Browse Topic: Energy storage systems

Items (6,073)
Solid-state hydrogen storage is severely limited by poor thermal performance of storage reactors, which leads to non-uniform temperature fields and slow reaction kinetics. A numerical model for metal hydride hydrogen storage technology was implemented by means of COMSOL Multiphysics 6.3, based on hydrogen sorption behavior for LaNi5-based material. After experimental validation, a spiral-wound tube with embedded turbulators was introduced into the reactor. The influence of turbulator cross-sectional ratio and shape on hydrogen-absorption performance was then investigated. When the turbu-lator occupied 1/40 of the cross-section, the temperature distribution became more uniform and the reaction rate increased markedly; the time to achieve 80% conversion was reduced by approximately 9.29%. The study demonstrates that tailoring the turbulator geometry (circular vs. square) and exploiting its synergy with the spiral tube accelerates reaction kinetics and balances the temperature field. Under 0.8 MPa and 313 K, a hydrogen uptake of 1.4 wt% was achieved. The simple structure can be mass-produced by CNC (Computer Numerical Control) tube-bending, making it attractive as a portable hydrogen source for mobile devices such as unmanned aerial vehicles.
Lin, JiangnanJin, Tingxiang
P2-type layered oxides are good cathode materials in high-performance sodium-ion batteries since they have desirable two-dimensional ion migration pathways. However, their instability at interfaces and their attenuation as cycles persist also remain a significant challenge. To increase their electrochemical stability, surface coating is also a good plan, but the balance between the coating and ionic conductivity is one of the key challenges. This study constructed an immensely thin layer of alumina (Al2O3) coating, and the influence of the amount of the coating (0.3-1.2 wt percent) on the working of the material was methodically examined. Electrochemical analysis showed that the lowest levels of Al2O3 (0.3 wt) provide the greatest improvement in performance. The optimized sample showed a retention capacity of 96.35 after 100 cycles of operation at 1C, significantly higher compared with samples that had increased coating contents. An analysis of cyclic voltammetry and impedance spectroscopy was subsequently done to corroborate the presence of a 0.3 wt% coating, which infected the electrode-electrolyte interface by inhibiting side reactions but minimally obstructing sodium-ion transport and thus promoting reaction reversibility and improved interfacial kinetics. These results highlight the importance of a less-is-more rule when it comes to surface coating and provide a novel understanding of how long-life sodium-ion battery cathodes can be designed by carefully engineered interfaces.
Hu, ChaoPeng, RuiZhou, YuZhou, DengmeiTian, Liangliang
The transition toward low global warming potential (GWP) refrigerants, driven by increasingly stringent environmental regulations and carbon reduction targets, has imposed new requirements on thermal management systems (TMSs) for electric vehicles (EVs). These systems must ensure efficient operation across a wide range of ambient conditions while maintaining high energy efficiency and environmental compatibility. Among potential alternatives, R290 (propane) has emerged as a promising natural refrigerant due to its favorable thermophysical properties and low environmental impact. In this study, an R290-based dual secondary loop TMS is proposed and evaluated for wide-temperature-range EV applications. A one-dimensional system model was developed using Dymola and validated through experimental testing on a dedicated performance test bench. TMS performance was investigated under multiple steady-state operating conditions, including high-load cooling, battery fast charging, and low-temperature heating, and benchmarked against a conventional R1234yf-based direct TMS. The results demonstrate that the R290-based dual secondary loop system achieves improved performance compared to a conventional R1234yf direct system, with a coefficient of performance (COP) increase of 4.29% under high-load cooling conditions at 43°C and up to 27.27% under high-load heating conditions at −10°C. Furthermore, under extreme low-temperature conditions (−18°C), the system delivers a heating capacity of 7 kW with a COP of 1.8, demonstrating strong low-temperature adaptability without the need for auxiliary heating. The results confirm that the proposed R290-based dual secondary loop system provides significant advantages in energy efficiency and wide-temperature adaptability, offering a promising solution for next-generation EVTMSs.
Zhang, YunpengMohammed, Mustafa MudassirGu, YiliangZhou, Guoliang
With the rapid development of the new energy vehicle energy storage industry, lithium-ion battery technology is undergoing a phase of rapid technological advancement. Enhancing battery energy density and safety remains a core challenge in overcoming industrial bottlenecks. During long-term cycling operations, deviations in state of charge (SOC), voltage, and temperature of individual cells inevitably occur, leading to reduced energy utilization efficiency. These deviations may also induce local overcharging and internal short circuits in individual cells, ultimately triggering thermal runaway incidents. While existing battery balancing strategies primarily focus on uniformity regulation, they fail to adequately address the coupling mechanisms of heat generation, heat storage, and thermal runaway propagation during balancing processes. Furthermore, the poor coordination between these strategies and thermal management systems makes it difficult to meet the complex safety requirements of high-energy-density batteries. To enhance the safety and energy utilization efficiency of battery systems during operation, this study focuses on the synergistic optimization of balancing strategies and thermal runaway prevention control. By establishing computer models of individual cells and battery packs in CATIA software, the research analyzes the evolution mechanisms of thermal runaway triggered by system state inconsistencies, while exploring the regulatory patterns of balancing parameters on thermal safety. Utilizing the ANSYS simulation platform, the study systematically examines the impact of three critical parameters—ambient temperature, discharge rate, and coolant flow rate—on battery temperature rise, providing theoretical support and technical references for the design of high-reliability lithium-ion battery pack systems.
