Rajeswari Chandrasekaran, Ph.D. Research and … & Advanced Engineering Electrochemical Energy Storage Devices for Electrified Vehicles Rajeswari Chandrasekaran, Ph.D. Research and

Research & Advanced Engineering

Electrochemical Energy Storage Devices for Electrified Vehicles

Rajeswari Chandrasekaran, Ph.D.Research and Innovation Center

Ford Motor Company, Dearborn, MI

Presented at

Institute for Mathematics and its Applications (IMA) Special Workshop: Mathematics and the Materials Genome Initiative

Keller Hall 3-180, University of Minnesota, September 14, 2012


Outline

• Brief Historical Review of Battery Chemistries

• Why Electrification?

• Ford’s Electrification Strategy & Our Research & Advanced Engineering Efforts

• USABC Goals (long-term) & Automotive Adoption Metrics: Hierarchy of Needs

• Materials & Modeling of Energy Storage Devices (focus on lithium-ion cell)

• Ford-University Collaborations

• Conclusion: Challenges & Opportunities

• Acknowledgements

Sep 14, 2012


Brief Historical Review of Battery Chemistries in Automobiles

Sep 14, 2012

Pb-Acid Ni-MH Li-ion

Starting-Lighting-Ignition (SLI)

HEV (e.g. Ford Fusion Hybrid, Ford Escape)

HEV, PHEV, EV

(courtesy: Google)


Why Electrification?

Sep 14, 2012

Reduce tail pipe emissions & Increased fuel economy

BEV: Focus Electric

HEV: e.g. Fusion Hybrid

AlsoC-MAX Hybrid &

Fusion Energi PHEV

PHEV: e.g. C-MAX Energi


Ford’s Vehicle Electrification Sustainability Strategy

Sep 14, 2012

Near Term

• Significant number of vehicles with EcoBoost engines

• Electric power steering – begin global migration

• Dual clutch and 6 speed transmissions replace 4 & 5 speeds

• Flex Fuel Vehicles

• Add Hybrid applications

• Increased unibody applications

• Introduction of additional small vehicles

• Battery management systems – begin global migration

• Aero improvements

• Stop/Start systems (micro hybrids) introduced

• CNG/LPG Prep Engines available where select markets demand

Mid Term

• EcoBoost engines available in nearly all vehicles

• Electric power steering - High volume

• Six speed transmissions - High volume

• Weight reduction of 250 – 750 lbs

• Engine displacement reduction aligned with weight save

• Additional Aero improvements

• Increased use of Hybrid Technologies

• Introduction of PHEV and BEV

• Vehicle capability to fully leverage available renewable fuels*

• Diesel use as market demands

• Increased application of Stop/Start

Long Term

• Percentage of Internal combustion engines dependent on renewable fuels

• Volume expansion of Hybrid technologies

• Continued leverage of PHEV, BEV

• Introduction of fuel cell vehicles

• Clean electric / hydrogen fuels

• Continued weight reduction actions via advanced materials

20072007 20112011 20202020 20302030

Long Term

Continue leverage of hybrid technologies and deployment of alternative energy sources

Full implementation of known technology

Mid TermNear Term

Begin migration to advanced technology

Slide from Ted Miller


Ford’s Research and Advance Engineering Efforts

• Energy Storage Research Department : 3 teams working on

materials, modeling, USABC, cell testing, etc.

• Most of the 1,000 engineers working on vehicle electrification are

located under one roof at the newly dedicated Advanced

Electrification Center in Dearborn, Mich.

• Doubling our battery-testing capabilities by 2013, helping

accelerate our hybrid and electric vehicle development by as much as

25 percent

• External collaborations: e.g. Ford is partnered with EC

Power/Penn State/Johnson Controls, Inc. in the DOE NREL’s

Computer-Aided Engineering for Electric Drive Vehicle Batteries

(CAEBAT) program

Sep 14, 2012

Research & Advanced Engineering Sept 14, 20127

USABC Goals for Advanced Batteries for EV

Present costs ($500 to $700)/ kWhFor EV (roughly 1/3rd the vehicle cost)

DOE Fast Charge Goals

Source: US DOE Vehicle Battery R&D:

Progress Update, David Howell et al.

Similar USABC goals exist for batteries for HEV and PHEV


Automotive Adoption Metrics*: Hierarchy of Needs

Sep 14, 2012


Why work on new active materials for advanced batteries?

Sep 14, 2012

Source: V. Srinivasan webpage, LBNL

Research & Advanced Engineering10

Why model electrochemical energy storage devices?

For Answers to these challenges: Modeling Design and optimization , Degradation analysis, Investigation of new materials for advance batteries, etc.

Can the cell

deliver?

Will the cell last the life of the vehicle?

Can I get m

ore electric

drive range?Can I charge the

pack fast?

Cells in parallel & series

Physics / Materials/Processes within the lithium-ion cell

Low temperature performance ?

