Browse Topic: Energy storage systems

Items (5,996)
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
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
Verlingieri, RebeccaCalabrese, LuigiFreni, AngeloMarocco, LucaScudeler, GabrieleDe Antonellis, Stefano
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
Penagos Vásquez, Diego AlejandroMarco-Gimeno, JavierMonsalve-Serrano, JavierGarcia, AntonioPerez Balastegui, Jose
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
Burke, BradleyKateregga, SunnySodre, Jose Ricardo
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
Yadav, Neeraj KumarAmbalakatte, AjithGeng, SikaiGopakumar Suja, GaganBirch, AlexanderCairns, AlasdairHarrington, AnthonyHall, Jonathan
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
Tramacere, EugenioFavelli, StefanoGalluzzi, RenatoTonoli, Andrea
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
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
Katta, LakshmiSeth, SaritaSingh, SandeepBhardwaj, AnilArora, Ajay Kumar
Solar seasonal thermal energy storage technology is an important means to solve the problem of seasonal uneven distribution of solar resources, and as the core component, the thermal storage capacity of the water pit directly affects the performance of the whole system. Accurately mastering the water pit temperature is essential for scientifically evaluating its thermal storage capacity. Based on the thermal storage water pit simulation software developed in the laboratory, this study focuses on determining the optimal number of temperature measurement points required for seasonal thermal energy storage water pits under an accuracy requirement of ±0.1°C, and establishes the mathematical relationship between the number of measurement points and the height-diameter ratio (H/D) as well as the inlet position. The proposed method can cover the temperature measurement point design for cylindrical and frustum-shaped water pits, and can also be referenced for prism-shaped configurations
Niu, PengbinMa, JianfuWang, FangxingQi, Shiyu
With the introduction of China’s dual-carbon goals (carbon peak and carbon neutrality), renewable energy has experienced rapid development in the country, particularly wind energy, which has established a pivotal role within the new energy sector. However, the inherent fluctuations in wind power generation pose significant challenges to maintaining grid stability and operational reliability. In power systems where the proportion of installed wind power capacity has significantly increased, the allocation of flexible resources becomes crucial. These resources help the system adapt to fluctuations in wind power generation and load demand, avoid wind power curtailment, and reduce costs. In addition, energy storage enhances grid flexibility and stabilizes renewable energy, but is constrained by high costs. Therefore, optimizing energy storage allocation and improving its economic efficiency have become urgent issues. This study focuses on flexibility adequacy assessment and resource
Peng, JianWei, JinpengZhu, ZhengyinHu, JianminLi, YuxiangMiao, GangZhang, Huaide
Bird accidental collision with overhead transmission lines poses a threat to the ecology of rare bird populations. This article analyzes the warning measures to prevent birds from accidental collisions at home and abroad. In response to the low efficiency of manual installation and the poor static warning effect in preventing birds from accidental collisions with overhead transmission lines, the visual characteristics of birds are analyzed. A drone-based automatic installation flash-type bird accidental collision warning device is proposed, which includes a fixture, a disc, and a luminous circuit. The fixture can be carried and installed on the overhead line by a drone and can be easily disassembled. The disc adopts eye-catching colors and has a hollow structure to reduce wind resistance load. The luminous circuit includes solar panels, charge and discharge control circuits, flicker control circuits, batteries, and luminous components. The drone suspension warning device test was
Wang, JianWang, XiulongLiu, BinLi, DanyuXu, Xunjian
This paper presents an intelligent continuous active Battery Management System (BMS) implementation in sodium-ion battery (SIB) energy storage systems (ESS). The 50kWh/100kWh SIB-ESS demonstration project by HiNa Battery Technology Co., Ltd. (HiNa), demonstrates better discharge voltage differential consistency 102mV (vs. 240mV without continuous active BMS) and achieving 97.6% capacity retention after 1,500 cycles. The average round-trip efficiency of the 50 kW/100 kWh energy storage station is 93.9%. The demonstration application of full-time active balancing in sodium-ion battery energy storage power stations provides valuable support for the further promotion of large-scale energy storage.