Yu, ZhengGong, JiFan, YiLiang, WeiLi, YueweiLiu, FashenXie, MaojunCen, Zucai
This paper focuses on the parameter matching of key components and the improvement of overall vehicle performance for a certain front-wheel drive pure electric vehicle. Firstly, based on the target performance of the vehicle, the rated/peak power, speed, and torque of the permanent magnet synchronous drive motor, as well as the capacity, voltage, and series-parallel scheme of the LiFePO4 power battery, are systematically calculated. Meanwhile, the gear ratio of the transmission system is determined based on the dual constraints of the maximum speed and the maximum gradeability. Subsequently, the vehicle model is built using AVL Cruise, and the maximum speed, 0-100 Km/h acceleration time, maximum gradeability, and NEDC range are simulated and verified under steady-state and transient conditions. The results show that the maximum speed of the prototype vehicle reaches 139 Km/h, the 0-100 Km/h acceleration is 7.98 s, the maximum gradeability is 33.2%, the power consumption per 100 Km is 12.12 KWh, and the range is 485 Km, all of which are superior to the design indicators. The research verifies the rationality of the proposed parameter matching scheme and can provide a theoretical basis and engineering reference for the forward development of the power system of pure electric vehicles of the same level.
He, YuefanZhang, BaopingTang, ShujianChen, HanbangJin, Biao
SAE TOMORROW TODAY - SAE JA1016: Scaling the Future of UAVs with Battery Interoperability135798/6/2026
From drone delivery to public safety and defense, the next generation of uncrewed aerial vehicles (UAVs) will be powered not just by better batteries, but by better battery standards. Listen in as we sit down with Jeff Yambrick, Chair of the SAE Battery Cell Size Standardization Committee, and Lisa King, Director of Advanced Battery Strategy at Leap Manufacturing, to discuss SAE JA1016 -- a new standard designed to simplify battery integration, accelerate commercialization, and strengthen the UAV supply chain. During this conversation, you'll learn why common battery formats are essential for reducing development costs and creating greater interoperability across commercial and defense applications. We also explore the importance of domestic battery manufacturing, supply chain resilience, and how standardization can accelerate innovation without limiting future battery technologies. To join the SAE Battery Cell Size Standardization Committee, email Dante Rahdar at Dante.Rahdar@sae.org. We'd love to hear from you! Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders, innovators and strategists making it all happen--and give us a review on your preferred podcasting platform. Follow SAE on LinkedIn, Instagram, Facebook, X, and YouTube. Follow host Grayson Brulte on LinkedIn, X, and Instagram.
Patterson, Lori
A research team led by Professor Lin Gui at the Institute of Physics and Chemistry, Chinese Academy of Sciences, reports the first fabrication of multi-layer flexible batteries using a combination of liquid metal microfluidic perfusion and plasma-based reversible bonding techniques.
This study investigates the suppression of lithium-ion battery (LIB) fires using composite aqueous extinguishing agents, with a 20 Ah lithium iron phosphate battery as the experimental subject. Based on the functional selection of coverage-isolation and cooling-smothering, three aqueous extinguishing agents, S-E-1, S-E-2, and S-E-3, were designed and developed using hydrocarbon surfactants. The results indicate that all three aqueous fire extinguishing agents can effectively suppress LIB fires. Through a comprehensive evaluation of extinguishing time, cooling rate during extinguishing agent release, and physical and chemical parameters of the extinguishing agents, the optimal formulation was determined to be 2% SDS (sodium dodecyl sulfate), 1% SDBS (sodium dodecyl benzene sulfonate), 3.5% CAB (cocamidopropyl betaine), 1% APG0810 (alkyl polyglycoside), 1% CDEA (coconut oil acid diethanolamine), 0.32% CH4N2O (urea), 1.5% NH4H2PO4 (ammonium dihydrogen phosphate), 0.5% C2H6O2 (glycol), 1.5% Na3PO4 (sodium phosphate), and deionised water, demonstrated the best performance. Reducing the extinguishing time to 14 seconds, a 41.7% reduction compared to pure water, and increasing the cooling rate to 0.816 °C·s^–1, which is 4.4 times that of pure water, with no reignition observed. This work contributes to the theoretical principles needed to engineer next-generation fire suppression materials for lithium-ion batteries that are both efficient and eco-friendly.
Yu, TaoZhu, ShunbingLi, KeZhang, Menglan
As the energy density of electric vehicle power batteries continues to increase, efficient and uniform heat dissipation has become critical to their safety and performance. The liquid cooling plate serves as the core component of the battery thermal management system, with its flow channel structure directly impacting heat dissipation efficiency and system energy consumption. Current liquid cooling plate flow channel designs often rely on empirical methods, making it challenging to simultaneously optimize both heat dissipation uniformity and flow resistance performance. This paper focuses on a single lithium battery as the research subject, employing a topology optimization approach to design the liquid cooling plate flow channel structure. Optimization targets include minimizing pressure drop at the inlet/outlet and minimizing temperature difference across the contact surface between the plate and the battery. Under constant inlet cross-sectional dimensions and flow velocity, numerical simulation of fluid heat transfer processes revealed an 11.17% reduction in temperature difference across the contact surface. This enhances lithium battery heat dissipation uniformity while reducing inlet/outlet pressure drop by approximately 10.98%. This approach reduces the system energy consumption of liquid cooling. It enables multi-objective co-optimization design for power battery liquid cooling plate structures. It provides new technical references for the refined design of cooling systems in automotive power battery packs.
