TEST SPECIFICATION FOR LI-ION BATTERY SYSTEMS FOR HYBRID ELECTRIC VEHICLES RELEASE 1.0 (2007-03-05) This specification was developed within the frame of the VDA-Initiative \"Energy storage system for HEV\". This initiative was formed by the vehicle manufactures Audi AG, BMW AG, DaimlerChrysler AG, Ford of Europe GmbH, Adam Opel GmbH, Dr. Ing. h.c. F. Porsche AG and Volkswagen AG under the leadership of the VDA. In case of requests, please contact Mr. E. Fritzsche, VDA (Fritzsche@vda.de). Test Specification for Li-Ion batteries Content: 1 Introduction..........................................................................................................................................4 2 Scope...................................................................................................................................................4 3 Definitions............................................................................................................................................4 4 Prerequisites........................................................................................................................................5 5 Basic information for testing..................................................................................................................5 5.1 General conditions..........................................................................................................................5 5.2 Test sequence plan.........................................................................................................................5 5.3 Test procedures..............................................................................................................................6 6 Procedure 1 – Preconditioning cycles...................................................................................................7 7 Procedure 2 - Standard Cycle (SC).......................................................................................................8 8 Procedure 3 - Energy and capacity test.................................................................................................9 8.1 Incoming cycles..............................................................................................................................9 8.2 Capacity at constant current discharge rates (1C; 10C; 20C, respectively supplier limit) and different temperatures ( at -25°C, RT, 40°C)..........................................................................................................9 8.3 Capacity at different Temperatures and discharge rates................................................................10 9 Procedure 4 - Power Test...................................................................................................................11 9.1 General.........................................................................................................................................11 9.2 Pulse Power Characterisation Profile.............................................................................................12 9.3 Test procedure..............................................................................................................................14 9.4 Data deliverables:.........................................................................................................................15 10 Procedure 5 - Energy efficiency test..............................................................................................15 10.1 General.....................................................................................................................................15 10.2 Driving situation........................................................................................................................15 11 Procedure 6 - Cold and hot cranking.............................................................................................16 11.1 Purpose....................................................................................................................................16 11.2 Test description........................................................................................................................17 11.3 Data deliverables......................................................................................................................17 11.4 Thermal testing.........................................................................................................................18 12 Procedure 7 - Self discharge.........................................................................................................18 12.1 Description................................................................................................................................18 12.2 Procedure.................................................................................................................................19 12.3 Test sequence..........................................................................................................................19 12.4 Data deliverables......................................................................................................................20 13 Procedure 8 - Abuse Testing of Electrical Energy Storage Systems (EESS)..................................20 13.1 Introduction...............................................................................................................................20 13.2 General Information for all Test Profiles....................................................................................20 13.3 Mechanical Abuse Tests...........................................................................................................21 13.4 Thermal Abuse Tests................................................................................................................21 13.5 Electrical Abuse Tests...............................................................................................................21 2 version 08: 2007-01-17 Test Specification for Li-Ion batteries 13.6 13.7 14 14.1 14.2 14.3 14.4 14.5 14.6 15 15.1 15.2 16 16.1 16.2 16.3 17 Expected Results......................................................................................................................22 Minimum Abuse Testing on Module Level Prior to EESS Parameter Testing.............................22 Procedure 9 - Accelerated Calendar Life Time Test.......................................................................22 General.....................................................................................................................................22 Accelerate calendar life test......................................................................................................22 Parameter check-up..................................................................................................................23 IR, OCV and Power test............................................................................................................23 Capacity...................................................................................................................................23 Data deliverables......................................................................................................................23 Procedure 10 - Lifetime – Cycle Life Test......................................................................................23 Preamble..................................................................................................................................23 Testing:.....................................................................................................................................24 Procedure 11 - Shock and vibration test........................................................................................27 Purpose....................................................................................................................................27 Test..........................................................................................................................................27 Requirement.............................................................................................................................28 Procedure 12 - Dewing test (temperature change).........................................................................28 Annex A Data Profile provided by the Battery Manufacturer......................................................................30 Annex B Result Table Templates...............................................................................................................33 Annex C: EUCAR Hazard Levels and Description......................................................................................40 Annex D List of abbreviations....................................................................................................................41 Annex E Testing Logbook..........................................................................................................................43 Annex F Cell Testing.................................................................................................................................44 