Professional Documents
Culture Documents
2
October 2012 Dallas 2
What does a battery monitor do?
Battery Subsystem
Capacity
VPACK
CHG DSG
Vbatt estimation
ICHG Safety/protection
VCHG VDSG Charging support
comm Gas
Communication
Battery
Charger
Gauge
Load
Tbatt
and Display
IDSG Logging
Rs
Ibatt
Authentication
System Monitor Cell
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October 2012 Dallas 3
How to estimate battery capacity?
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October 2012 Dallas 4
Voltage lookup
discharging)
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October 2012 Dallas 5
OCV curve
Voltage
Level
rises same
rate End of discharge voltage
Capacitor 0% 100%
Fullness
Level rises
slower
OCV Curve
Level rises
Full charge voltage
faster
Voltage
Battery 0% 100%
Fullness
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October 2012 Dallas 6
OCV voltage table: DOD representation
OCV(DOD)
4300
4100
Vmax 3900
Voltage_a(DOD)
Vmin 3700
Voltage_a
3500
Poly_a(DOD)
3300
3100
2900
0 0.2 0.4 0.6 0.8 1 1.2
DOD
Flat Zone
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October 2012 Dallas 7
Current integration
One can also measure how
much water goes in and out
In batteries, battery capacity
changes can be monitored by
tracking the amount of
electrical charges going in/out mL
marks
q (t ) q 0 I (t ) dt
I(t)
q k q 0 t k I k
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October 2012 Dallas 8
Basic Smart Battery System
CHG DSG
VPACK Vbatt
ICHG
VCHG VDSG
Battery Model
comm Gas
Charger
Gauge Tbatt
Load
IDSG
Ibatt
Rs
qk q 0 t k I k
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October 2012 Dallas 9
Circuit model
VOC a function of SOC
Rint is internal resistance
Rs and Cs model the short
term transient response
RL and CL model the long term
transient response
DC model
Vbatt and Ibatt are the battery
voltage and current
All parameters are function of
temperature and battery age
Transient model
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October 2012 Dallas 10
Table lookup
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Factors affecting capacity estimation
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October 2012 Dallas 12
PCB component accuracy
Example
Current sensing resistor Gas
Gauge
Trace length (resistance)
V (t ) I (t ) Rs
R+ R-
I (t )
Rs
V (t )
I (t )
Rs r
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October 2012 Dallas 13
Instrumentation accuracy
ADC Resolution
Sampling rate
Voltage drift / calibration
Voltage
Noisy immunity
ADC count
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October 2012 Dallas 14
Battery model fidelity
Steady-state (DC)
Transient (AC)
Capacity degradation DC model
Aging
Overcharge
Transient model
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October 2012 Dallas 15
Model parameter extraction
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October 2012 Dallas 16
Temperature
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Safety
High operating temperature
Cathode coatings help considerably 100 125 150 175 200 225 250
Temperature (C)
LiFePO4 shows huge improvement!
Thermal runaway is > 350C
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October 2012 Dallas 18
Cell Safety
Safety Elements
Pressure relief valve
PTC element
Aluminum or steel case
Polyolefin separator
Low melting point
(135 to 165C)
Porosity is lost as melting
point is approached
Stops Li-Ion flow and shuts
down the cell
Recent incidents traced to
metal particles that pollutes the
cells and creates microshorts
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October 2012 Dallas 19
Safety and protection
Over/under voltage
Over temperature time
FET failure Trip Margin
(time)
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October 2012 Dallas 20
Overcurrent Protection Details
B a tte ry
C u rre n t
AFE
AFE
S C P (C H G a n d D S G ) H a r d w a r e P r o te c tio n
T u rn O ff F E T s
R e c o v e r a b le
G a s -G a u g e IC
S o ftw a re C o n tro l
AFE
B o th C H G a n d D S G
O C P (D S G O n ly )
(1 - s U p d a t e I n t e r v a l )
T u rn O ff F E T s
R e c o v e r a b le
2 n d -L e v e l S a fe ty O C P
(B lo w C h e m ic a l F u s e )
P e rm a n e n t 1 s t-L e v e l O C P
(2 n d T ie r ) 1 s t-L e v e l O C P
T u rn O ff F E T s (1 s t T i e r )
R e c o v e r a b le
T u rn O ff F E T s
R e c o v e r a b le
T im e
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October 2012 Dallas 21
Basic Battery-Pack Electronics
Discharge MOSFET Charge
MOSFET
Chemical Fuse Q1 Q2
Pack+
Rs Sense
Current ADC Resistor
Pack
No Charge
4.20 V
No Charge
4.15 V
Safe Region
T1 T2 T5 T6 T3 T4
(100C) (450C)
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October 2012 Dallas 23
Why Are Battery Packs Still Failing?