Ma, HonghuiZheng, YuqingYang, Minghao
Laser welding technology for aluminum alloy electrode and busbar connections: addressing challenges in battery module assembly. In this work, a CFD framework was built in ANSYS Fluent using a Gaussian rotating heat-source representation, while a VOF approach was used to capture the transient gas–liquid interface in deep-penetration welding. A three-dimensional, transient, thermal-fluid coupled numerical model of the dual-layer heterogeneous aluminum alloy laser deep penetration weld pool was established concurrently with laser deep penetration welding experiments. Results indicate: Peak flow velocities in the weld pool during welding are concentrated along the weld centerline, with flow vectors predominantly directed axially along the weld. Once a quasi-steady keyhole regime is established, vaporization-induced recoil pressure becomes the primary driver governing melt circulation. The liquid metal first impinges on the pool bottom along the keyhole wall and then recirculates upward near the pool boundary, producing strong vortical motion. These findings are intended to support parameter selection and process optimization for laser welding of layered dissimilar aluminum components used in battery tab–busbar assemblies.
Lv, WenjunWu, Yan
In recent years, with the rapid increase in the market penetration of new energy vehicles, safety issues in electric vehicles, particularly those characterized by thermal runaway of power batteries, especially fire incidents caused by mechanical abuse from underbody impacts, have become a major focus of industry attention and social concern. This paper systematically compiles key data from electric vehicle underbody collision incidents, covering core parameters such as impact location, geometric features of obstacles (shape and size), and vehicle speed during accidents. Based on this data, the study further reviews existing underbody scraping evaluation protocols both domestically and internationally, with a focused comparison of the differences in mechanical load and battery pack response between two typical test methods: horizontal underbody scraping and 3° inclined underbody scraping. The findings of this research aim to provide data support for the refinement of relevant evaluation standards and to offer theoretical foundations and practical references for automotive manufacturers in optimizing the design and validation strategies for underbody protection of battery packs.
Wang, QingguiHe, QikeLi, WenboLi, ChunLi, Xiaodong
Hydrogen-powered aircraft primarily utilize the conversion of liquid hydrogen into gaseous hydrogen to replace aviation kerosene, where hydrogen is directly combusted to provide propulsion. This study applied Amesim software to establish a complicated model simulating the liquid hydrogen to gaseous hydrogen conversion and ignition combustion processes. The simulation contains converting liquid hydrogen into gaseous hydrogen through a heat exchanger and simulating the mixture of gaseous hydrogen and air in the engine combustion chamber, and then igniting the mixture. The pressure, temperature, and flow rate of gaseous hydrogen and air during the ignition and combustion process in the engine combustion chamber, as well as the outlet temperature of the combustion chamber, are simulated and analyzed. The results demonstrate that during the simulation process, the internal pressure of the liquid hydrogen storage tank, the outlet pressure and flow rate of the liquid hydrogen pump, and the pressure and flow rate of gaseous hydrogen meet the requirements of the ignition combustion test. In addition, varying gaseous hydrogen flow rates had significant impacts on the temperature of the combustion chamber during combustion.
Gao, PengfeiWang, Lijian
This article focuses on a wide range of high-precision storage and supply systems. Under the rated flow rate of 2.928 mg / s of the proportional flow controller, the instantaneous flow fluctuation range of the BangBang valve reaches 2.963 mg / s, exceeding the control accuracy requirement of 1% for the proportional flow controller. By establishing mathematical models of the BangBang valve, proportional valve, and proportional flow controller for simulation analysis, the trend of the simulation results is consistent with the experimental results. Furthermore, considering the spatial layout and weight of the storage and supply system, this paper proposes a method to improve the accuracy of flow output by adding 180 mL of air capacity between the proportional valve and the proportional flow controller. Ultimately, the maximum flow fluctuation of the proportional flow controller at the moment of the BangBang valve opening and closing is 2.941 mg / s, which meets the control accuracy of the proportional flow controller. Moreover, the error between the output flow rate of the proportional flow controller and the rated working flow rate is minor after increasing the air capacity.
Li, ZhongLi, ZongliangYan, ZelongHuang, Tiankun
This document provides recommendations to identify battery group sizes and dimensions for 6 V, 8 V, 12 V, and 24 V lead acid batteries.
Starter Battery Standards Committee
This recommended practice (RP) presents a methodology to evaluate RESS Cells Closure Integrity (Leak Tightness) requirement. This RP applies to two types of RESS Cells, each containing liquid electrolyte: Lithium ion (Li-ion) Cells and Sodium ion (Na-ion) Cells. The Equivalent Channel Method is used as a suggested cell closure integrity requirement for a given RESS Cell design during its production and product validation phases. The Closure Integrity requirements intended to assure no electrolyte leakage and no excessive moisture ingress during the usage of these cells as part of the RESS (Battery Pack), which is crucial to assure the safety and performance of these RESS. This RP specifies non-destructive Integrity (leak) testing processes of the Cell Closure. It describes approved leak testing technologies, testing procedures, tooling requirements, and leak test systems validation/verification requirements. This document may be applied to RESS Cell Closure Integrity testing during their initial product validation and their in-line 100% of production integrity/leak testing. This RP applies to RESS Cells with rigid packaging (cylindrical or prismatic) or flexible packaging (pouch).
Battery Standards Testing Committee
Batteries generate a large amount of heat during operation, and if it cannot be dissipated in a timely and effective manner, it will seriously affect the performance, lifespan, and even safety of the battery. Therefore, battery heat dissipation has become a key challenge in the development of new energy vehicles. The traditional liquid cooling system has problems such as complex design and control, and the need to improve heat dissipation efficiency. To address these issues, this study proposes an optimized design scheme for battery environment heat dissipation control system based on liquid cooling heat dissipation system. This study first conducted an in-depth analysis of the thermal generation mechanism of lithium-ion batteries and studied existing examples of thermal management schemes. On this basis, an innovative forward and reverse circulation device was designed, combined with a liquid cooling heat dissipation structure. The Keil uVision4 programming software was used to write the microcontroller control program, and the circuit was simulated and verified using Proteus simulation software. This study established an experimental platform and conducted physical testing and thermal imaging detection. By collecting temperature change data under different heat dissipation modes and analyzing the experimental data, the results show that the optimized liquid cooling heat dissipation system significantly improves the heat dissipation efficiency. The system exhibits good performance under different cooling modes.