Zhou, YuanchaoMao, XuefeiChen, KaiLiu, GuangyuKang, LibinShi, DongliangFang, DonglinZhu, HuayangXu, FeiWang, Yinglai
With new energy vehicles developing rapidly, battery safety, as an important part of the impact on the range of new energy vehicles and vehicle safety, has become the focus of attention. The battery pack protection plate is a core component to protect the battery, its performance needs not only impact resistance, but also lightweight, honeycomb sandwich structure with its excellent energy absorption characteristics and weight reduction performance by the battery pack protection plate performance research. At present, the core-to-face sheet interaction in conventional sandwich structures subjected to impact loads has not been fully elucidated, and the quantitative characterization of damage is insufficient, so this paper aims to optimize the lightweight impact-resistant structure by exploring the synergistic energy dissipation mechanism between the high-strength core material and the steel plate. The study combines theory and simulation, adopting ideal rigid-plastic film theory to
Zhang, GuanghaoZhang, MingmingLuo, ChangjieZhou, JunZhang, FengqiangYu, WenzeLi, JiongfengGuo, Qingrong
This paper presents a multi-physics modeling approach for a hybrid propulsion system designed for High-Altitude Long-Endurance Unmanned Aerial Vehicles (HALE UAVs), integrating solid oxide fuel cells (SOFCs), lithium-ion batteries, and a jet engine. A dynamic model was developed to analyze the coupled characteristics of pressure, temperature, and power under steady-state conditions. Simulation results demonstrate that the internally integrated system achieves efficient fuel and waste heat recovery, delivering a net power output of 300–700 kW, sufficient to meet the operational demands of HALE UAVs. Key innovations include a heat exchanger maintaining SOFC stack inlet temperatures above 850 K for optimal performance and a compressor-fan subsystem enhancing gas compression efficiency. Experimental validation confirmed the accuracy of the SOFC model, with simulated electrical characteristics aligning closely with empirical data. The proposed hybrid system addresses limitations in specific
Zhang, LinZhang, DiZhao, LuluLi, Xi
In China, the installed capacity of renewable energy sources such as wind and photovoltaic power has ranked first in the world for consecutive years, and new energy has become a core driver of energy structure transition. However, the strong volatility and intermittency of new energy output seriously affect the safe and stable operation of the power system, and high-efficiency energy storage technology is the key to solving this problem. Focusing on the short-term high-power charging and discharging characteristics of high-temperature superconducting magnets (SMES), this study proposes a Hybrid Energy Storage System (HESS) that combines SMES with Battery Energy Storage Systems (BESS) to enhance the short-term power support capability of electrochemical energy storage. Variational Mode Decomposition (VMD) is introduced to establish a multi-level power allocation method, which addressing issues such as mode mixing, end effects, and low decomposition efficiency that are prone to occur in
Liu, HaiyangWang, PengfeiZhou, WenLu, JingWu, YananYin, YunkuoJiang, Liping
The global automotive industry is accelerating its transition toward low-carbon solutions, with hydrogen fuel cell vehicles offering core advantages of zero emissions and extended range. Their critical component is the Type III fiber-wound hydrogen storage tank, whose performance directly impacts vehicle operational safety and driving range. This technology has now achieved widespread adoption. However, two significant challenges persist in the dome region of these tanks: first, modeling accuracy is difficult to control due to dynamic variations in thickness and winding angles; second, fiber thickness buildup frequently occurs near the pole holes. These issues compromise both the design reliability and manufacturing quality of hydrogen storage tanks. Therefore, this study adopted a combined approach of theoretical analysis and numerical simulation. First, based on composite mechanics theory and calibrated with experimental data (Tensile, Compression, and Shear Tests on NOL and
Wang, JianguoZhang, QianCao, XuewenZheng, XuanxuanLi, Jiajie
In this paper, the design and process research of uniform filling linear trajectory for filament wound hydrogen storage tank with unequal polar holes are carried out. Firstly, by optimizing the slip coefficient, the winding angles of the left and right heads are smoothly and continuously transitioned to the cylindrical section. We study the necessary conditions for achieving the central angle of uniform filling, and calculate the tangent points of the trajectory line based on the continuous fraction principle. Meanwhile, the slip coefficients at the left and right ends that satisfy stable winding and uniform covering are determined. Based on the equal contour constraint conditions, we analyze the motion trajectory equation of the four-axis winding machine and convert it into the corresponding machine code for actual winding operations. Experimental results show that stable winding of fibers on the surface of the unequal-polar-hole mandrel is achieved, and uniform filling and winding