Bibliography..............................................................................................................................................45 3 version 08: 2007-01-17 Test Specification for Li-Ion batteries 1 Introduction According to the latest development on batteries, Li-Ion cell based batteries will build the most effective al-ternative for traction batteries to be used in hybrid vehicles. Since these batteries offer a useful compromise between costs, performance and weight, they are going to replace other technological solutions during the next years. In mid terms most of the hybrid vehicles will be equipped with battery systems consisting of Li-Ion cells. Since already several specifications exist, which define requirements and application advices for battery systems for hybrid vehicles; it would also be necessary to identify tests for these requirements. The aim of this specification is the definition of tests in order to make sure that a battery system is able to meet the harsh requirements of the automobile industry. Most of the tests defined in this specification are not newly developed. The content of this specification based on existing specifications i.e. from USABC, EUCAR FreedomCar and other sources, which were in some cases slightly modified and adopted to the requirements of the European OEMs. 2 Scope This specification defines tests and related requirements for battery systems, sub-systems or modules based on Li-Ion cells to be used in hybrid electric vehicles (HEV). It includes the necessary equipment and software to operate the system and the interfaces to the vehicle. The specification is designed for system testing. However, if in specific cases a testing on cell level shall be performed, Annex F specifies the test related to individual Li-Ion cells (cell-level). 3 Definitions Note: For the explanation of the abbreviations, which are not related to a definition but used in this specification, please refer to Annex E. 3.1 Battery system: energy storage system that includes Li-Ion cells, cooling and cooling interface, electrical-management in-cluding cell-balancing, contactors, fuses and HV-interface, handling manual, data interface, full system with test mode software (full SOC-range shall be allowed for capacity and energy determination) 3.2 Battery sub-system or module part of a battery system that includes Li-Ion cells, cooling (similar with the system), battery management system (sensors, cell balancing, data interface (identical to system), handling manual) 3.3 DUT device under test within this standard a battery system, sub-system or module 3.4 HEV hybrid electric vehicle vehicle using both a rechargeable energy storage system and a fuelled power source for propulsion 3.5 RT room temperature 23 °C +/- 2 °C (climate controlled chamber) 3.6 energy density and specific energy two values need to be delivered: a) energy density and specific energy related to the cell (by volume and mass) b) energy density and specific energy related to the complete battery system (by volume and mass) Note: The battery system shall include the cooling system to the point of a reversible attachment of the coolant 4 version 08: 2007-01-17 Test Specification for Li-Ion batteries lines or air ducts, respectively. For liquid cooled systems the coolant mass inside the battery system shall be included. 3.7 SOC state of charge the available capacity in a battery expressed as a percentage of rated capacity 4 Prerequisites A battery system or module to be tested according to this specification has to fulfil the following prerequi-sites: – the DUT shall be at least an A-sample and not representing a prototype status – the high voltage safety design shall be tested and approved according the requirements given in ISO 23273-1 and -3 – the Li-Ion cells of the DUT shall be tested according to the system design requirements1 – the requirements for safety, lifetime and performance shall be confirmed according to the system de-sign requirements – the relevant test results shall be provided for each test sample – the DUT shall be delivered together with a written confirmation (summary of results) that it fulfils the system design requirements – the DUT shall be delivered with the complete set of system and user manual, including all necessary documentation for operation and needed interface parts for connection to test equipment (i.e. connec-tors, plugs including cooling) – the supplier shall ensure that the cells of the DUT are representing the production ready design. The BMS shall enable the defined tests, i.e. in defined test modes and shall be able to communicate with the test bench via CAN. Note: CAN according to the VDA system design requirements 5 Basic information for testing 5.1 General conditions If not otherwise defined before each test the DUT has to be stabilised at the test temperature for a minimum of 12 h. This period can be reduced if the thermal stabilisation is reached, defined as after one interval of 1 h the change among all individual cell temperatures is lower than 1°C. If not otherwise defined each charge and each SOC change, has to be followed by a rest period of 30 minutes. 5.2 Test sequence plan Before a system will be admitted for the tests according to this specification several prerequisites shall be fulfilled. Basically the battery supplier has to provide the necessary information and documentation, that the system will be able to fulfil the basic requirements as defined in the system design requirements. After that, a detailed test plan will be agreed on. These procedures and the sequence of testing according to this specification are summarized in Figure 2. 1 See Bibliography, [8] 5 version 08: 2007-01-17 Test Specification for Li-Ion batteries Figure 1 - Test sequence plan 5.3 Test procedures A detailed overview about the test procedures is given in Figure 2, where the references to the specific clauses are also given. 6 version 08: 2007-01-17 Test Specification for Li-Ion batteries Figure 2- Test plan – General overview 6 Procedure 1 – Preconditioning cycles 6.1 Description: The test samples shall be subjected to some electrical cycles, before starting the real testing sequence, in order to be sure that an adequate stabilisation of the battery performance is reached. 6.2 Procedure: The procedure to be adopted is the following: 7 version 08: 2007-01-17 Test Specification for Li-Ion batteries – The discharges shall be performed at 2C or at a different current if suggested and/or used by the manufacturer in testing before delivery. The charging is done according to the recommendations of the battery manufacturer. – Preconditioning cycles shall be three to five in number. Fewer cycles can be allowed if the discharge is performed at the same discharge regime used by the manufacturer during in-factory test and the relevant documentation is available. – The battery is considered as \"preconditioned\" when the discharged capacity during two consecutive discharges does not change by a value greater than 3 % of the rated capacity (two h discharge or other discharge regime adopted during test according to battery manufacturer indications); if the dis-charge regime is equal to that used by the manufacturer on the same battery during factory tests, the second cycle can be compared directly with the data from the manufacturer. The following applies to modules and single cells: – If electric precondition can not be achieved in five cycles due to weakly cell(s)/module(s), the limiting cell(s)/module(s) shall be removed (if possible replaced). If it is necessary to remove one or more cells/modules, the preconditioning shall be continued for another three cycles. – If at the end of five cycles (or eight cycles if one or more cells/modules have been removed) of electric preconditioning the required uniformity is not reached, this event shall be noted in the test report and the test sequence continued. For battery systems it shall only be noted that the capacity is not stable and the individual cell voltages at end of discharge shall be noted. 6.3 Data Deliverables: If the required uniformity is not reached this shall be noted in the test report. 7 Procedure 2 - Standard Cycle (SC) To ensure that each test is done with the battery in the same initial condition, a standard cycle, described below, shall be performed prior to each test. The standard cycle is normally performed at room temperature. Other temperatures are required in some special tests. The standard cycle (SC) comprises a standard discharge phase (SDCH) followed by a stan-dard charge phase (SCH). Standard Discharge (SDCH): Discharge rate: • Discharge limit: • According to the specifications given by the battery manufacturer. 1C or other specific discharge regime according to the specifications given by the battery manufacturer. Standard Charge (SCH): Charge procedure and end of charge criteria: • According to the specifications given by the battery manufacturer. Rest period after charge: • 30 minutes. Note: If, for any reason, the time interval between the end of the standard cycle (SC) and the start of a new test is longer than 3 h, it is necessary to repeat the standard cycle (SC). 8 version 08: 2007-01-17 Test Specification for Li-Ion batteries 8 Procedure 3 - Energy and capacity test 8.1 Incoming cycles For the conditioning of the battery system an electric preconditioning test has to be performed by using the standard procedure as defined in clause 6. 