Ding, XvqiangNi, YiweiGu, ChenZhang, JinChen, MingyangJiao, Yunxiao
Modern electric vehicles can go hundreds of miles without a recharge, but that long range can diminish faster if battery health isn’t properly tracked and managed. And to do that, you need some smart software — and some smarts from working with NASA.
Thermal runaway assessment in automotive battery development is still largely driven by isolated abuse tests, while design decisions require quantitative insight into how cell geometry, material thresholds, and thermal boundary conditions influence thermal runaway onset and severity. This paper presents a systematic sensitivity study using a coupled electrochemical and thermal model augmented with Arrhenius-based decomposition reactions to represent the dominant exothermic pathways. Thermal runaway onset is defined using a temperature rise-rate criterion to distinguish gradual heating from runaway acceleration. Two trigger modes are considered: an internal short circuit initiated by nail penetration and an external heating trigger. Four parameter groups are investigated: cell length scaling, separator decomposition temperature, external heating power, and the convective heat transfer coefficient to the environment. For the nail-triggered internal short circuit, larger cells exhibit lower peak temperatures but longer times to reach the maximum, indicating a geometry-driven shift from rapid escalation to a slower, more moderated evolution. In the external heating case, increasing cell size significantly delays onset, while peak temperature shows a nonlinear trend and approaches saturation rather than scaling inversely with size. Increasing the separator decomposition temperature also shows a saturation effect because alternative reactions can dominate the triggering sequence. External heating power exhibits a threshold: below a critical level, convective losses balance the input and prevent runaway. Even when external heating is stopped at an intermediate temperature, higher preheating power can still lead to higher peak temperatures due to a larger remaining reactive inventory when the internal short circuit occurs. Improved heat rejection consistently delays onset, reduces peak temperature, and accelerates cool-down. Overall, the study extends prior trigger-specific analyses by providing a unified reduced-order sensitivity view across two abuse pathways and by identifying threshold and saturation behaviors that translate directly into design-relevant robustness levers.
Ceylan, DenizKulzer, André CasalWinterholler, NinaGiek, MichaelWeinmann, Johannes
Hybrid electric vehicles rely heavily on battery pack power capability, which is often compromised by non-uniform aging and thermal gradients. Conventional battery models typically use bulk state-of-health metrics, failing to capture localized degradation that leads to current imbalances and reduced pack utility. This paper presents a multi-scale modelling framework that integrates Electrochemical Impedance Spectroscopy data into a fractional-order equivalent circuit model to simulate localized degradation in Lithium Iron Phosphate cells. Results show that the terminal voltage of LFP cells can be accurately modelled using the proposed fractional-order equivalent circuit with a discrete transfer-function implementation, maintaining root-mean-square errors below 20 mV across most state-of-health and state-of-charge conditions. The validated cell model is then extended to a degradation-aware battery pack representation. The battery pack in this work utilizes a 200-kWh, 800 V architecture consisting of five modules connected in parallel, each module composed of 13 parallel strings of 250 series cells, evaluated under multiple degradation scenarios. By integrating this pack model into a Class-8 series hybrid powertrain simulation, this study quantifies how cell-to-cell heterogeneity impacts vehicle performance under the VECTO regional delivery drive cycle. At the vehicle level, these battery constraints influence engine duty cycles and battery pack stress metrics. When localized degradation reaches up to 40% in one module while the remaining modules degrade up to 20% to 30%, such inhomogeneous degradation reduces the minimum pack terminal voltage by approximately 27% and increases peak discharge current by more than 30%, resulting in more rapid degradation. These battery-level limitations translate into higher fuel consumption by up to 6% in a charge-sustaining scenario.
Safavi, Seyed RezaHomayouni, HoomanShoa, TinaWang, JasonMcTaggart-Cowan, Gordon
Electrification using battery systems is one of the most relevant solutions regarding ecological challenges within multiple application cases such as mobility, power tools or stationary power supply. Nonetheless besides recent achievements in some cases battery systems are still lacking behind operational requirements compared to conventional propulsion systems, therefore limiting the potential of electrification. Especially when purpose design possibilities are limited. Besides improving properties of cell materials, better usage of the available installation space offers potential for optimization of the battery system. The development of battery systems is complex, as it involves multiple system levels and domains, along with a wide range of design options and architectures. Battery cells that can be manufactured in flexible formats enable possibilities to make more efficient use of available installation spaces. At the same time, these additional degrees of freedom increase design complexity and significantly expand the solution space. For example, numerous options for sizing and positioning of the cells are available that are interacting with the cooling system and housing design. Also, additional challenges regarding electrical and thermal load distribution occur using format flexible cells. To support developers, new methods and tools are necessary to handle this complexity. Therefore, the authors present a methodology that includes an installation space optimization using format-flexibly produced pouch cells that generates different possible layouts of cells and modules, an approach for electrical and thermal modeling of the battery system that is applicable for varying cell arrangements as well as possibilities for a fast criteria-based evaluation of different cell and module arrangements that can be used for an overall optimization of the battery system. Finally, the authors are discussing benefits and disadvantages of the presented methodology as well as the usage of format flexibly produced pouch cells using an illustrative case study.