Heat Imbalance
Space-limited design
causes local heat imbalance
Cell degradation
accelerated >10C
Temperature Profile
along Section Line
Variation
Between
Leads to cell imbalance Cells
Single/insufficient thermal
sensor(s) compromise
safety
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October 2012 Dallas 24
Cell Balancing
Battery cells voltages can get out of balance, which
could lead to over charge at a cell even though the
overall pack voltage is acceptable.
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October 2012 Dallas 25
Passive Cell Balancing: Simplest Form
turns on VO V
VO VO
Charge resumes when V VH
C e ll A
cell A voltage drops to
safe threshold
V D iff_ S ta r t C e ll B
ta tb tc td te tf
bq77PL900, 5 to 10 series-cell Li-Ion
battery-pack protector for power tools
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October 2012 Dallas 26
Fast Passive Cell Balancing
R1
Fast cell balancing
R4
Cell 2
strength is 10x ~ 20x
Q2
1 k higher
R2 bq2084/
R4 bq20zxx
Cell 1
Q2 VCell
1 k
RDS(on) Internal CB ICB
R3
R DS(on)
R
VCell
Fast CB ICB
R4
Where R4 << RDS(on)
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October 2012 Dallas 27
Charging support
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October 2012 Dallas 28
Communication and Display
Communication
To the System or Charger
Industry specification
Display
LED, LCD
Capacity indication
Fault indication
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October 2012 Dallas 29
Logging
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Section 2
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October 2012 Dallas 32
How Much Capacity is Really Available?
Voltage, V
4.5
Open circuit voltage (OCV)
4.0
I RBAT
3.5
EDV
3.0
0 1 2 3 4 6
Capacity, Ah
Usable capacity : FCC
Full chemical capacity: Qmax
External battery voltage (blue curve) V = V0CV I RBAT
Higher C-rate EDV is reached earlier (higher I RBAT)
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October 2012 Dallas 33
What Does A Fuel Gauge Do?
3V 0%
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October 2012 Dallas 05/19/17
34
Current Integration Based Fuel-gauging
Battery is fully charged
During discharge capacity
is integrated
4.2V State of charge (SOC) at
each moment is RM/FCC
FCC is updated every
time full discharge occurs
Q
0% RM = FCC - Q
3V
FCC
SOC = RM/FCC
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October 2012 Dallas 05/19/17
35
Learning Before Fully Discharged
fixed voltage thresholds
It is too late to learn
when 0% capacity is
reached Learning
FCC before 0%
4.2V
We can set voltage
threshold that
correspond to given
7% percentage of
EDV2 3% remaining capacity
EDV1
0%
EDV0 However, true voltage
corresponding to 7%
FCC depends on current
and temperature
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October 2012 Dallas 05/19/17
36
Learning before fully discharged with
current and temperature compensation
CEDV
CEDV Model: Modeling last part of
Predict V(SOC) under any discharge allows to
OCV current and temperature calculate function
4.2V V(SOC, I, T)
Substituting SOC=7%
allows to calculate in
EDV2 (I1) real time CEDV2
threshold that
EDV2 (I2) corresponds to 7%
capacity at any current
and temperature
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October 2012 Dallas 05/19/17
37
CEDV Model Visualization
OCV curve defined
Voltage by EMF, C0
OCV corrected by
I*R (R is defined by
R0, R1, T0)
I*R
Further correction
by low
temperature (TC)
Actual battery
voltage curve
Reserve Cap: C1
shifts fit curve
Battery Low laterally
3% 4% 5% 6% 7% 8% 9%
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October 2012 Dallas 38
CEDV Formula
Where:
CV = EMF*[1 EDVC0*(10T)*log(Cact)/(256*65536)]
Cact = 256/(2.56*RSOC + EDVC1) 1 for (2.56*RSOC + EDVC1) > 0
Cact = 255 for (2.56*RSOC + EDVC1) = 0
EDVC1 = 2.56 * Residual Capacity (%) + Curve Fit factor
Tadj = EDVTC*(296-T) for T< 296oK and Tadj < T
Tadj = 0 for T > 296 oK and Tadj max value = T
age = 1 + 8 * CycleCount * A0 / 65536.