8.2 8.2.1 Capacity at constant current discharge rates (1C; 10C; 20C, respectively supplier limit) and different temperatures ( at -25°C, RT, 40°C) Description This test measures device capacity in ampere-hours at constant current discharge rate corresponding to the manufacturer’s rated 1C capacity in ampere-hours (e.g., if the rated one-hour discharge capacity is 10 Ah, the discharge rate is 10 A). Discharge is terminated on a manufacturer-specified discharge voltage limit. If the manufacturer does not provide a discharge voltage limit, or if the provided limit is unrealistically low, either an appropriate value is determined from the literature or 55 % of the maximum charge voltage is used. The one-hour rate (1C) is used as reference for static capacity and energy measurement and as a \"stan-dard\" rate for module and system-level testing. In addition the 10C and the 20C rate capacity determination have to be performed to meet the hybrid systems requirements. All three tests have to be performed at -25 °C, RT and 40 °C. 8.2.2 Procedure: a) Discharge phase: Constant current with the following discharge rates: 1C, 10C, 20C and/or as high as permitted by the battery manufacturer Cmax. The battery temperature has to be monitored. If this temperature is too high to start the charge phase extend rest period until the temperature is low enough to proceed Note The charge phase shall not be started until the temperature of the system is fully equilibrated to the proper charge temperature, or a fixed equilibration time period shall be used to allow for full equilibration of all test sample types. b) Charge phase: Charge procedure, end of charge criterion: • • According to manufacturer’s specifications. Rest after charge: 30 minutes Note: If, for any reason, the time interval between the end of the standard cycle and the beginning of a new test is longer than 3 h, it is necessary to repeat the standard cycle. Based on the preconditioning cycles under clause 8.1 the output capacity of these cycles will be evaluated. The spread in output capacity between the last three consecutive cycles shall be less than 2 %. Step no. 1 2 Step Temperature RT RT Standard Charge Discharge at 10C This cycle will be repeated three times. All tests are to be terminated at the manufacturer’s discharge voltage limit, but not lower than 55 % of the maximal charge voltage. Step no. 1 2 Step Temperature RT RT Standard Charge Discharge at 20C This cycle will be repeated three times. All tests are to be terminated at the manufacturer’s discharge voltage limit, but not lower than 55 % of the maximal charge voltage. 9 version 08: 2007-01-17 Test Specification for Li-Ion batteries 8.2.3 Data Deliverables: Data to be reported in the test report include current, voltage, capacity, specific energy, energy density, spe-cific average power, battery temperature and surrounding temperature. Capacity in ampere-hours and watt-hours at the specified discharge rate are reported based on manufacturer-specified discharge termination conditions. Ampere-hours and watt-hours returned (and the corresponding overall charge/discharge efficien-cies) are also reported for the manufacturer-specified charge algorithm. Energy removed (watt-hours) is reported as a function of depth of discharge (in percent of rated capacity). These data are used for the later calculation of available energy. In addition a diagram regarding the EODV dispersion of the cells for 1C dis-charge is needed. 8.2.4 Capacity Fade For devices subjected to life testing, the change in static capacity from the beginning-of-life value (measured just prior to the start of life testing) to some later point in time has to be reported periodically as capacity fade, expressed as a percentage of the original (BOL) capacity as shown in the following equation, where t0 refers to the time of the initial (BOL) RPT and t1 refers to the time of the later RPT where capacity fade has to be determined. 8.3 8.3.1 Capacity at different Temperatures and discharge rates Description: The test will determine the capacity at different temperatures at two different constant current discharge rates. The different discharge rates will then be performed in a row before the temperature is changed and the test is repeated at this new temperature. 8.3.2 Procedure: Between each step a minimum of 0,5 h rest has to be performed. Step no. Step Temperature RT -25°C -25°C -25°C -25°C -25°C -25°C -25°C -25°C -25°C -25°C -25°C -25°C RT RT RT RT RT RT 1) Standard Charge 2) Acclimatisation 3) Discharge at 1C 4) Standard Charge 5) Discharge at 1C 6) Standard Charge 7) Discharge at 1C 8) Standard Charge 9) Discharge at 20C 10) Standard Charge 11) Discharge at 20C 12) Standard Charge 13) Discharge at 20C 14) Acclimatisation 15) Standard Charge 16) Discharge at 1C 17) Standard Charge 18) Discharge at 1C 19) Standard Charge 10 version 08: 2007-01-17 Test Specification for Li-Ion batteries 20) Discharge at 1C 21) Standard Charge 22) Discharge at 20C 23) Standard Charge 24) Discharge at 20C 25) Standard Charge 26) Discharge at 20C 27) Standard Charge 28) Acclimatisation 29) Discharge at 1C 30) Standard Charge 31) Discharge at 1C 32) Standard Charge 33) Discharge at 1C 34) Standard Charge 35) Discharge at 20C 36) Standard Charge 37) Discharge at 20C 38) Standard Charge 39) Discharge at 20C 40) Acclimatisation 41) Standard Charge Cut-off requirements: RT RT RT RT RT RT RT RT 40°C 40°C 40°C 40°C 40°C 40°C 40°C 40°C 40°C 40°C 40°C 40°C RT RT – Voltage according to battery manufacturer, but not lower than 55 % of the maximal charge voltage. – at -25 °C and a discharge rate of 20C the discharge current shall be continuously reduced in order to maintained the minimum allowed voltage and the discharge has to be stopped as soon the current reaches the 5C rate. 8.3.3 Data deliverables: Data to be reported in the test report includes current, voltage, capacity, specific energy, energy density, specific average power, battery temperature and surrounding temperature. In addition a diagram showing capacity versus temperatures at different discharge rates shall be presented. Diagrams showing voltage versus time during the first and last discharge to test the homogeneity of the cell capacities is to be included in the test report. Result table templates can be found in Annex B. 8.3.4 Rated Capacity (Ah): The manufacturer’s specification of the capacity in ampere-hours obtained from the battery discharged by a constant current at 1C rate to the end-of-discharge condition, usually the cut-off voltage. If the 1C capacity obtained during testing differs more than 5 % from the manufacturer’s specification, this shall be clearly stated in the test report and the measured value shall be used as rated capacity. 9 Procedure 4 - Power Test 9.1 General The power test is intended to determine the dynamic power capability, the ohmic cell resistance and the overall cell resistance as well as the OCV of the battery under test as a function of SOC and temperatures. The test procedure combines the PNGV / FreedomCar “Hybrid Pulse Power Characterisation Test” and the EUCAR “Internal Resistance, Open Circuit Voltage and Power Determination Test”. 11 version 08: 2007-01-17 Test Specification for Li-Ion batteries The test will be performed at four different temperature values (40°C, RT, 0°C and -10°C) and cover a SOC-range of 80 % to 20 % within five steps (80 %, 65 %, 50 %, 35 %, 20 %) whereas the last step at 20 % SOC may only be performed if the maximum discharge current of the battery under test is equal or less than a 10C current rate in order to avoid a deep discharge of the battery under test. 9.2 Pulse Power Characterisation Profile The objective of this profile is to demonstrate the discharge pulse power (2 s, 10 s and 18 s) and regenera-tive charge pulse power (2 s and 10 s) capabilities at various SOC. The normal test protocol uses constant current at levels derived from the manufacturer’s maximum rated pulse discharge current with an upper limi-tation of 400 A. Only in case the battery under test reaches during discharge the lowest allowable discharge voltage (Discharge Voltage Limit), the current shall be reduced such that the battery terminal voltage is maintained at the lowest allowable discharge voltage throughout the 18 s discharge pulse. The current of the regenerative charge pulse shall be kept constant and is calculated as 75 % of the discharge pulse current. Only in case the battery under test reaches during regeneration the highest allowable charge voltage (Charge Voltage Limit), the current shall be reduced such, that the battery terminal voltage is maintained at the highest allowable charge voltage throughout the 10 s regenerative charge pulse. The test profile consists of a 18 s discharge pulse followed by a 40 s rest period to allow the measurement of the cell polarisation resistance. A 10 s regenerative charge pulse with 75 % current rate as the discharge pulse is then performed in order to determine the regenerative charge capabilities. The discharge current is defined as positive and the charge current as negative (see also Table 1 and Figure 3). Table 1: Pulse power characterisation profile Time Increment [s] 18 40 10 40 Figure 3 shows an example for a battery that can be discharged with a 20C