Müller-Welt, PhilipBause, KatharinaSpohn, HannesAlbers, Albert
With the continued expansion of electric mobility, liquid-cooled thermal management systems have become indispensable for ensuring the performance, durability, and safety of automotive battery packs. This work presents a novel cooling-plate design that integrates offset strip-fin turbulators to enhance convective heat transfer between lithium-ion cells and the circulating coolant. A comprehensive multi-region CFD model of the full battery pack is developed, incorporating an implicit lumped-parameter representation of cell heat generation. The numerical predictions are validated against dedicated experimental measurements available in the literature. Subsequently, a parametric study is conducted in which the number of hydraulic sub-modules and the inlet/outlet configurations are systematically varied to generate all feasible design permutations. The resulting configurations are compared to assess thermal performance and to quantify the benefits—as well as the potential penalties—introduced by the turbulators relative to the experimentally validated baseline.
Montenegro, GianlucaOnorati, AngeloDella Torre, AugustoTariq, Muhammad HasnainBonetti, Elisa
HV Power nets of electric vehicles consist of various HV components such as batteries, inverters, auxiliaries and cables. During in-vehicle testing, multiple failures of an auxiliary inverter were observed, caused by resonance issues within the component filter. Initial investigations revealed that these resonances, absent during manufacturer testbench evaluations, were influenced by the vehicle power net and its impedance characteristics. To better understand the underlying causes and identify preventative measures, extensive simulations were performed. The results demonstrate a diminishing influence of the power net capacitance when significantly larger than the component capacitance. Also, they highlight the critical impact of cable inductance on the component resonance frequency when comparable to the component’s inductance. A simplified electrical equivalent circuit was used to derive an equation predicting the resonance frequency as a function of the component’s capacitance/inductance and the cable length to the main power net capacitances. Based on these findings, recommendations for component filter design and testing protocols were proposed to mitigate similar failures in future applications.
Schmiel, FabianAurand, TobiasKoehnlechner, BenjaminZimmer, Markus
The widespread adoption of electric vehicles is currently hindered by long charging durations and limited infrastructure. While fast-charging technologies address these issues, they impose significant thermal loads on high-voltage components. Within this architecture, the Battery Disconnect Unit plays a critical role as it monitors and controls the connection between the battery, powertrain, and charging system. However, the high currents required for fast-charging often drive these units' temperatures beyond safe operating limits, necessitating advanced thermal solutions that do not require extensive redesigns of the vehicle's electrical layout. To address this challenge, this study proposes a passive thermal management solution using Phase Change Material heat transfer devices to enhance the thermal robustness of the component. The methodology employs a dual approach involving initial experimental testing to pinpoint specific thermal hotspots under high-power conditions, followed by detailed numerical simulations using GT-Power software to predict system behavior. Furthermore, the paper provides a comparative analysis of various configurations, assessing their impact on temperature reduction, response time, and thermal uniformity. The results demonstrate that appropriately designed passive solutions significantly improve thermal performance, effectively enabling higher charging power capabilities while minimizing system complexity and integration effort. This innovation provides a scalable and efficient path for improving overall vehicle performance and safety during rapid energy transfer events.
Salameh, GeorgesGoumy, GuillaumeFrecinaux, AnthonyRatajczack, ChristellePalluel, MarlèneNoiseau, PascalLardeux, Sébastien
This paper presents Stochastic Gradient Pulse Adaptation (SGPA), a real-time adaptive pulse-charging system for rechargeable electrochemical batteries that dynamically adjusts charging aggressiveness based on the battery's internal response, as opposed to predetermined CC–CV or fixed pulse profiles. SGPA is different from traditional charging methods that use static current de-rating and conservative voltage limits. Instead, SGPA uses gradient-based feedback from terminal voltage behaviour, temperature changes, internal resistance changes, and state of charge to continuously adapt pulse amplitude and duty cycle. This algorithm boosts the charging intensity when the electrochemical circumstances are good. It lowers the pulses slowly when signs of thermal or impedance-related stress show up. Simulation-based proof-of-concept experiments on a heavy-duty multi-battery system show that charging time is less than with multi-CCCV charging, while still keeping the current distribution across packs balanced. The suggested SGPA method adds an adaptive charging algorithm that is easy to understand and ready to use. It makes fast charging more efficient without lowering voltage and thermal safety limits.
Prakashkumar, BalagopalMannar, Vignesh
Current lithium-ion batteries should generally only be charged above 0 °C, as charging below this temperature can promote lithium plating and irreversible degradation. However, conventional pack-level heating elements increase system mass and design complexity. In addition, heat is transferred from outside into the cell, causing the temperature inside the cell to rise slowly. This study evaluates internal Joule heating of cylindrical Li-ion cells using a zero-mean square-wave current excitation and quantifies the associated aging impact. LG INR21700-M50L cells were tested at 0 °C, −10 °C, and −20 °C with three excitation frequencies (50 Hz, 1 Hz, 10 mHz) at 5 A amplitude. Each cycle consisted of 30 min heating followed by 60 min cooling; reference capacity-based state of health (SOH) was assessed every 50 cycles up to 400 cycles. A maximum surface temperature rise of 14.3 K was achieved, with larger temperature rise at lower ambient temperature and lower excitation frequency. Capacity fade remained below approximately 1% for most conditions; however, at −20 °C and 10 mHz a pronounced SOH decrease to 87% was observed, indicating a critical operating regime. The results provide practical guidance for pulse-heating parameter selection and highlight the need for safeguards and further diagnostics in extreme low-frequency excitation at very low temperatures. This heating approach is particularly suitable for simpler battery-electric applications without thermal management, such as e-bikes or power tools. However, it may also be relevant for applications with existing thermal management systems, as it simplifies battery pack design.
Raiber, StefanAllmendinger, FrankDegler, DavidParschau, Anke
This document provides recommendations involving BEV battery data retention and battery design that enhance the potential for BEV battery reuse and serviceability and that can improve recyclability. These recommendations have been developed by a group of professionals skilled in the secondary-use of batteries and in the research, development, and manufacture of BEV batteries and battery systems.