Customer

Sep 14, 2012


Modeling/simulation/theory in electrification research

Sep 14, 2012

Cells in parallel & series

Physics / Materials/Processes within the lithium-ion cell

CONTROLS/ELECTRONICS

On-Board Prognostics & Diagnostics (e.g. SOC estimation), Charging, Battery Management

System

THERMAL MANAGEMENT

(e.g. liquid cooling or air cooling)

POWERTRAIN

Research & Advanced Engineering Sep 14, 201212

Lithium-Ion Cell Sandwich

z=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:

Negative electrode active material (secondary particle)

Positive electrode active material (secondary particle)

Binder

Carbon additive

Pores filled by electrolyte

z=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive


z=0 z=LLn LpLsz=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive


Li-ions travel from (-) to (+) during discharge within the cell (spontaneous direction)


Materials/Components in Lithium-ion cell

Sep 14, 2012

Other components: Binder: e.g. PVDF, conductive carbon, current collectors, electrolyte additives, coatings, etc.

P. Arora and Z. Zhang, Chem. Rev., 2004, 104, 10.

LiCo1/3Ni1/3Mn1/3O2

Min Yang and Junbo Hou, Membranes 2012, 2, 367-383; doi:10.3390/membranes2030367

Si

Electrolyte: Inorganic salt + organic solvente.g. LiPF6 in EC/DMC, etc.

Active Materials

J.-M. Tarascon & M. Armand, Nature 2001, 414, 359-367.

Separator


Lithium-Ion Cell Models

z=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive


z=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive



Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive


• Continuum Model

• Single Particle Model

• Equivalent Circuit Model

• Surrogate (e.g. Response Surface) Model

• Reduced Order Model

• Molecular Modeling, etc. (new materials)


Continuum Modeling of the Lithium-ion Cell Sandwich

Sep 14, 2012

z=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive


z=0 z=LLn LpLs

Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive



Current

Collector

Current

Collector

Composite Negative

Electrode

Composite Positive

ElectrodeSeparator

Legend:



Binder

Carbon additive


Possible limitations

within cell• Thermodynamic OCV

limitations

• Electronic resistance – Positive

– Negative

• Ionic resistance & Concentration Overpotential

– Positive

– Negative

– Separator

• Charge transfer resistance– Positive

– Negative

• Solid phase diffusion limitations (within particle)

– Positive

– Negative


Types of Model Input Parameters

Can be

• Material properties, design (process) adjustable parameters & initial &operating conditions

• Related to thermodynamics, lithium insertion/de insertion charge transferkinetics, electrolyte phase mass & charge transport , solid phase diffusionand matrix phase charge transport

• Constant or function of concentration, temperature, etc.

• Constant or varying with age (cycling/storage) of the cell

• More based on other relevant physics/processes considered in a modelCoupled electrochemical-thermal model (such as thermal conductivity, etc.)

Stress Volume changes

Side reactions

Estimation of parameters/properties from experiments/modeling is a field by itself!


Adding complexity/Modifications…

Sep 14, 2012

Modifications Additional Physics Geometry Operating

Conditions

Thermodynamics Non-isothermal Micro-Macro scale coupling

CC-CV charging,CC discharging

Any changes to reaction kinetics (such as multi-electron transfer)

Volume changes (porosity and electrode dimension changes that leads to stress, 2D flow problem, reservoir modeling, etc. )

Spiral geometry (jelly roll)

Impedance

Modified solid phase transport equations

Stress Prismatic/Pouch (jelly roll)

Pulse

Multiple active materials Solid electrolyte interphase Prismatic (stacked)

Cycling/Calendar

Particle size distribution Capacity/power fade (i.e. Life) mechanisms

Tab locations Cyclic voltammetry

Varying transport properties (with concentration, temperature, aging)

Open-circuit potential fade (due to structural changes)

GITT

New materials Contact resistances … …

Double layer capacitance


Illustration of cell geometries

Sep 14, 2012

Spirally wound cylindrical lithium-ion cell

Spirally wound prismatic lithium-ion cell

Ref: Pankaj Arora and Zhengming (John) Zhang, Chem. Rev. 2004, 104, 4419-4462


Ford-University Collaborations in Energy Storage Research

• University Research Program (URP)

• Ford-MIT Alliance

• Summer Internships & Full-time employments

• Joint proposals

Sep 14, 2012


Conclusions: Challenges and Opportunities

New energy storage materials discovery & engineering analysis: Key

enabler for advance electrified vehicles to compete with ICE-driven

vehicles in terms of cost, range, charge acceptance vs. gas refueling time

& efficiency, etc.

Modeling Challenges

•Computational time vs. accuracy

•Parameter estimation & optimization

•On-board prognostic and diagnostic tools

•…

Sep 14, 2012


Acknowledgements

• Ted Miller & Andy Drews

• Ed Krause and Bala Chander

• University collaborators: Vyran George, Prof. Tom Fuller (Georgia

Tech), Prof. Jeff Sakamoto (Michigan State)

Sep 14, 2012

Rajeswari Chandrasekaran, Ph.D. Research and … & Advanced Engineering Electrochemical Energy Storage Devices for Electrified Vehicles Rajeswari Chandrasekaran, Ph.D. Research and

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