rate. 25Cumulative Time[s] 18 58 68 108 Imax 0 Current -0,75 x Imax 0 2015discharge10current [C-rate]500-5charge-1020406080100-15-20 time [s] Figure 3 - Pulse Power Characterisation Profile - Current 12 version 08: 2007-01-17 Test Specification for Li-Ion batteries voltage4,U6U0U4U5U2U1U3U73,5U8U93voltage [V]2,521,510,5002040time [s]6080100 Figure 4 – Pulse power characterisation profile - Voltage For the peak power, regenerative power and resistance determination, the battery terminal voltage has to be measured at the times given in Table 2 of the pulse power characterisation profile. Table 2: measured voltages Time [s] Voltage The following calculations shall be performed: 2 s-discharge resistance: 10 s-discharge resistance: 18 s-discharge resistance: overall discharge resistance: 2 s-charge resistance: 0 U0 2 U1 10 U2 18 U3 19 U4 58 U5 60 U6 68 U7 69 U8 108 U9 IR2s,dch=U0−U1 ,∆t=2 seconds I1IR10s,dch=U0−UI22 ,∆t=10 seconds IR18s,dch=U0−U3I3 ,∆t=18 seconds IRdch=U3−UI35 ,∆t=40 seconds IR2s,cha=U5−U6I6 ,∆t=2 seconds 13 version 08: 2007-01-17 Test Specification for Li-Ion batteries 10s-charge resistance: overall charge resistance: 2 s-discharge power: 10 s-discharge power: 18 s-discharge power: 2 s-regenerative power: 10 s-regenerative power: open circuit voltage IR10s,cha=U5−UI77 ,∆t=10 seconds IRcha=U9−UI77 ,∆t=40 seconds P2s,dch=U1∗I1 ,∆t=2 seconds P10s,dch=U2∗I2 ,∆t=10 seconds P18s,dch=U3∗I3 ,∆t=18 seconds P2s,reg=U6∗I6 ,∆t=2 seconds P10s,reg=U7∗I7 ,∆t=10 seconds UOCV=U0 9.3 Test procedure Before each test, the battery shall have been kept at the test temperature for a minimum of 12 h. This period can be reduced if thermal stabilisation is reached, defined as less than a 1°C change of temperature among all individual cell temperatures during an interval of one h. At each test temperature, the battery under test shall be discharged and charged with a standard cycle (1C discharge and standard charge) followed by a minimum 30 minutes rest period assuming that the cell tem-perature has reached the required temperature. The fully charged battery is then discharged with a 1C rate to the initial SOC of 80 % followed by a minimum 30 minute rest phase and the pulse power characterisation profile described in Table 1. The next SOC step is reached by a 1C discharge followed by a 30 minutes rest phase and the pulse power profile is repeated. 2By this procedure all SOC values (80 %, 65 %, 50 %, 35 % and 20 %) will be tested. Follow the test se-quence as defined in Table 3. 2 If possible 14 version 08: 2007-01-17 Test Specification for Li-Ion batteries Table 3: Test sequence step no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 acclimatisation standard cycle Pulse Power Characterisation + stand. charge acclimatisation standard cycle Pulse Power Characterisation + stand. charge acclimatisation standard cycle Pulse Power Characterisation + stand. charge acclimatisation standard cycle Pulse Power Characterisation + stand. charge acclimatisation standard cycle Pulse Power Characterisation + stand. charge cycle RT RT RT 40°C 40°C 40°C 0°C 0°C 0°C -10°C -10°C -10°C RT RT RT temperature 9.4 Data deliverables: The following data shall be delivered by using the equations described in Clause 9.2: • • • • • • • Discharge power for 2 s, 10 s and 18 s peaks as a function of SOC and temperature. Regenerative power for 2 s and 10 s peaks as a function of SOC and temperature. Discharge resistance for 2 s, 10 s and 18 s peaks as well as the overall resistance as a function of SOC and temperature Charge resistance for 2 s and 10 s peaks as well as the overall resistance as a function of SOC and temperature Open circuit voltage as a function of SOC and temperature Deviation from 1st and last test at RT, if any If the charge or discharge current had to be reduced due to voltage limits, the calculated internal re-sistance values shall be marked clearly in the protocol and in the result tables 10 Procedure 5 - Energy efficiency test 10.1 General For HEV application the energy efficiency of the used battery system has a significant influence to the com-mon vehicle efficiency. It affects directly the fuel consumption and emission levels of the HEV. To evaluate a battery system on this property, it shall be done for a preferably realistic scenario. That means, the criteria are completely different from any “long-time” discharge/charge periods such as applied in electric vehicles, using relative low C-rates. 10.2 Driving situation The test simulates the following driving situation: For acceleration e.g. onto a highway or during an overtake process, the driver request the maximum HEV power (max. battery discharge power). Consecutively there is a rolling phase without battery use for an assumed time of 40 s. After that there is a braking (recuperation) 15 version 08: 2007-01-17 Test Specification for Li-Ion batteries phase for assumed 10 s to recharge the battery. Of course, the actual demands will be different because the HEV systems of the OEM’s will differ, but for comparison reasons and evaluation of battery systems it is a common base. Conditions: – RT, 40°C, 10°C – 3 different SOC: 35 %, 50 %, 65 % – 30 minute rest period before each power pulse sequence application (for equilibrium) – adequate rest period (2 h to 6 h, see general conditions 5.1) after temperature change for stabilisation – power test performed at 20C rate 10 s discharge, followed by a rest of 40 s, followed by 20C rate and 10 s charge (“regenerative”) pulses. Evaluation: – energy during discharge has to be determined => W_out [Wh]. – energy during charge has to be determined => W_in [Wh]. – determination by integration of power over time during each pulse Important: The charge balance (Ah) during this pulse sequence shall be neutral. That means the recharged Ah shall be exactly the same as discharged Ah before. In case of voltage limitations and current degradations during the power sequence caused by them, only the charge-neutral phases can be evaluated. This case has to be remarked clearly in the results. The following term gives the energy efficiency [%] η = 100 * W_out / W_in [%] (expected values 75 to 90 %, depending on chemistry and system) Example: Based on a fictive 300 V battery with 6 Ah it corresponds (estimated) to the following data: The discharge/charge during 10 s discharge at 20C: – Electrical power assist (e.g.): – Regenerative power (e.g.): – SOC swing: 0,333 Ah 32,40 kW 39,60 kW 5,555 % 90,0 Wh 110,0 Wh 81,8 % – energy output during 10 s discharge at 20C (e.g.): – energy input during 10 s charge at 20C (e.g.): – Energy efficiency These values seem realistic, appearing during typical acceleration or boost phases during driving. 11 Procedure 6 - Cold and hot cranking 11.1 Purpose The cold cranking test is intended to measure 5 s power capability at low temperature (-30°C). The test is conducted at the lowest SOC level allowable as specified by the supplier. The aim is to generate a data basis including time depending power output at low temperatures. Sampling rate during testing shall be 50 ms. Start under warm conditions is intended to ensure engine start at temperatures higher then those specified as normal operating conditions (e.g. 70°C). Power may not be an issue at high temperatures but safety and lifetime considerations may be of importance. 16 version 08: 2007-01-17 Test Specification for Li-Ion batteries 11.2 Test description The test consists of the following sequence of activities: – 1) At RT discharge the fully charged device at a 1C constant current discharge rate to the lowest SOC level allowable as specified by the supplier (minimum state of charge). – 2a) Reduce the temperature to –30°C, and soak the device for a period according Clause 5.1 to en-sure it has reached thermal equilibrium at this temperature. Set constant voltage (minimum allowable voltage, for example 2,5 V per cell but not less than 55 % of maximum charging voltage) for 5 s and monitor the power versus time profile. Repeat this procedure after a rest time of 10 s. – 2b) Increase the temperature to 70°C, and soak the device for a period according to clause 5.1 to en-sure it has reached thermal equilibrium at this temperature. Set constant power for 5 s and monitor the voltage versus time profile. Repeat this procedure after a rest time of 10 s. – 3) Perform the test profile defined in Table 4 and Table 5 respectively. The pulse power level required for 5 s pulses is 5 kW (minimum power-assist) or 15 kW (maximum power-assist). Note: The profile pulses shall be performed for the full 5 s duration (even if the test power has to be limited to stay within the minimum discharge voltage) to permit the later calculation of cold cranking power capability. Table 4: Cold cranking test profiles as time dependent power at constant voltage Time In-crement (s) 5 10 5 10 5 Cumulative System Voltage applicable for 2a Time (V) (s) 5 15 20 30 35 2,5 V x number of cells OCV 2,5 V x number of cells OCV 2,5 V x number of cells System Power applicable for 2a (kW) minimum 5 0 5 0 5 maximum 15 0 15 0 15 Note Exact value may depend on electrochemistry. Table 5: Warm start test profiles as time dependent power Time In-crement (s) 5 10 5 10 5 11.3 Data deliverables The deliverables as graphic presentation are power versus time profiles including current, voltage and tem-perature values. At high temperatures module pressure (if possible) or venting activities shall be monitored. Cumulative Time (s) 5 15 20 30 35 Maximum System Power ap-plicable for 2b (kW) 15 0 15 0 15 Minimum System Power ap-plicable for 2b (kW) 5 0 5 0 5 17 version 08: 2007-01-17 Test Specification for Li-Ion batteries 11.4 Thermal testing 11.4.1 Purpose Modules equipped with a certain coolant circuit shall be tested according to a thermal testing procedure. In addition values shall be provided, which are relevant for designing a cooling system, such as system heat capacity and heat transfer coefficient. 