Secondary Battery Use Committee
This document establishes standardized dimensional cell geometry, performance-test procedures, and reporting requirements for secondary (i.e., rechargeable) pouch cells used in Group 1 sUAV. It defines reference geometries, test conditions, and uniform data formats to allow direct comparison of pouch-cell performance across manufacturers and to improve interoperability within the sUAV ecosystem.
Battery Cell Size Standardization Committee
Tire exterior noise has become increasingly critical in vehicle acoustics due to two key developments: updated pass-by noise regulations, which amplify the relative contribution of tire noise, and the rise of Battery Electric Vehicles (BEVs), which lack traditional powertrain noise. Design trends in BEVs—such as increased vehicle mass from battery packs and the widespread use of large-diameter, wide, low-profile tires—further intensify tire noise due to stiffer constructions and altered contact dynamics. A common method for predicting tire noise is the source-transfer-receiver model, where the tire is represented by a set of monopoles with volume velocity Q derived from near-field measurements. Acoustic propagation is modeled via p/Q transfer functions. Despite its simplifications, this approach is practical for vehicle development, enabling clear separation between source and transfer mechanisms and facilitating targeted noise control strategies. In previous work, we proposed a rigorous framework to optimize both the spatial distribution and strength of the monopole sources. Positions were identified using an L1-norm regularization via the Lasso algorithm, promoting sparsity and physical interpretability. Strengths were estimated using an L2-norm Tikhonov regularization, which stabilizes the solution against measurement noise. While the Tikhonov regularization parameter was previously tuned manually through trial and error, we now enhance predictive accuracy by selecting it via a cross-validation technique, ensuring a more robust and data-driven optimization. Besides this, compared to the previous work the approach here is validated for the prediction of both indoor and outdoor pass-by noise, as well as for multiple tire types providing different noise levels. Results demonstrate the method’s robustness, accuracy, and applicability for acoustic development in modern vehicle platforms.
Morin, BenjaminDi Marco, FedericoHorak, JanLafont, ThibaultKim, MinkyuKang, Min KyooYoo, Ji Woo
This SAE Standard applies to lead-acid 12 V heavy-duty storage batteries as described in SAE J537 and SAE J930 for uses in starting, lighting, and ignition (SLI) applications on motor vehicles and/or off-road machines. These applications have some of the following characteristics: High levels of power are required to start the vehicle’s internal combustion engine. The need to supply this power limits the maximum depth of discharge to a fraction of the total capacity of the battery. The battery must be maintained at a charge level sufficient to perform this primary function by the vehicle’s voltage-regulated charging system. The vehicle’s engine powers a voltage-regulated charging system that limits the charging voltage when spinning at sufficient speed and when total loads do not exceed its output limits. The battery is subject to deeper discharging than a typical automotive application as a result of the following conditions: High daily hours of use High numbers of starts per day Electrical loads often exceeding charging system output (at idle) Batteries will be classified into two types for this life test. Type 1 applies to BCI group sizes typically with reserve capacity (RC) rating of 250 minutes or less. Type 2 applies to larger batteries typically with reserve capacity greater than 250 minutes.
Starter Battery Standards Committee
This paper presents a novel concept for battery electric vehicles (BEVs), referred to as the low-voltage reconfigurable electric vehicle (LVREV). The LVREV is designed to bridge the gap between L- and M-class vehicles by adopting a <60 V multi-phase powertrain combined with a swappable battery system, maintaining the overall vehicle mass below one ton. This configuration enables adaptable driving range, optimized energy consumption in urban environments, and enhanced safety. The LVREV features two distinct operating modes. Frugal mode is intended for urban use and employs a smaller battery pack to maximize efficiency and reduce vehicle mass, while Dual mode is tailored for longer extra-urban trips through the use of a dual-battery configuration. The key innovations of the LVREV concept include a reconfigurable vehicle architecture capable of meeting both urban and extra-urban mobility requirements, thus providing a highly versatile transportation solution. In addition, the low-voltage powertrain improves safety and lowers system costs, facilitating manual battery replacement and compatibility with domestic charging infrastructure. By integrating these technological solutions, the LVREV expands the potential of low-voltage electric vehicles and supports the development of more flexible, efficient, and user-oriented mobility concepts. Experimental and simulation results demonstrate the feasibility of the proposed solution and provide initial validation of the reconfigurable powertrain and battery architecture.
Tramacere, EugenioFavelli, StefanoGalluzzi, RenatoTonoli, Andrea
Thermal safety in lithium-ion batteries is a critical aspect due to their increasing use in energy storage systems and electric vehicles. To investigate thermal abuse conditions, numerous studies employ specialized equipment to accurately measure physical variables during thermal runaway events. However, such tests typically require robust equipment which limit their availability in conventional laboratory environments. In this context, the present study proposes and evaluates an experimental methodology based on the use of a climate chamber combined with an instrumented reduced-volume container, to reproduce severe external heating conditions. The thermal behavior and gas emissions associated with thermal runaway events were characterized in six cylindrical lithium-ion batteries of two different chemistries. Six cylindrical cells with NMC and NCA cathode chemistries were subjected to thermal abuse tests. In addition, gaseous emissions and mass loss were quantified after the event. Based on these tests, the results showed that NMC cells reached a higher average maximum surface temperature of 1086°C, whereas NCA cells exhibited the highest pressure values, with an average of 24.64 bar. Gas emissions presented high concentrations of CO and CO₂, reaching values of up to 381,555 ppm. Furthermore, both chemistries experienced a mass loss exceeding 50% after the test. Overall, the results indicate that both cell types exhibit similar behavior in terms of gas emissions, while NMC cells show greater thermal severity during the exothermic event. This work demonstrates that a system based on a climate chamber combined with an instrumented container is capable of reproducing severe thermal runaway conditions comparable to those achieved in specialized abuse-testing facilities, enabling the simultaneous characterization of temperature, pressure, and gas emissions in lithium-ion cells.
