Batteries for EV Applications

Batteries for EV Applications introduces principles of operation of secondary batteries and their different chemistries: Lead Acid, Nickel Metal Hydride, and Lithium Ion. The relationship between cells, modules, and packs will be discussed in the context of sizing batteries to meet vehicle performance needs. The mechanical construction of batteries will be described. A review of various components in battery packs for xEVs will allow the learner to understand functional purposes and trade off with cost. The course will look at test procedures recommended by regulatory bodies for safe operation and transportation of batteries.  Learners will learn how to build equivalent circuit models (ECM) for cells. Concepts of battery life, secondary life, and various failure modes of batteries will be addressed. The course will introduce battery management systems (BMS) and various accessories needed for eliciting durable performance from battery packs.

• Electrical engineers
• Mechanical engineers
• Systems engineers
• Project engineers
• Program managers
• Technical leaders
• System integrators
• Electric power conversion engineers

This course will integrate in active learning exercises and a mini project to allow students to practice the principles being taught

1 Introduction to Batteries

• Key Components
• Types of battery construction
• Key battery parameters and battery performance metrics

2 Battery Chemistry

• Become conversant with chemical reaction formulae
• Gain an appreciation that not all battery types are ‘created equal’
• Be able to state the suitability of a particular battery chemistry for a particular application
• Gain awareness that battery chemistries are constantly evolving

 3 Batteries for EVs

• Gain an appreciation of battery sizing for electric vehicles
• Draw parallels with engine sizing
• Understand the advantages and disadvantages of using higher voltage batteries
• Identify approaches to specify size and type of a battery

Mini-Project: Part 1                  

4 Battery Safety

• Identify the main hazards that batteries pose
• Understand the different root causes that can lead to batteries becoming hazardous
• Learn that batteries will remain safe when systems and controls are appropriately engineered

5 Battery Management Systems

• Understand the purpose and function of a Battery Management System (BMS)
• Appreciate common BMS components and architectures
• Define limitations of BMS’s

6 Battery Modelling

• Understand the role of battery modelling
• Explore types of battery modelling and examine their inherent advantages/disadvantages
• Learn about different battery modelling tools
• Know how to create a basic battery model

Mini-Project: Part 2                  

7 Battery Degradation

• Learn what contributes to battery degradation
• Understand the metrics used to evaluate battery degradation
• Identify mitigations that help reduce battery degradation
• Evaluate what level of degradation is acceptable

8 Battery Testing

• Identify Mechanical Testing Processes
• Identify Electrical Testing Processes
• Identify Cross Coupling between testing processes
• EOL Testing
• Explain what you are really testing for?"

9 Static (Non-mobile) Applications

• Explore four static  (non mobile) applications associated with electrified vehicles
• Define the applications and their context
• Identify challenges for applications
• Identify benefits for applications

Mini-Project: Part 3                  

10 Mobile Applications

• Gain understanding of the wide range of electrification opportunities for vehicles
• Identify hybrid arrangements and hybridisation levels
• Become familiar with specific case studies
• Build insight into the broader impact of electrification in vehicles

11 Second Life Considerations

• Understand why we might consider an alternative to ‘new’
• Identify the risks and benefits of lease models/second life
• Consider what the future state may look like
• Identify when it makes sense to Recycle vs Reuse

 12 Battery Supply Chain

• Identify key raw materials used in battery manufacture
• Understand key manufacturing processes for batteries (especially Li-ion)
• Examine how IP impacts battery manufacturing
• Consider the strategic market for batteries

13 Future Battery Technologies 

• Achieve insight into the future state of battery technology
• Identify Different formats & chemistries of the future/on the horizon - Solid State?
• Consider what may come next and When NEXT is.
• Identify the rationale behind future trends
• Build a question-based framework that helps define future direction

Mini-Project: Part 4

Daniel Le

Daniel Le, Ph.D. – Director of Engineering xEV Battery Applications Flex|N|Gate – Flex-Ion

Dr. Daniel Le has 13+ years in lithium ion battery and systems development for automotive applications. His experience and expertise include battery modeling, algorithm development, global battery system development, and securing global production programs. Dr. Le has lead multiple global lithium ion production programs working with teams across North America, Europe, and China.

Dr. Le is an established technical leader in the industry and holds several patents in lithium ion battery development. He is the Director of Engineering for xEV Battery Application at Flex-N-Gate. He is responsible for the technical and commercial development of new applications for future customer programs within Flex-Ion, a newly established division of Flex-N-Gate for Lithium ion cell and battery development.

Thanh Nguyen

Mr. Nguyen is the SVP of Deployment for 6K which manufactures battery materials for e-mobility market. At 6K, he’s responsible for geographic expansion, supply chain, and partnerships. He has over 35 years of experience in a variety of roles ranging from engineering, product management, sales, and marketing. In the lithium-ion space and prior to 6K, he was an SVP of Business Development and Growth at Packet Digital serving the unmanned arial vehicles (UAV) industry; VP of Sales and Marketing at Farasis – a lithium-ion cell, module, and pack manufacturer for the EV market; various roles at Johnson Controls Power Solutions (now known as Clarios) Lithium-Ion group. Before that, he spent a long career in the semiconductor and network infrastructure in several startups and Fortune 500 companies. He holds a BS in Electrical Engineering at Penn State and an MBA from Regis University.