11.4.2 Test description The module shall be instrumented with thermo-sensors delivering a minimum temperature resolution of 0,25 K. Each module temperature shall be measured at least at three different positions representing high-est and lowest cell temperatures. T_cell (at least at three different positions on a module) T_coolant_in T_coolant_out The test consists of the following sequence of activities: 1.1. Start at the specified target SOC, SOC = 60 % at 25 °C. 1.2. Set constant coolant flow rates (air or liquid) and perform a charge neutral energy test profile as defined in clause 15.2. Vary coolant flow rate to a low, middle and high value within the specified range of the thermal system. Monitor the following temperatures until cell temperature difference (T_cell) is less than 1 K for a period of 10 min. The flow rate of the coolant shall be measured. 1.3. Vary the coolant inlet temperature T_coolant between 10 °C, 20 °C and 30 °C. 11.4.3 Data deliverables Report the following values for each test (nine tests in total): – Heat generated during cycling (calculation to be specified) [W] (calculated with values obtained from the test cycle using the energy throughput deviation at equal SOC level) – Heat dissipation into the coolant – (Allowable) Delta_T coolant in/out – Delta_T coolant in/out – (Allowable) Delta_T coolant in / T_cell – Delta_T coolant in / T_cell – Cp Thermal capacity of each module – SOC profile versus time – Outer heat radiation shall be minimised by suitable measures to determine the thermal capacity. [W/module] [K] [K] [K] [K] [KJ/Kg K] – Power and temperature profile versus time 12 Procedure 7 - Self discharge 12.1 Description The self discharge behaviour shall be measured with a complete and fully operational battery system. The BMS shall be supplied with the necessary auxiliary power (12 V d.c. power supply) in order to be able to control necessary battery system functions during the rest period, e.g.: – Battery system cell balancing Note The calculated self-discharge rate[s] are intended to take into account any possible parasitic or operational dis-18 version 08: 2007-01-17 Test Specification for Li-Ion batteries charge contribution of the cell balancing circuitry itself beyond the inherent self-discharge rate of the battery cells themselves. – Periodical BMS wake-up activities The self-discharge rate of the battery system shall be measured for five different rest periods and at three different temperatures. The battery system is discharged to 70 % SOC and then left at open circuit for a certain time. The BMS shall be able to perform control activities (cell balancing, regular wake-up activities). The remaining capacity shall then be determined by a 1C discharge. 12.2 Procedure Temperature Acclimatisation: The tests shall be performed in a temperature controlled test chamber at the given temperatures. Before each test cycle at a given temperature, the battery shall be kept at the test temperature for a minimum of 12 h. This period can be reduced if thermal stabilisation is reached, defined as less than 1°C change among individual cell temperatures during an interval of 1 h. 0 °C, RT and 40 °C. To ensure that each test is done with the battery in the same initial condition, a standard cycle, described in Annex A, shall be performed prior to each test. Discharge the battery system to 70 % SOC at 1C-rate 1 h, 6 h, 24 h, 48 h and 168 h. If the self discharge rate is less than 5 % of the rated capacity, add a further self dis-charge rest period of 336 h. The auxiliary energy consumption (12 V d.c. level) for the BMS and if required for other battery system electronics shall be measured continuously and expressed in Wh per each rest period. Temperatures: Standard cycle: Discharge rate: Rest period: Auxiliary Energy: 12.3 Test sequence a) Temperature 1st test sequence: 0 °C Step No. Procedure 1 Temperature Acclimatisation 2 Standard cycle (SC) 3 Discharge C to 70 % SOC 4 Discharge C+SCH 5 Discharge to C 70 % SOC 6 Open circuit for 1 h 7 Discharge C+SCH 8 Discharge C to 70 % SOC 9 Open circuit for 6 h 10 Discharge C+SCH 11 Discharge C to 70 % SOC 12 Open circuit for 24 h 13 Discharge C+SCH 14 Discharge C to 70 % SOC 15 Open circuit for 48 h 16 Discharge C+SCH 17 Discharge C to 70 % SOC 18 Open circuit for 168h 19 Discharge C+SCH If self discharge rate at rest period 168 h is less than 5 % continue with step 20 19 version 08: 2007-01-17 Test Specification for Li-Ion batteries 20 Discharge C to 70 % SOC 21 Open circuit for 336 h 22 Discharge C+SCH b) Repeat test sequence at step 1 with temperature acclimatisation at RT c) Repeat test sequence at step 1 with temperature acclimatisation at 40°C Cut-off criteria for each discharge cycle: Voltage according to battery manufacturer Charge: According to the standard charge procedure (SCH) defined in Annex A. 12.4 Data deliverables Data to be reported is the 1C capacity from the 70 % capacity discharge, including the initial ones and the loss of capacity after each rest period, expressed in percentage of the initial 70 % discharge for each tem-perature. The auxiliary energy consumption (12 V d.c. level) for the BMS and if required for other battery system elec-tronics shall be expressed in Wh per each rest period. Result table templates can be found in Annex B. One graph, including all data for the three test temperatures, showing residual capacity versus rest period shall be presented. The self discharge behaviour shall be measured with a complete and fully operational battery system. The BMS shall be supplied with the necessary auxiliary power (12 V d.c. power supply) in order to be able to control necessary battery system functions during the rest period, e.g.: – Battery system cell balancing – Periodical BMS wake-up activities The self-discharge rate of the battery system shall be measured for five different rest periods and at three different temperatures. The battery system is discharged to 70 % SOC and then left at open circuit for a certain time. The BMS shall be able to perform control activities (cell balancing, regular wake-up activities). The remaining capacity shall then be determined by a 1C discharge. 13 Procedure 8 - Abuse Testing of Electrical Energy Storage Systems (EESS) 13.1 Introduction Abuse testing is performed to characterize EESS responses to off-normal conditions or environments. The primary purpose of abuse testing is to gather response information to external / internal inputs that are de-signed to simulate actual use and abuse conditions. This response information is used to expose the vulner-abilities, if any, associated with a given EESS design under a given set of circumstances and to help quan-tify the hazard mitigation efforts that shall be taken for a particular EESS design. The information gained from this testing will be used to identify, quantify, and report abuse tolerance and potential safety issues related to EESS design. All required abuse testing activities related to EESS, module or pack level, are based on the following test manual: FreedomCAR: Electrical Energy Storage System – Abuse Test Manual for Electric and Hybrid Elec-tric Vehicle Applications. Issue: SAND 2005-3123, June 2005 It is expected that EESS suppliers performed already abuse testing activities on cell and module pack level prior to the common performance parameter testing activities with the OEMs. These abuse test shall be performed and the results reported according to the below mentioned mechanical, thermal and electrical abuse tests, too. The EESS supplier is requested to perform and report at a minimum the abuse test results according to § 13.7. 13.2 General Information for all Test Profiles Reference to FreedomCAR EESS Abuse Test Manual § 2 20 version 08: 2007-01-17 13.3 Mechanical Abuse Tests Reference to FreedomCAR EESS Abuse Test Manual § 3 13.3.1 Controlled Crush Reference to FreedomCAR EESS Abuse Test Manual § 3.1 13.3.2 Penetration Reference to FreedomCAR EESS Abuse Test Manual § 3.2 13.3.3 Drop Reference to FreedomCAR EESS Abuse Test Manual § 3.3 13.3.4 Immersion Reference to FreedomCAR EESS Abuse Test Manual § 3.4 13.3.5 Roll-over Simulation Reference to FreedomCAR EESS Abuse Test Manual § 3.5 13.3.6 Mechanical Shock Reference to FreedomCAR EESS Abuse Test Manual § 3.6 13.4 Thermal Abuse Tests Reference to FreedomCAR EESS Abuse Test Manual § 4 13.4.1 Thermal Stability Reference to FreedomCAR EESS Abuse Test Manual § 4.1 13.4.2 Simulated Fuel Fire Reference to FreedomCAR EESS Abuse Test Manual § 4.2 13.4.3 Elevated Temperature Storage Reference to FreedomCAR EESS Abuse Test Manual § 4.3 13.4.4 Rapid Charge / Discharge Reference to FreedomCAR EESS Abuse Test Manual § 4.4 13.4.5 Thermal Shock Cycling Reference to FreedomCAR EESS Abuse Test Manual § 4.5 13.5 Electrical Abuse Tests Reference to FreedomCAR EESS Abuse Test Manual § 5 13.5.1 Overcharge / Overvoltage Reference to FreedomCAR EESS Abuse Test Manual § 5.1 13.5.2 Short Circuit Reference to FreedomCAR EESS Abuse Test Manual § 5.2 version 08: 2007-01-17 Test Specification for Li-Ion batteries 21 Test Specification for Li-Ion batteries 13.5.3 Overdischarge / Voltage Reversal Reference to FreedomCAR EESS Abuse Test Manual § 5.3 13.5.4 Partial Short Circuit Reference to FreedomCAR EESS Abuse Test Manual § 5.4 13.6 Expected Results All performed abuse tests shall response to the table \"EUCAR Hazard Levels and Descriptions\" and the results shall at least response with \"Hazard Level 4 – No fire or flame, no rupture, no explosion; Loss of electrolyte excepted\" (see Annex D). 