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October 2012 Dallas 39
Impedance Track Fuel Gauging
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Current Direction Thresholds and Delays
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October 2012 Dallas 41
What is Impedance Track?
1. Chemistry table in Data Flash:
10,000 foot View
OCV = f (dod)
dod = g (OCV)
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October 2012 Dallas 42
Close OCV profile for the Same Base-
Electrode Chemistry
4.2
OCV profiles close for all
tested manufacturers
3.93
Most voltage deviations from
average are below 5mV
Voltage, V
3.4
Same OCV database can be
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 used with batteries produced
DOD, fraction by different manufacturers as
Manufacturer A long as base chemistry is
B same
C
D
E
Generic database allows
4 significant simplification of
fuel-gauge implementation at
2.67 user side
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October 2012 Dallas 1.33
43
Resistance Update
400
300
Ra
200
100
Before Update
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
dod
Discharge direction
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October 2012 Dallas 44
Ra Table: Interpolation and Scaling Operation
Grid 14
m: Last visited grid
Grid 0
k: Present grid
found by interpolation
All 15 grid points are
ratiometrically updated from any
valid gridpoint measurement.
Changes are weighted
according to confidence in Step 1
accuracy Interpolation
Step 2
Scale After
Step 3
Scale Before
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October 2012 Dallas 45
Timing of Qmax Update
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October 2012 Dallas 46
FCC Learning
4
1.3 10
8000
4
1.2 10
7800
4
1.1 10
FCC, mAh
V, mV
7600 4
1 10
7400 9000
7200 8000
0 0.2 0.4 0.6 0.8
DOD
SM B FCC
true FCC
Ra grids
Voltage
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October 2012 Dallas 47
Modeling temperature
dT 1
Ri Vbatt Voc I batt Ri hc A T Ta
2
m cp I batt
2
dt R
Heating Cooling
** Dynamic Lithium-Ion Battery Model for System Simulation, L. Gao, S. Liu and R. A. Dougal, IEEE Transaction on Components and Packaging
Technologies, vol. 25, no. 3, September 2002.
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October 2012 Dallas 48
RemCap Simulation (concept)
Start of discharge
V
I*R
(loaded) OCV
V > 250mV
EDV
Vterm
Time
Q/2
I Q/4
Qstart RsvCap
Q Q . . . . . Q
Time
RemCap
points of discharge
0.5
curve
0
For all 3 cases, error
0.5 stays below 1%
during entire 250
1
cycles
1.5
0 50 100 150 200 250 300
It can be seen that
Cycle Number error somewhat
error at 10% decreases from 10 to
error at 5% 3% due to adaptive
error at 3%
nature of IT algorithm
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October 2012 Dallas 50
CEDV, Impedance Track Comparison
Property CEDV Impedance Track
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October 2012 Dallas 51
October 2012 Dallas 52