Академический Документы
Профессиональный Документы
Культура Документы
for the
Electric Aircraft Symposium
23 April 2010
Rohnert Park, CA
NREL/PR-5400-48673
Design
Manufacturing
Operations
Testing
Analysis
Conclusions
Recall #
Description
Incidents qty
Injury qty
0
Recall qty
May-05
05-179
Jun-05
05-204
Apr-06
06-145
20
15,700
Aug-06
06-245
1,800,000
Jul-07
07-267
1,400
Oct-08
09-035
Dell, HP, Toshiba laptop batteries, Sony cell (Japan) made from 0ct 04
to Jun 05
19
100,000
63
totals
128,000
10,000
2,055,100
Crimp seal
Due to
JR top
insulator
cell internal
short
Separator
Insulator
Crimp Seal
Native or FOD
Failure
Failures
Failure
Contamination
JR wrap
Jellyroll top
Jellyroll bottom
Jellyroll outside
Positive tab
insulator
insulator
wrap insulator
insulator
JR bottom insulator
+ tab insulator
2-Fault Tolerant?
Approved!
Within safe voltage, energy,
energy density, surface/volume
ratio, and chemistry
Wrt leakage
Wrt cell internal shorts
Rejected!
Design
Manufacturing
Operations
Visual, Mass, OCV, AC impedance, insulation resistance, fit check with housing
15 depress/repress cycles with final one holding vacuum for 3 days (& at 35C)
5 thermal cycles with 3 hr dwells at the extremes (-14 to 45C)
2 Capacity cycles at room temperature
one at high rate (C/2 charge to 21V with 1A taper, C/2 discharge to 15V)
one at mission rate (5A charge to 21.5V with 1A taper, 3.8A discharge to 16V)
OCV, CCV, Thermistor Check, Insulation Resistance, Bonding, Mass, and Visual Inspection
Thermal cycling with 3 hr dwells at the extremes (-14 to 45C)
Random vibration at 0.06 g2/Hz for 1 minute/axis (0.03 is mission, 0.04 is standard
workmanship level)
1 hot and 1 cold mission simulation cycle (charge at ambient, discharge in vacuum)
1 autocyle (discharge, charge, discharge, recharged to 30%) with the LIB Charger GSE
9 rejects
Average
sdev
sdev%
Min
Max
Range
Range%
-3sigma
+3sigma
Range
Range%
Lo Rejects
Hi Rejects
Total Rejec
Count
Reject%
3.8046
0.00197
0.052%
3.7771
3.8072
0.0301
0.792%
3.7986
3.8105
0.0118
0.311%
9
0
9
1057
0.85%
Average
sdev
sdev%
Min
Max
Range
Range%
-3sigma
+3sigma
Range
Range%
Lo Rejects
Hi Rejects
Total Rejects
Count
Reject%
3.8047
0.00117
0.031%
3.8016
3.8072
0.0056
0.146%
3.8012
3.8082
0.0070
0.184%
0
0
0
1048
0.00%
2Ah 18650
3.8
3.75
3.7
55Ah cell
3.65
3.6
44Ah cell
3.55
30Ah cell
3.5
52Ah cell
3.45
3.4
3.35
0
10
15
20
Average
sdev
sdev%
Min
Max
Range
Range%
-3sigma
+3sigma
Range
Range%
Lo Rejects
Hi Rejects
Total Rejects
Count
Reject%
1.2245
0.01368
1.117%
1.2138
1.4602
0.2464
20.123%
1.1835
1.2655
0.0821
6.704%
0
9
9
1057
0.85%
Average
sdev
sdev%
Min
Max
Range
Range%
-3sigma
+3sigma
3sRange
3sRange%
Low Rejects
High Rejects
Total Rejects
Count
Reject%
2.1589
0.0050
0.233%
2.1380
2.1821
0.0441
2.044%
2.1437
2.1740
0.0302
1.400%
2
2
4
857
0.23%
7.00%
6.00%
5.00%
4.00%
3.00%
2.00%
1.00%
0.00%
StDev%
Range%
3sRange%
18650 Self-Discharge
Average
sdev
sdev%
Min
Max
Range
Range%
-3sigma
+3sigma
3sRange
3sRange%
Low Rejects
High Rejects
Total Rejects
Count
Reject%
0.0178
0.0027
15.149%
-0.0313
0.0220
0.0533
300.093%
0.0097
0.0258
0.0162
90.895%
3
0
3
857