13.7 Minimum Abuse Testing on Module Level Prior to EESS Parameter Testing At least the following abuse testing activities on module level (≥ 500 Wh module) shall be reported by the EESS supplier prior to the EESS parameter testing activities: Mechanical Abuse Tests: - Controlled crush in X- and Y-direction of the module according to § 13.3.1 - Nail penetration according to § 13.3.2 Thermal Abuse Tests: Electrical Abuse Tests: - Thermal stability according to § 13.4.1 - Simulated fuel fire according to § 13.4.2 - Overcharge according to § 13.5.1 - Short Circuit according to § 13.5.2 - Over discharge according to § 13.5.3 14 Procedure 9 - Accelerated Calendar Life Time Test 14.1 General This test is aimed at testing the calendar life time of the battery under test within a shortened period of time. The test procedure is based on the LIBERAL test procedures for accelerated life testing of Li-Ion batteries. In order to save time and cost, only the test conditions which normally show the strongest aging effect will be applied. Therefore, only a storage temperature of 60 °C and a SOC of 80 % (which is the highest SOC an-ticipated during normal operation) is selected. 14.2 Accelerate calendar life test To be able to separate the effects of aging and the effects of cycling on the battery under test, a storage test at elevated temperature shall be performed parallel with the cycling tests. For the calendar life test it is suffi-cient to test cells only. The cells have to be charged to the SOC selected for the test and shall be placed in a climatic chamber. The duration of the test is normally six month. The voltage of each cell will be checked and noted at least once a week. It is not recommended to continually load the cells by measurement instruments. The temperature used in the test is 60 °C. The cells shall be stored at 80 % SOC. Parameter check-ups are performed every six weeks and also before the storage test starts. The parameter check-ups are performed at room temperature. The cells are cooled down to room temperature and dis-charged with 1C to the manufacturer's recommended end of discharge voltage, followed by a standard charge. After the parameter check-up a standard charge is performed, followed by a 1C discharge to the SOC the particular cell is tested at. The cell is then placed in the climatic chamber again and the calendar life test continues. 22 version 08: 2007-01-17 Test Specification for Li-Ion batteries 14.3 Parameter check-up In the parameter check-up the capacity, several internal resistances, the pulse power and the open circuit voltage are calculated from the same test profile. The parameter check-up is performed before the cycling or storage begins, every sixth weeks during cycling or storage and after the cycling or storage is completed. If the cycling is interrupted during a longer period, the six weeks are extended accordingly to the duration of the cycling break. The parameter check-up is per-formed on single cells. Table 6 - Parameter check-up test sequence during cycling or storage Step Interruption of cycling or storage Discharge Temperature equilibration Charge Discharge Charge Power, IR and OCV test profile Charge Discharge Continue cycling or storage 14.4 IR, OCV and Power test The IR, OCV and power test is performed according the procedures in clause 9. 14.5 Capacity The capacity is determined by the 1C discharge performed according to clause 8.2. 14.6 Data deliverables In addition to the data deliverables included in the parameter check-up test, following data shall be reported: • • • The voltage versus time from the weekly voltage controls. Remaining capacity after storage period (“self discharge”) versus storage time. The module or system weight shall be monitored 1C-discharge to EODV Cooling until RT is reached According to the standard charge procedure 1C-discharge to EODV to measure the capacity According to the standard charge procedure For each SOC-level from 80 to 20% in steps of 15% According to the standard charge procedure 1C-discharge to predetermined SOC-level Place the test object in the heated climate chamber and con-tinue testing (no temperature equilibration) Note 15 Procedure 10 - Lifetime – Cycle Life Test 15.1 Preamble Additionally to other aging factors (i.e. time, temperature), the energy throughput has a significant influence for the life-time of a battery. For choosing a relevant aging profile concerning the energy throughput, the real conditions during driving shall be considered. That means, the applied high C-rates and SOC-swing shall cover the vehicle demands in a proper way. Further, the usable SOC range shall be covered by the energy cycling test. This is impor-tant to get reliable and significant data for life-time prediction. On the other hand, the battery shall not be stressed too much. Therefore the thermal management and monitoring of the battery is mandatory, as well as certain rest phases are needed for equilibrium and cell balancing. 23 version 08: 2007-01-17 Test Specification for Li-Ion batteries 15.2 Testing: 15.2.1 Preparation During the test it is needed, to maintain the battery temperature by its cooling equipment within a tempera-ture range between RT and 40 °C (i.e. RT during rest periods, certain higher during operation). Maybe, addi-tional rest periods between the cycles will be needed to hold the battery within the designated range. The test profile, shown in Figure 5, covers a SOC swing of 20 % within 5 minutes. To use the battery in a wider SOC band, the test shall be performed at different start SOC. After each 2 test profile cycles (see Table 7) corresponding 22 h, the next SOC start point shall be ad-justed. A rest of 2 h before a new cycling start is defined to allow certain equilibrium within the cell chemistry and to bring all cells to a voltage balanced status (this will be normally performed by the integrated cell volt-age balancing circuitry). [ Note: The balancing occurring in this 2 hour period may alter the previously adjusted SOC value. The different SOC shall be adjusted by 5C discharges or charges. The cycling continues for 22 h, followed by a rest of 2 h. The complete test sequence: …start… Set SOC to 80 % (at 5C) 2 x test profile (Figure 5), 22 h: 80 % 60 % 80 % Set SOC to 65 % (at 5C) Rest for 2 h 2 x test profile (Figure 5), 22 h: 65 % 45 % 65 % Set SOC to 50 % (at 5C) Rest for 2 h 2 x test profile (Figure 5), 22 h: 50 % 30 % 50 %, Rest for 2 h …repeat 24 version 08: 2007-01-17 Test Specification for Li-Ion batteries Figure 5 - Current profile for energy cycle test Table 7: Times for current profile time increment time cumulative (s) (s) 5 5 10 15 32 47 20 67 5 72 10 82 37 119 20 139 5 144 10 1 37 191 20 211 5 216 7 223 49 272 28 300 Note: Because of different time delays and slew rates of various battery testers which will be used, no shorter pulses than 5 s were defined. current (C-rate) 20 10 5 0 15 10 5 0 -15 -10 -5 0 -12,5 -7,5 -5 0 charge accumulated (% SOC) 2,778 5,556 10,000 10,000 12,083 14,861 20,000 20,000 17,917 16,528 10,000 10,000 8,2 6,806 0,556 0,000 Parameter Check: before applying the energy cycling test the standard cycle shall be performed – The internal resistance, high power behaviour shall be monitored every week, by evaluation of the cy-cling test data (U, I) after a two h rest period and at the different SOC. – every 2 weeks the standard cycle shall be performed for 1C capacity determination – The module or system weight shall be monitored 15.2.2 Conditions: – Ambient: start at RT in a temperature chamber with an adequate safety equipment. 25 version 08: 2007-01-17 Test Specification for Li-Ion batteries – 3 different start SOC: 80 %, 65 %, 50 % alternating as described. – 2 h rest period before each energy cycle test profile application for equilibrium and cell balancing – Designated (or comparable) battery cooling has to operate. – During cycling, the test equipment and/or the battery electronic shall be assured that no cell limits will be exceeded. By achieving voltage limits (U_min, U_max), the current has to be reduced automati-cally to avoid any abuse operation. 15.2.3 Monitoring and Data logging: All cell voltages have to be monitored and logged. The amount of stored data may be reduced by logging only during selected (critical) parts of the test sequences. All available temperature sensor data shall be monitored and logged. 