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III.B.7 Stand Alone Battery Thermal Management System (DENSO) Christopher Johnson, NETL Program Manager Subcontractor: DENSO International America, Inc. Brad Brodie, Project Manager DENSO International America, Inc. 24777 Denso Drive Southfield, MI 48086 www.densocorp-na.com Phone: (248) 350-8851; Fax: (248) 350-7774 E-mail: bradley_brodie@denso-diam.com Start Date: October 2011 Projected End Date: September 2014 Objective Reduce the vehicle battery pack size by 20% (or increase driving range by 30%) through an optimized battery thermal management system. Technical Barriers Cost – This project’s first priority is to develop a thermal system that would allow battery pack size reduction of 20%. This is possible because current battery packs are oversized to guarantee they have acceptable performance for the advertised life of the battery pack. One major reason for the oversize of the battery pack is from cell degradation due to exposure to high temperatures. This project will attempt to address the exposure to high temperatures, and thus enable size reduction of the battery pack. Performance – It is also known in the industry that cell performance is reduced at low temperatures. This project will also attempt to improve battery pack performance by efficiently warming the batteries in cold ambient temperatures. Technical Targets Develop a simulation program that will duplicate the battery thermal behavior in the vehicle. Develop a detailed thermal system design based on the information from the simulation program. Produce a prototype thermal system and bench test to prove the system is able to achieve the goals of the project. Accomplishments Established set test conditions to which the battery pack will be evaluated. Basic cell characteristics have been identified and used for the simulation model. Developed a battery pack simulation model using AMEsim software which can duplicate the conditions from vehicle testing. Developed initial thermal system models in AMEsim software. Evaluated scenarios based on input from Chrysler. Includes a mix of ambient temperatures and driving profiles. Battery model from Phase I was combined with thermal system, BMS, and battery life calculations into one simulation model. Introduction The objective of this project is to design a thermal system that will enable a PHEV/EV battery pack size reduction by 20%. The project is broken into three phases. Phase I will involve understanding the thermal requirements for the battery pack. A simulation program will be established to duplicate the battery thermal behavior in the vehicle. Phase II is the design of the thermal system, using the battery pack model created in Phase I, that can both cool and heat the battery pack to allow the size reduction and performance improvement. In Phase III, prototype thermal system is made based on the design in Phase II. Phase III also includes bench testing to prove the system is able to achieve the goals of the project. Approach The intent of the program is to demonstrate that a thermal system could enable the reduction of the battery pack size through optimal thermal management. The key points are considering performance at cold temperatures and battery life when exposed to high temperatures. A battery pack model will be created in AMEsim to simulate the battery pack. This will be done using equivalent circuit models (empirical), a physics-based model would be too complicated for the purpose of this FY 2013 Annual Progress Report 87 Energy Storage R&DPDF Image | Advanced Battery Development
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