0.35%
3.16
3.14
3.14
N2-592-S-21
3.12
V
o
l
t
s
,
V
N2-592-S-22
N2-592-S-23
3.1
N2-592-S-24
N2-592-S-25
N2-592-S-26
3.08
N2-592-S-27
N2-592-S-28
3.06
N2-592-S-29
N2-592-S-30
V3.04
3.02
3.02
5.00
10.00
Days
15.00
N2-592-S-32
N2-592-S-33
V
3.1
o
l
t 3.08
s
, 3.06
3.04
0.00
N2-592-S-31
3.12
0.00
N2-592-S-34
N2-592-S-35
N2-592-S-36
N2-592-S-37
N2-592-S-38
N2-592-S-39
N2-592-S-40
5.00
10.00
Days
15.00
3.06
3.065
3.055
3.05
V
o
l
t
s
,
V
N2-596-Y-2
N2-596-Y-3
3.045
N2-596-Y-4
N2-596-Y-5
N2-596-Y-6
3.04
N2-596-Y-7
N2-596-Y-8
3.035
N2-596-Y-10
N2-596-Y-11
N2-596-Y-12
3.055
V
o 3.05
l
t 3.045
s
, 3.04
N2-596-Y-9
3.03
N2-596-Y-13
N2-596-Y-14
N2-596-Y-15
N2-596-Y-16
N2-596-Y-17
N2-596-Y-18
N2-596-Y-19
3.035
N2-596-Y-20
3.03
3.025
0.00
3.06
N2-596-Y-1
3.025
5.00
10.00
Days
15.00
0.00
5.00
10.00
Days
15.00
Thermal cycling
Shock & Vibration
Repress/Depress
Capacity performance
Mission simulation life
OCV vs SOC, temperature
Calendar life and self-discharge vs
SOC and temperature
Abuse Tolerance
Lack of contamination
No Li deposits or plating
Consistent active material
coating with smooth edges
Solid weld connections
without splatter
Photos courtesy of Exponent
Deliverables
Analyses
Thermal analysis by NREL
80 cell battery in
test enclosure
10 m resistor
A
C
Center-most
cell
B
E
F
G
Temperature (oC)
Center cell
Edge cell
GRP
Al plate-c
Al plate-p
Corner cell
Box
Time (s)
Bank 1
+
Bank 2
-
Bank 3
+
Bank 4
-
Bank 5
+
....
12 V
Cell Bank 3
8V
Short path
16 V
....
Rshort
Short Condition
(SOC0 = 100%)
10 m
Cell 42
Cell 56
Cell 56 Tmax
(Bank 4)
External-to-pack, earth
97oC @ 6000-s
75oC @ 6000-s
Internal-to-pack, earth
150oC @ 16-s
146oC @ 16-s
Internal-to-pack, space
153oC @ 16-s
147oC @ 16-s
20 m
Internal-to-pack, space
525oC @ 110-s
522oC @ 110-s
30 m
Internal-to-pack, space
595oC @ 240-s
591oC @ 240-s
10 m:
20 m:
Time (s)
Time (s)
35
Time (s)
Temperature (oC)
Temperature (oC)
10 m:
Cell 42
Rest of bank 3
Time (s)
36
Analysis Findings
Model agrees fairly well with external short test data
Relocating short from pack-external to pack-internal
will cause substantial additional heating of cells that
can lead to cell thermal runaway
37
Conclusions
A portfolio of mitigating measures are necessary to ensure safety
Selecting a mature cell design produced in large volumes with an
absence of CPSC recalls is a very prudent measure
NDE and DPA sampling and cell production line audits, targeted on
defect and contamination control, are critical for assessing cell
production quality
Operating cells within positive margins of voltage, current, temperature
is also very important for life and safety
Detailed thermal models can predict short circuit vulnerabilities of a
battery design
Example; certain external cell shorts that are internal to battery assembly are
predicted to lead to cell thermal runaway in spacesuit battery
Implies similar vulnerability to cell internal shorts, but verification needed
Acknowledgements
Gi-Heon Kim, Larry Chaney, and Ahmad Pesaran at
NREL for their thermal analysis contributions
ABSL, Exponent, and Mobile Power Solutions for
providing key data for this study