15.2.4 Adjustment of SOC and cell balancing: During long-time running cycling tests there is generally an accumulating effect of inevitable inaccuracies of each test bench. In order to avoid unbalances between the cells and drifting in SOC, the OCV has to be measured and controlled at the end of the 2 h rest period. If a voltage unbalance of approximately 80 mV difference in cell voltage (corresponds roughly >10 % SOC) rebalancing of the cells shall be done. Normally this function is implemented in the battery control electronic. Otherwise it has to be performed by individual charge or discharge of the affected cell(s). The SOC during cycling has to be checked at the end of the rest time (20 s) between the cycles in order to avoid a drift. The OCV has to be kept in the corresponding voltage window which has to be defined after the first h during cycling. If the SOC has drifted (OCV out of the voltage window), re-adjustment of the SOC has to be done (e.g. by 3C charge or discharge for some seconds) before cycling will be continued. Using the experience of the first hours/days of testing, may be this fine-tuning can be programmed on the test bench or shall performed by the operator someway. 15.2.5 SOC / DOD definition Due to ageing during the cycling test, a capacity loss is expected. Therefore it is very important to have a clear definition of the SOC respectively DOD. The rated capacity, determined in clause 5.1 defines the range between 100 % (fully charged) and 0 % SOC (fully discharged). For adjustment of the SOC values the 100 % value shall be taken as basis. 15.2.6 End of test The end of test criteria is defined: – the energy cycle profile can not performed without degradations (current reduction concerning the voltage limits) – the requirements of the parameter check between the energy cycling sequences can not longer ful-filled End of life Not the same as “end of test” -correlation between Explanation: Depending of the type of a specific car and depending of the OEM’s strategy, the allowed battery power use (and “ageing reserve”) may be very different. So the driver will feel a decreasing battery power – or not, de-pending on that. But the battery will work further on, of course with reduced power assist. So, “end of life” could be a very soft term. Example: - for better imagination of power/energy values and consideration background Based on a fictive 300 V battery with 6 Ah it corresponds to the following data: Discharge/charge during 10 s discharge at 20C: Electrical power assist at 20C (e.g.): 0,333 Ah 32,40 kW 26 version 08: 2007-01-17 Test Specification for Li-Ion batteries Regenerative power at 20C (e.g.): 39,60 kW 90,0 Wh 110,0 Wh 81,8 % energy output during 10 s discharge at 20C (e.g.): energy input during 10 s charge at 20C (e.g.): energy efficiency These seem to be realistic values, which will appear during typical acceleration, boost phases and recupera-tion phases during driving. Concerning the energy throughput, the resulting values are given herewith: • • Assumption: average speed of 60 km/h roughly calculated by \"300 V x I x time\" and summing of all steps o o o o o o Energy output each 5-minute cycle: Energy output each h: 0,36 kWh 4,32 kWh 95 kWh 665 kWh 3990 kWh 7980 kWh 5 km 60 km 1 320 km 9 240 km 55 440 km 110 880 km Energy output each day (22h operation): Energy output each week : Energy output each 6 week: Energy output each 12 week (1848 h operation): 16 Procedure 11 - Shock and vibration test 16.1 Purpose This test checks the DUT for malfunctions and breakage caused by vibration. Vibration of the body is random vibration induced by rough-road-driving. The main failure to be identified by this test is breakage due to fatigue. 16.2 Test Perform the test according to 60068-2- random vibration. Use test duration of 8 h for each plane of the DUT. The r.m.s. acceleration value shall be 27,8 m/s². The PSD vs. frequency are referred to Figure 6 and Table 8. 27 version 08: 2007-01-17 Test Specification for Li-Ion batteries Key: Y X PSD [(m/s2)2/Hz] frequency [Hz] Figure 6 – PSD of acceleration vs. frequency Table 8 – Values for PSD and frequency Frequency [Hz] 10 55 180 300 360 1000 PSD [(m/s²)²/Hz] 20 6,5 0,25 0,25 0,14 0.14 16.3 Requirement Breakage shall not occur. Functional status A (see Part 1 of ISO 16750) is required during operating mode 3.2 as defined in ISO16750-1, and functional status C during periods with other operating modes. 17 Procedure 12 - Dewing test (temperature change) +80 °C, Perform the test in reference to IEC 60068-2-30, Db, Variant see Figure 7: – upper temperature – number of cycle 5, Operating mode 2.1 according to ISO 16750-1 during the complete test sequence. Operating mode for a functional test during the high temperature phase shall be defined between customer and supplier. The temperature and humidity profile was defined to generate dewing effected like in the vehicle environ-ment. 28 version 08: 2007-01-17 Test Specification for Li-Ion batteries Figure 7 – Dewing circle version 08: 2007-01-17 29 Test Specification for Li-Ion batteries Annex A Data Profile provided by the Battery Manufacturer The following tables shall be filled in by the test institute and included in the test report. In addition diagrams of capacity versus constant current discharge (at different ambient temperatures) and power versus constant power discharge (at different ambient temperatures) shall also be included in the test report. The information shall be provided by the battery manufacturer. System description Battery Type Name Date of Manufacturing Nominal Battery Voltage (V) Rated Capacity (Ah) Nominal cell voltage (V) Number of modules Number of cells Description of the internal con-nections Type of electrolyte Size Cell: Module: System: Weight (kg) Volume (dm3) Dimensions - length (mm) - width (mm) - height (mm) Receiving date [dd.mm.jjjj; hh:mm] Peripherals and Instruction BMS Yes: No: Thermal management Yes: No: Safety devices Yes: No: Operating manual Yes: No: version 08: 2007-01-17 30 Test Specification for Li-Ion batteries System description Auxiliary equipment Thermal BMS Connectors Other Tray Total Weight Volume Dimensions - length - width - height Power consumption General data Manufacturer Company Address www-address Contact person Name Tel E-mail Fax version 08: 2007-01-17 31 Test Specification for Li-Ion batteries Operating Conditions Charging Method Charging time Temperature limits (°C) min: max: Max continuous charge current (A) Max charge current (A), duration (s) Max battery temp. during charge (°C) Max voltage during charge (V) Charging factor coulomb: energy: Full description of the charging procedure shall be given in Appendix. The description shall include a charge diagram Discharging Temperature limit (°C) min: max: Cut off voltage Constant current (V) 100% DOD Constant power (V) Max continuous discharge current (A) Max discharge current (A), duration (s) Performance Characteristics Capacity (Ah) 1C: 2C: 5C: 10C: 20C: Cmax: Specific Energy (Wh/kg) 1C: 2C: 5C: 10C: 20C: Cmax: Energy Density (Wh/l) 1C: 2C: 5C: 10C: 20C: Cmax: Specific Power (W/kg) 1C: 2C: 5C: 10C: 20C: Cmax: Power Density (W/l) 1C: 2C: 5C: 10C: 20C: Cmax: Expected life version 08: 2007-01-17 32 Test Specification for Li-Ion batteries Annex B Result Table Templates Battery Information Battery information Manufacturer Nominal Voltage (V) Rated Capacity1 (Ah) Number of parallel strings Battery size2 (mm, cells, modules or system) Weight of test sample (kg) Volume of test sample (l) Cell weight (kg) Cell volume (l) Number of cells 1. This value shall be used for calculation of DOD, i.e. the rated capacity corresponds to 100 %. 2. Definition of battery size and what shall be included in the weight, is described in chapter 3.6. version 08: 2007-01-17 33 Test Specification for Li-Ion batteries Self Discharge Parameter Test: Self Discharge (Battery name, Nominal voltage, Rated capacity) Battery weight [kg]: Cell weight [kg]: Number of cells: Nominal Voltage [V] Rated nominal 1C [Ah] Date [dd.mm.jjjj; hh:mm] Self Discharge Rest period [h] Initial C @ 70% SOC I 1C DCH [A] EESS Discharge Voltage Limit, DVL DVL @ 1C & 0°C [V] DVL @ 1C & RT [V] DVL @ 1C & 40°C [V] 0°C Capacity RT Aux. Energy [Wh] Capacity 40°C Aux. Energy [Wh Capacity [Ah] Capacity Loss [%] [Ah] Capacity Loss [%] [Ah] Capacity Loss [%] Aux. Energy [Wh 1 6 24 48 168 336 34 version 08: 2007-01-17 Test Specification for Li-Ion batteries Capacity Determination Parameter Test: Capacity Determination (Battery name, Nominal voltage, Rated capacity) Battery weight, (kg): Cell weight, (kg): Number of cells: Rated nominal 1C-capacity (Ah) Imax,dch (A) High Discharge Current, IHDC (A) High Charge Current, IHCC (A) Discharge Voltage Limit, DVL 3(V) Date [dd.mm.jjjj; hh:mm] Discharge Capacity and Energy Determination Rate Temperature Capacity (Ah) Specific Energy (Wh/kg) Energy Density (Wh/l) Coulomb Effi-ciency (%) Energy Effi-ciency (%) Average Spe-cific Power (W/kg) -25°C 1C RT 40°C -25°C 20C RT 40°C -25°C C max RT 40°C 3 If necessary specify different DVL-values according to discharge rate and temperature. 