Advances in Battery Manufacturing, Service, and Management Systems

Jingshan Li, Shiyu Zhou, Yehui Han, Jingshan Li, Shiyu Zhou, Yehui Han

• Publisher: Wiley-IEEE Press
• Year: 2016
• Print ISBN: 9781119056492
• eBook ISBN: 9781119060635
• Edition: 1
• Topic: Technology & Engineering
• Subtopic: Automotive Transportation & Engineering
• Index: Technology & Engineering

Addresses the methodology and theoretical foundation of battery manufacturing, service and management systems ( BM 2 S 2 ), and discusses the issues and challenges in these areas

This book brings together experts in the field to highlight the cutting edge research advances in BM 2 S 2 and to promote an innovative integrated research framework responding to the challenges. There are three major parts included in this book: manufacturing, service, and management. The first part focuses on battery manufacturing systems, including modeling, analysis, design and control, as well as economic and risk analyses. The second part focuses on information technology's impact on service systems, such as data-driven reliability modeling, failure prognosis, and service decision making methodologies for battery services. The third part addresses battery management systems (BMS) for control and optimization of battery cells, operations, and hybrid storage systems to ensure overall performance and safety, as well as EV management. The contributors consist of experts from universities, industry research centers, and government agency. In addition, this book:

• Provides comprehensive overviews of lithium-ion battery and battery electrical vehicle manufacturing, as well as economic returns and government support
• Introduces integrated models for quality propagation and productivity improvement, as well as indicators for bottleneck identification and mitigation in battery manufacturing
• Covers models and diagnosis algorithms for battery SOC and SOH estimation, data-driven prognosis algorithms for predicting the remaining useful life (RUL) of battery SOC and SOH
• Presents mathematical models and novel structure of battery equalizers in battery management systems (BMS)
• Reviews the state of the art of battery, supercapacitor, and battery-supercapacitor hybrid energy storage systems (HESSs) for advanced electric vehicle applications

Advances in Battery Manufacturing, Services, and Management Systems is written for researchers and engineers working on battery manufacturing, service, operations, logistics, and management. It can also serve as a reference for senior undergraduate and graduate students interested in BM 2 S 2.

Part I
Battery Manufacturing Systems

Chapter 1
Lithium-Ion Battery Manufacturing for Electric Vehicles: A Contemporary Overview

Wayne Cai

Manufacturing Systems Research Laboratory, General Motors Global R&D Center, Warren, MI, USA

1.1 Introduction

During the last few decades, environmental concern about the petroleum-based transportation has led to renewed and stronger interest in electric vehicles (EV). In an EV, energy storage devices (such as batteries, supercapacitors) or conversion devices (such as fuel cells) are used to store or generate electricity to power the vehicle. The first highway-capable EV with mass production in the modern age was GM's EV1 [1], which used lead-acid-based batteries as onboard energy storage. With the advancement of newer generations of high-density energy storage batteries such as the metal-hydride batteries and most recently the lithium-ion (Li-ion) batteries, battery electric vehicles (BEVs) have seen tremendous growth in the past decade. Batteries used as the power and energy sources to drive BEVs are called traction batteries.

A BEV falls into one of the following four categories: hybrid electric vehicle (HEV), plug-in electric vehicle (PHEV), extended range electric vehicle (EREV), and pure BEV. An HEV is generally powered by an internal combustion engine and a battery pack. The internal combustion engine is the primary source of energy during medium or high-speed driving conditions with the batteries serving as the main power source in stop-and-go traffic as well as power assist in vehicle acceleration, where the batteries are also called power batteries. The battery pack is relatively small and recharged by the internal combustion engine and regenerative braking. An exemplary vehicle is Toyota's Prius (2015 model year), offering an EPA-estimated 50 mpg fuel economy using a small 4.3 kWh of Li-ion battery pack [2]. A PHEV operates under either the battery mode, the internal combustion engine mode, or a combination of the two modes. The battery pack, however, can be charged via an external electrical power grid. An exemplary vehicle is Toyota's Prius Plug-in [2]. Depending on the design intent and the size of the battery pack, the traction batteries in PHEV can be either power or energy batteries. An EREV differs from a PHEV in that the battery pack is relatively large and the vehicle operates primarily under the electric mode. The internal combustion engine in the vehicle is used exclusively or primarily to charge the traction batteries (although the internal combustion engine can also be used to assist the battery mode driving in special circumstances). An exemplary vehicle is GM's Chevrolet Volt [3]. A pure BEV is powered entirely electrically by an onboard battery pack through the traction motors. The battery pack is typically recharged via an external electrical power grid. Although many automakers are mass-producing BEVs in the marketplace, the most notable models are Tesla Model S [4], Nissan LEAF [5], and BMW i3 [6,7]. Figure 1.1 shows a complete landscape of major BEV manufacturers and their Li-ion battery cell suppliers. A comparison with refe...

Table of contents

• Cover
• Series Page
• Title Page
• Copyright
• Preface
• Contributors
• Part I: Battery Manufacturing Systems
• Part II: Battery Service Systems
• Part III: Battery Management Systems (BMS)
• Index
• IEEE Press Series on Systems Science and Engineering
• End User License Agreement