 BFG Detection of Unhealthy Battery: Cycle 1

0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 S O C ( % ) Battery 1

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 S O C (% ) Battery 3

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 S O C ( % ) Battery 2

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 60 70 80 90 100 S O C ( % )

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 50 60 70 80 90 100 S O C ( % )

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 50 60 70 80 90 100 S O C ( % )

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5%

HDM BFG identifies weak battery during

0 10 20 30 40 50 0 5 10 15 20 25 30 35 S O C ( % ) AH Discharged Battery 4 Theoretical - 5% 0 10 20 30 40 50 0 5 10 15 20 25 30 35 S O C ( % ) AH Discharged Battery 6 10 20 30 40 50 60 70 80 90 100 S O C ( % ) Battery System 6 Batteries Combined

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 0 5 10 15 20 25 30 35 S O C ( % ) AH Discharged Battery 5 Theoretical - 5% Battery5

(22)

BFG Accuracy Established: Cycle 3 BFG Accuracy Established: Cycle 3

0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 S O C ( % ) Battery 1

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 S O C ( % ) Battery 2

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 70 80 90 100 Battery Monitor Theoretical SOC Theoretical + 5% 70 80 90 100

Battery Monitor SOC Theoretical SOC Theoretical + 5% 70 80 90 100 S O C ( % )

Battery Monitor SOC Theoretical SOC Theoretical + 5% 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 S O C ( % ) Battery 3

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% HDM BFG achieves 95% accuracy by discharge cycle 3 30 40 50 60 70 80 90 100 S O C ( % ) Battery System

Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 60 70 0 5 10 15 20 25 30 35 S O C ( % ) AH Discharged Battery 4 Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 60 70 0 5 10 15 20 25 30 35 40 S O C ( % ) AH Discharged Battery 6 Theoretical + 5% Theoretical - 5% 0 10 20 30 40 50 60 70 0 5 10 15 20 25 30 35 S O C ( % ) AH Discharged Battery 5 Theoretical + 5% Theoretical - 5%

(23)

Effects of Unhealthy Battery on Bank 1* Effects of Unhealthy Battery on Bank 1*

String # Battery # Individual Battery Voltage @ End Point Discharge Current From To SOC % SOH % 1 1 11.3V 12A 19A 10 73 2 11.5V 16 78 2 3 11.4V 10A 18A 12 71 4 11.4V 12 73 5 10.8V 0 50

* Battery Bank 1: Optima Batteries

• String 3: Divergence of voltage and reduction in discharge current

cause over-current stress on Strings 1 and 2

3 5 10.8V 18A 4A 0 50 6 12.0V 36 78 Sum 1 - 3 Sum 1 - 6

System Battery End Voltage: 22.8V

System Discharge Current:

(24)

Effects of Unhealthy Battery on Bank 2* Effects of Unhealthy Battery on Bank 2*

String # Battery # Individual Battery Voltage @ End Point

Discharge Current From To SOC % SOH % 1 1 11.3V 33A 49A 14 77 2 11.4V 19 80 2 3 10.6V 33A 6A 0 55 4 12.1V 51 93 5 11.2V 12 75

* Battery Bank 2: Hawker Batteries

• String 2: Divergence of voltage and reduction in discharge current

cause over-current stress on Strings 1 and 3

3 5 11.2V 34A 45A 12 75 6 11.5V 22 87 Sum 1 - 3 Sum 1 - 6

System Battery End Voltage: 22.7V

System Discharge Current:

(25)

Weakest Battery Threshold Weakest Battery Threshold

vs. Conventional Threshold at 21V vs. Conventional Threshold at 21V String # Battery #

Battery Voltage Discharge Current Charge Current @ End Point 1

(Bat 3 SOC=0%)

@ End Point 2 (Bat Voltage=21V) @ 100% SOC @ End Point 1 @ End Point 2 @ Low SOC 1 1 11.3V 9.9V

36A 51A 20A 20A

2 11.4V 11.1V

3 10.6V 9.6V

By extending the system run-time (e.g. by 30 minutes), would be at

2 3 10.6V 9.6V 30A 6A 65A 3A 4 12.1V 11.5V 3 5 11.2V 9.7V

36A 45A 17A 19A

6 11.5V 11.3V

Sum 1 - 3

Sum 1 - 6

(26)

60 70 80 90 100 S O C ( % )

Battery System Battery Monitor SOC Theoretical SOC Theoretical + 5% Theoretical - 5%

System-Level Monitoring During Complete Charge-Discharge Cycles 0 10 20 30 40 50 0 200 400 600 800 1000 1200 1400 1600 1800 2000 S O C ( % ) AH Discharged/Charged

(27)

Single BFG at 95% Accuracy Single BFG at 95% Accuracy for up to 6 Individual Batteries for up to 6 Individual Batteries

• Provides breadth and depth necessary for Cost-Effective Battery Management Systems and CBM

• User Level

– Ensures power system reliability and performance – Ensures power system reliability and performance

• Maintenance Level

– Enables precision pinpoint of unhealthy batteries for CBM

• Incorporates theoretically scalable algorithm, for banks

greater than 6 batteries (i.e. important for larger, stationary energy storage systems)

(28)

Thank You!

Contact Information:

Dr. David Liu, VP of R&D: davidliu@hdm-sys.com

Dr. David Liu, VP of R&D: davidliu@hdm-sys.com

HDM Systems, Inc. 226 Lincoln Street Allston, MA 02134 Tel: 617.562.4054 Fax: 617.562.4013 Web: www.HDM-Sys.com

(29)

Appendix Appendix Appendix Appendix

(30)

20 40 60 80 100 S O C ( % )

Initial Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries, 24V in Series, 10A/40A Alternating Loads)

Fuel Gauge SOC Theoretical SOC Fuel Gauge SOH: 95% at Discharge Time = 0 20 40 60 80 100 S O C ( % )

2nd Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries, 24V in Series, 10A/40A Alternating Loads)

Fuel Gauge SOC Theoretical SOC Fuel Gauge SOH: 89%

at Discharge Time = 0 min.

SOC Measured by Dual

SOC Measured by Dual--Tracking Method:Tracking Method: Partial Discharge

Partial Discharge –– Cycle 1 to Cycle 4Cycle 1 to Cycle 4

0

0 20 40 60 80 100

Discharging Time (min)

0

0 20 40 60 80 100

Discharging Time (min)

20 40 60 80 100 S O C ( % )

3rd Discharge Cycle (100% to 50% SOC) (2x55AH 12V Batteries, 24V in Series, 10A/40A Alternating Loads)

Fuel Gauge SOC Theoretical SOC

Fuel Gauge SOH: 86% at Discharge Time = 0 20 40 60 80 100 S O C ( % )

4th Discharge Cycle (100% to 0% SOC) (2x55AH 12V Batteries, 24V in Series, 5A/40A Alternating Loads)

Fuel Gauge SOC Theoretical SOC

Fuel Gauge SOH: 83% at Discharge Time = 0

(31)

50 60 70 80 90 100 S O C ( % ) Battery H2 50 60 70 80 90 100 S O C ( % ) Battery System

Partial Charge and Discharge Cycles Partial Charge and Discharge Cycles

of Battery Bank of Battery Bank

SOC accuracy reaches 90-95% after four partial charge and

0 10 20 30 40 50 0 50 100 150 200 S O C ( % ) AH Discharged/Charged 0 10 20 30 40 50 0 100 200 300 400 500 600 S O C ( % ) AH Discharged/Charged

(32)

BFG: Water Submersion Test

BFG was submersed in water at 25°C for three hours, and was tested for operational performance

References

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