35 version 08: 2007-01-17 Test Specification for Li-Ion batteries Peak Power (Measurement values according to Power Test in §7) Parameter Test: Peak Power (Battery name, Nominal voltage, Rated capacity) Battery weight, (kg): Cell weight, (kg): Number of cells: Discharge Voltage Limit, DVL (V) Date [dd.mm.jjjj; hh:mm] Peak Power at different SOC (-10°C) SOC 80% 65% 50% 35% 20% P2s,dch (W/kg) Rated nominal 1C-capacity (Ah) Imax,dch (A) High Discharge Current, IHDC (A) High Charge Current, IHCC (A) P10s,dch (W/kg) P18s,dch (W/kg) P2s,cha (W/kg) P10s,cha (W/kg) OCV (V/cell) Date [dd.mm.jjjj; hh:mm] Peak Power at different SOC (0°C) SOC 80% 65% 50% 35% 20% P2s,dch (W/kg) P10s,dch (W/kg) P18s,dch (W/kg) P2s,cha (W/kg) P10s,cha (W/kg) OCV (V/cell) 36 version 08: 2007-01-17 Test Specification for Li-Ion batteries Date [dd.mm.jjjj; hh:mm] Peak Power at different SOC (RT) SOC 80% 65% 50% 35% 20% P2s,dch (W/kg) P10s,dch (W/kg) P18s,dch (W/kg) P2s,cha (W/kg) P10s,cha (W/kg) (V/cell) OCV Date [dd.mm.jjjj; hh:mm] Peak Power at different SOC (40°C) SOC 80% 65% 50% 35% 20% P2s,dch (W/kg) P10s,dch (W/kg) P18s,dch (W/kg) P2s,cha (W/kg) P10s,cha (W/kg) (V/cell) OCV 37 version 08: 2007-01-17 Test Specification for Li-Ion batteries Internal Resistance and OCV (Measurement values according to Power Test in §7) Parameter Test: Internal Resistance and OCV Battery name, Nominal voltage, Rated capacity Battery weight, (kg): Cell weight, (kg): Number of cells: Discharge Voltage Limit, DVL (V) Rated nominal 1C-capacity (Ah) Imax,dch (A) High Discharge Current, IHDC (A) High Charge Current, IHCC (A) Date [dd.mm.jjjj; hh:mm] Internal Resistance and OCV in -10°C at different SOC SOC 80% 65% 50% 35% 20% (mΩ/cell) IR2s,dch IR10s,dch (mΩ/cell) IR18s,dch (mΩ/cell) (mΩ/cell) IRdch IR2s,cha (mΩ/cell) IR10s,cha (mΩ/cell) (mΩ/cell) IRcha OCV (V/cell) Date [dd.mm.jjjj; hh:mm] Internal Resistance and OCV in 0°C at different SOC SOC 80% 65% 50% 35% 20% (mΩ/cell) IR2s,dch IR10s,dch (mΩ/cell) IR18s,dch (mΩ/cell) (mΩ/cell) IRdch IR2s,cha (mΩ/cell) IR10s,cha (mΩ/cell) (mΩ/cell) IRcha OCV (V/cell) 38 version 08: 2007-01-17 Test Specification for Li-Ion batteries Date [dd.mm.jjjj; hh:mm] Internal Resistance and OCV in RT at different SOC SOC 80% 65% 50% 35% 20% (mΩ/cell) IR2s,dch IR10s,dch (mΩ/cell) IR18s,dch (mΩ/cell) (mΩ/cell) IRdch IR2s,cha (mΩ/cell) IR10s,cha (mΩ/cell) (mΩ/cell) IRcha (V/cell) OCV Date [dd.mm.jjjj; hh:mm] Internal Resistance and OCV in 40°C at different SOC SOC 80% 65% 50% 35% 20% (mΩ/cell) IR2s,dch IR10s,dch (mΩ/cell) IR18s,dch (mΩ/cell) (mΩ/cell) IRdch IR2s,cha (mΩ/cell) IR10s,cha (mΩ/cell) (mΩ/cell) IRcha OCV (V/cell) 39 version 08: 2007-01-17 Test Specification for Li-Ion batteries Annex C: EUCAR Hazard Levels and Description Hazard Level 0 1 Description No effect Passive protection activated Defect / Damage Classification Criteria & Effect No effect. No loss of functionality. No defect; no leakage; no venting, fire or flame; no rupture; no explo-sion; no exothermic reaction or thermal runaway. Cell reversibly dam-aged. Repair of protection device needed. No leakage; no venting, fire or flame; no rupture; no explosion; no exo-thermic reaction or thermal runaway. Cell irreversibly damaged. Repair needed. No venting, fire or flame*; no rupture; no explosion. Weight loss <50% of electrolyte weight (electrolyte = solvent + salt). No fire or flame*; no rupture; no explosion. Weight loss ≥50% of electro-lyte weight (electrolyte = solvent + salt). No rupture; no explosion (i.e., no flying parts). No explosion, but flying parts of the active mass. Explosion (i.e., disintegration of the cell). 2 3 4 5 6 7 Leakage ∆ mass < 50% Venting ∆ mass ≥ 50% Fire or Flame Rupture Explosion * The presence of flame requires the presence of an ignition source in combination with fuel and oxidizer in concentra-tions that will support combustion. A fire or flame will not be observed if any of these elements are absent. For this rea-son, we recommend that a spark source be use during tests that are likely to result in venting of cell(s). We believe that “credible abuse environments” would likely include a spark source. Thus, if a spark source were added to the test con-figuration and the gas or liquid expelled from the cell was flammable, the test sample would quickly progress from haz-ard level 3 or 4 to hazard level 5. 40 version 08: 2007-01-17 Test Specification for Li-Ion batteries Annex D List of abbreviations A Ah Aux. BMS BOL C °C CAN cha CHA Cp CVL dch DC DCH DOD DUT DVL EESS EODV EUCAR EV h HCC HCchEP HCdchEP HDC HE HEV HP HV Hz I IEC IR ISO Ampere Ampere hours Auxiliary Battery Management System Beginning Of Life Capacity, expressed in Ampere hours (Ah) Temperature degree expressed in Celsius Communication Area Network charge Charge Thermal capacity of each module Charge voltage limit discharge Direct Current Discharge Depth of discharge Device under test Discharge voltage limit Electrical Energy Storage System End of discharge voltage European Council for Automotive Research Electric Vehicle hour(s) High Charge Current High current charge end power High current discharge end power High Discharge Current High Energy Hybrid Electric Vehicle High Power High Voltage Hertz Current International Electrotechnical Commission Internal Resistance International Organization for Standardization 41 version 08: 2007-01-17 Test Specification for Li-Ion batteries J K Li Li-Ion LIBERAL Mn Ni OEM OCV P PNGV PSD RPT RT s SC SCH SDCH SOC t T TBD U USABC V VDA W Wh Joule Kelvin Lithium Lithium-Ion Lithium Battery Evaluation and Research – Accelerated Life test direction (ENK6-CT-2002-00626) Manganese Nickel Original Equipment Manufacturer Open Circuit Voltage Power Partnership for a new generation of vehicles Power Spectral Density Reference performance test Room Temperature (23 ± 2°C ref. 3) seconds Standard cycle Standard charge Standard discharge State of charge Time Temperature to be defined Voltage United States Advanced Battery Consortium Volt Verband der Automobilindustrie Energy Watt hours efficiency η 42 version 08: 2007-01-17 Test Specification for Li-Ion batteries Annex E Testing Logbook The following scheme is an example for a test logbook, which shall be delivered for each DUT by the test institute. The purpose of this logbook is to report all actions carried out with the DUT versus date and the time, when these actions were taken. Note: For the evaluation of the test it is necessary to have these information, i.e. in order to record rest periods be-tween two actions. Testing Logbook (Battery Name) Date/time Action Power/ Current Temp. Remark 43 version 08: 2007-01-17 Test Specification for Li-Ion batteries Annex F Cell Testing F.1 General The cell manufacturer shall ensure that the cells to be tested fulfil the Design Requirements Specification (see [8]). The cell manufacturer shall be also aware that the cells as part of the system shall also be able to fulfil all system requirements. For testing of advanced Li-Ion technologies or for pre-testing by battery manufacturers, most of the tests described in this test specification may be performed on cell level, as well. For testing on cell level, the supervision of the single cell voltages and cell temperatures has to be carried out by the test bench. Care has to be taken in order not to overcharge, over discharge or overheat the cells. The cell manufacturer has to supply the minimum and maximum cell voltage (in dependence on current rate and temperature), the maximum charge and discharge pulse (in dependence of temperature), the maximum continuous charge and discharge current (in dependence of temperature) allowed as well as the minimum and maximum operation temperature as well as all other relevant information. F.3 Number of DUT Note: It is recommended that each test shall be carried out at least with 3 DUT. It might be possible to test these three cells in serial connection. The number of Li-Ion cells to be tested shall be agreed between the customer and supplier. F.4 Testing Note: If some adjustments of the test procedure according to the system tests necessary, those adjustments are ex-plained under the relevant topic. The following tests shall be applied on cell level. Parameter Test 8. 9. 10. 11. Energy & Capacity Power Test – An additional power test shall be performed at – 30 °C. Energy Efficiency Test Self Discharge Test – On cell level the BMS support is not available. Life Cycle Test 14. Accelerated Calendar Life Test – but the test cycle shall run at 30 % humidity – an additional test cycle shall be carried out at 90 % humidity 15. 13.7 Cycle Life Test Minimum Abuse test on cell level – perform all tests listed in 13.7 Validation 44 version 08: 2007-01-17 Test Specification for Li-Ion batteries Bibliography [1] EUCAR (European Council for Automotive Research): Specification of Test Procedures for Safety Testing of Traction Batteries; Traction Battery Working Group, March 2003 [2] EUCAR (European Council for Automotive Research): Specification of test procedures for high volt-age hybrid electric vehicle traction batteries; Traction Battery Working Group, Draft April 2004 [3] FreedomCar: Battery Test Manual for power-assist Hybrid Electric Vehicles, October 2003 [4] FreedomCar: Battery technology life verification test manual, February 2005 [5] FreedomCar: Electrical energy storage system – Abuse test manual for electric and hybrid electric vehicle applications; June 2005 [6] USABC (United States Advanced Battery Consortium): Development of advanced high power bat-teries for hybrid electric vehicle applications [7] USABC (United States Advanced Battery Consortium): Electrochemical storage system – abuse test procedure manual [8] System design requirements specification (VDA Initiative Circle \"Energy Storage System\VDA) 45 version 08: 2007-01-17