Penagos Vásquez, Diego AlejandroMarco-Gimeno, JavierMonsalve-Serrano, JavierGarcia, AntonioPerez Balastegui, Jose
Vehicle fleet decarbonization is a key objective for the coming years, with electrification representing the primary pathway to achieving the targets set by the European Union. The share of battery electric trucks in new registrations has been gradually increasing especially in light and medium size trucks. The replacement rate of diesel long-haul trucks with zero emission trucks is still low due to challenges posed by added complexity and limitations of battery charging. Depot overnight charging is not sufficient to cover the energy needs of a truck covering large distances and careful planning of the route using public charging infrastructure is crucial for an optimized route minimizing extra costs and range anxiety. The current work aims to develop a methodology to propose the optimal charging locations for a given route of a battery electric truck based on nearby stations along the route. Our study uses an open-source optimization algorithm for the fixed route vehicle charging problem coupled with a powertrain simulation model that is used to calculate the energy consumption and the electric range of the vehicles. A variety of constraints, such as initial State of Charge, lowest allowed State of Charge threshold, maximum trip duration, distance deviation, have been implemented in different scenarios from real world locations with a goal to investigate the impact of planning constraints and charging infrastructure in the optimal planning of electric truck routing. The results of our analysis indicate that the integration of an accurate energy consumption calculation model to a route and charging optimisation algorithm can be proven beneficial for minimizing the time penalty due to charging.
Perdikopoulos, MichailDoulgeris, StylianosLivitsanos, GeorgiosKazakis, ThomasMellios, GiorgosNtziachristos, Leonidas
This work investigates the integration of a Sorption Thermal Energy Storage (TES) into the Heating, Ventilation and Air Conditioning (HVAC) system of electric vehicles. The proposed device reduces the energy demand for cabin heating under winter conditions, leading to a driving range increase. The TES dehumidifies the cabin air through a desiccant bed (zeolite 4A), preventing window fogging, enabling higher air recirculation rates, and consequently reducing the required heating power. An experimentally validated numerical model was used to analyze the adsorption and regeneration processes and to identify suitable operating conditions. Regeneration was found to be effective at moderate temperatures (from 120°C), with a counter-current airflow configuration providing faster and more efficient desorption compared to parallel-flow one. A simplified model integrating TES, HVAC unit and cabin was developed and used to compare different configurations. Heating energy consumption with and without TES under different ambient conditions, passenger loads, airflow rates, and regeneration states was evaluated. Heating energy savings ranged from 19% to 71%, increasing with higher external humidity. Considering the desiccant bed volume, equal to 1.65 L, electric energy savings up to 1.7 kWh L-1 for heat pump systems and 3.3 kWh L-1 for electric heaters were estimated, corresponding to a potential driving range increase of 13.4 km L-1 and 33.5 km L-1, respectively. Preliminary TES tests on a mock-up vehicle confirmed the effective dehumidification capacity of the proposed technology.
Verlingieri, RebeccaCalabrese, LuigiFreni, AngeloMarocco, LucaScudeler, GabrieleDe Antonellis, Stefano
Ammonia (NH3) fuelled engines have emerged as a promising route toward net-zero emission targets due to NH3’s carbon-free nature, ease of storage, and established handling infrastructure. However, the low laminar burning speed and narrow flammability limits of NH3 pose a significant combustion challenge, which can be addressed through hydrogen (H2) co-fuelling. For practical implementation, on-board H2 production via thermal catalytic cracking of NH3 is an attractive solution, as it eliminates the need for external H2 storage and associated handling and capital costs. Previous studies by the present authors identified a lean operating strategy that achieves an equimolar ratio of NOx and unburned NH3 (α NH3NOx ≈ 1), enabling complete conversion to nitrogen and water vapour when coupled with a Selective Catalytic Reduction (SCR) system. This strategy was further validated using cracked NH3 derived H2 in place of bottled H2 through an on-board cracker, thereby representing a practical system configuration. However, the required H2 fraction, and consequently the size and power demand of the onboard cracking system, is strongly influenced by engine architecture and operating conditions. The present study investigates the effect of compression ratio (CR) and stroke length, on H2 fraction requirements to achieve an optimum α of unity in an externally boosted SI engine. Results demonstrate that the high CR = 17.5, long stroke configuration reduces H2 enrichment by 50–60% compared to a low CR = 12.5, short-stroke engine architecture, allowing smaller onboard H2 generation systems. At high-speed, high-load conditions, it achieves over 45% thermal efficiency with stable NH3 combustion and no H2 supplementation, maintaining an α ≈ 1. Across the full operating map, NOx emissions comply with IMO Tier III and EPA Tier 4 norms, demonstrating near-zero-emission operation.
Yadav, Neeraj KumarAmbalakatte, AjithGeng, SikaiGopakumar Suja, GaganBirch, AlexanderCairns, AlasdairHarrington, AnthonyHall, Jonathan
The EU funded innovation project High-Voltage fast-charging Efficient electric vehicle Powertrains (HiVEP) develops innovative technologies for mass-market electric vehicles (EVs) by advancing architectures operating above 800 V. These architectures integrate silicon carbide (SiC)-based power electronics, rare-earth-free electric machines with active winding reconfiguration, high C-rate batteries, and optimized thermal management systems. HiVEP aims to enable fast charging in less than ten minutes, reduce energy consumption by at least 25%, extend the driving range by 20%, and cut system costs by up to 20% in volume production. This article deals in detail with the project objectives, the methodological approach, and the expected key innovations, as well as the technical, environmental, and social impacts. The discussion situates HiVEP within the European research and innovation landscape, emphasizing its role in accelerating adoption of sustainable mobility solutions.
Schernus, ChristofNada, ShadyNeuhaus, ChristophEwald, JensSwierc, DanielKallur-Krishnamoorthy, RajeshVasiliadis, Harilaos
With the United Kingdom’s goal to achieve a fully decarbonised energy sector by 2035 and achieve net zero greenhouse gas emissions by 2050, the transition of the UK’s passenger car fleet to battery electric vehicles (BEVs) plays a crucial role in reaching this goal. This study evaluates the environmental and energy impact of large-scale BEV adoption by modelling future uptake scenarios using historical fleet data combined with assumed impact of future policy such as the 2030 ban on the sale of new petrol and diesel vehicles. Three predictive models have been developed: fast uptake, in which approximately 100% of the passenger car fleet is replaced by BEVs; moderate uptake, where a large majority of passenger cars are BEVs; and slow uptake, in which BEV adoption does not reach a majority. The results have shown that, if a medium- or large-scale adoption is possible by 2040 predicting nearly 37 million BEVs on the road, the associated electricity demand is predicted to rise close to 110 TWh annually, signifying the need for rapid development in renewable energy generation. Although BEVs significantly reduce transport sector emissions, the overall climate impact is dependent on a continued effort of grid decarbonisation.
Burke, BradleyKateregga, SunnySodre, Jose Ricardo
Improved energy efficiency and lower CO2 emissions are the two major drivers for the emergence of E-mobility. Growth of electric vehicles (EVs) has sustained ever since their introduction till 2020 and has substantially increased thereafter. EVs require specialized lubricants, which are different from conventional lubricants mainly due to the addition of new hardware technology including e-motor, inverter, battery, and new materials (copper windings, elastomers, plastic, and other materials). Lubricant when used in an advanced powertrain electric vehicle specifically in E-powertrains may encounter the e-motor and must deliver unique performance attributes such as optimal electrical properties, thermal management, and material compatibility apart from the traditional features including extreme pressure, friction performance, oxidation, and wear control. In the current study, we have investigated conventional GL5, manual transmission fluid (MTF), automatic transmission fluid (ATF), and dedicated e-fluids to understand additive and viscosity effects on aforesaid performance traits. Our study emphasized that additive chemistry plays a significant role on key properties such as electrical properties, corrosion resistance, oxidation resistance, and tribological performance.
Katta, LakshmiSeth, SaritaSingh, SandeepBhardwaj, AnilArora, Ajay Kumar
Harbinger revealed its HC Series Cab during Work Truck Week 2026 in Indianapolis, Indiana. The HC Series is a new line of medium-duty, low cab forward vehicles available as both an electric and plug-in hybrid model. Harbinger states that the HC Series' hybrid powertrain uses a range-extended hybrid platform with a gasoline engine to recharge the truck's batteries, extending range up to 500 miles (805 km), depending on upfit configuration and drive cycle.
Wolfe, Matt
Among the enduring challenges of storing energy – for wind or solar farms, or backup storage for the energy grid or data centers – is batteries that can hold large amounts of electricity for a long time.
Climate change was poised to create an interesting catch-22 for electric vehicles. Electrifying transportation can go a long way to reducing carbon emissions that are driving up global temperatures. But warmer temperatures also accelerate the degradation of batteries, whose performance can be a make-or-break factor for people considering an EV purchase.
These days, no one blinks an eye at two-day, one-day, or even same-day package deliveries. Despite the plethora of localized fulfillment and distribution centers cropping up to meet demand, delivery trucks still need to make considerably long drives, often on highways. To reduce fuel and maintenance costs as well as carbon emissions, companies are investing in electric trucks for their delivery fleets. While turning to electric trucks is a promising solution, the battery packs incorporated into these automotive designs often fall short in the lifetime needed to make consistent long-distance highway travel feasible.
Researchers have developed a solar-powered reactor to break down hard-to-recycle forms of plastic waste – such as drinks bottles, nylon textiles and polyurethane foams – using acid recovered from old car batteries, and converting it into clean hydrogen fuel and valuable industrial chemicals.
Researchers at Columbia Engineering have developed a new gel electrolyte that both improves the lifetime and safety of anode-free lithium batteries, an emerging battery architecture that could dramatically boost energy density while simplifying manufacturing. Although such design promises higher energy density and lower cost, the approach has long been plagued by short battery life and safety concerns caused by unstable lithium plating and parasitic reactions at the electrode-electrolyte interface.
As the electric vehicle era enters full scale, demand is increasing for batteries that can travel farther and last longer. Lithium-metal batteries have been attracting attention as a next-generation technology capable of surpassing the capacity limits of existing lithium-ion batteries. However, during the charging process, needle-shaped crystals called “dendrites” grow, shortening battery life and increasing the risk of fire, which has been identified as the biggest obstacle to commercialization. A Korean research team has developed a key technology that can solve this challenge.
A new DC-DC power converter is superior to previous designs and paves the way for more efficient, reliable, and sustainable energy storage and conversion solutions. The Kobe University development can efficiently interface with a wide range of energy sources while enhancing system stability and simplicity at an unprecedented efficiency.
Globally, the battery recycling market is projected to grow from $12.8 billion in 2025 to $19.8 billion by the end of 2030 according to BCC Research LLC. The expanding electric vehicle market will contribute to this expansion as EVs are damaged or their batteries are degraded beyond their usefulness. This is in addition to the personal technology batteries that permeate almost every aspect of our lives.
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