Chen, BaosenFu, JianhuiCao, XuewenYu, Libin
Although carbon fiber-reinforced aluminum-lined hydrogen storage vessels (Type III) exhibit outstanding specific strength and specific stiffness, the constraints imposed by their design parameters on fatigue performance and ultimate load-bearing capacity remain incompletely elucidated. We propose a fatigue life prediction method for high-pressure vessels that couples progressive damage in the fiber composite with cumulative damage in the metallic liner, aimed at forecasting the fatigue performance of Type III pressure vessels under cyclic loading. Furthermore, a finite element analysis systematically investigates the influence of key design parameters, for nominal pressure, liner diameter and liner thickness, on fatigue performance and ultimate load-bearing capacity. Results indicate that fatigue life significantly decreases with increasing nominal pressure and liner diameter, with nominal pressure exerting a more pronounced effect. Notably, altering the autoclave pressure alone cannot
Bi, ZhihaiZhang, Qian
To enhance the safety and efficiency of power batteries for new energy vehicles, a high-fidelity thermal management simulation model for lithium-ion batteries was established using a multi-scale coupled approach encompassing "cell-module-pack" levels. Charge/discharge experiments within the 15–45°C temperature range and under various State of Charge (SOC) conditions were conducted to obtain cell characteristic parameters. A second-order RC equivalent circuit model was constructed and validated. A three-dimensional thermal model of the battery pack was developed using the NX and STAR-CCM+software platforms and validated through high/low-temperature humidity tests. Results indicate that simulation errors for battery pack temperature and cooling line pressure were both below 3%. The model accurately simulates thermal behavior from microscopic cell characteristics to macroscopic battery pack dynamics.
Luo, ZhaoyangSong, Lan
With the rapid growth of renewable energy sources such as photovoltaics, energy storage systems, and wind power, hybrid AC/DC microgrids (H-MGs) are gradually emerging as a key technology for achieving efficient interconnection between generation units and load demands. However, issues such as communication delays, unequal power sharing, and the restoration of voltage and frequency in hybrid microgrids have posed serious threats to the stable operation of microgrids. We also need to appropriately adjust the simulation parameters to ensure that the proposed control framework maintains sufficient flexibility under different load conditions and achieves high operating efficiency in simulation. To tackle these challenges, this paper proposes a distributed secondary control strategy grounded in coordinated consensus and combined with droop-based interlinking converters (ICs) to realize power coupling between the AC and DC subgrids. The proposed method enables precise active-power sharing
Yu, PeijieZhang, FanghaiSun, WeiYuan, WeiboPeng, Bo
To address the issues of battery overcharge damage caused by voltage imbalance and excessive grid-connected inrush current when high-rate charge-discharge energy storage batteries are connected to the DC side of cascaded energy storage converters, this paper proposes a three-stage pre-charging control strategy considering battery characteristics. This strategy achieves rapid charging and voltage balancing control of energy storage modules through the orderly connection of three stages: “uncontrolled rectification - sorting and voltage balancing - balancing maintenance”. In the first stage, an uncontrolled rectification method with series soft-start resistors is adopted to reduce the inrush current at power-on. In the second stage, based on the FPGA parallel full-comparison sorting algorithm, the DC-side voltage of each sub-module is quickly balanced by switching sub-modules. In the third stage, the number of fixed sub-modules to be cut off is maintained to continuously optimize the
Gu, CongWu, RuiZhou, WenCai, WenjieTian, YunxiangYang, Zhiqing
Aimed at the high energy consumption for battery heating of a light hybrid truck in low-temperature winter, this paper proposes an optimized battery thermal management scheme based on motor waste heat and PTC cooperation. Then it verifies its energy-saving performance based on multi-condition simulation and testing. Taking the constant-speed condition at -5°C as an example, firstly, the accuracy of the battery thermal management model is verified by comparative simulation and test. Then, based on the verified model, the battery thermal management model is simulated under typical winter conditions at 0°C and 5°C. The analysis results show that, when the battery temperature is raised from the initial state to a certain target, the energy consumption of the motor waste heat-assisted PTC heating scheme is obviously less than that of PTC heating. The energy saving rates are 33.137% at -5°C, 32.45% at 0°C, and 32.56% at 5°C, respectively. The research results have proved that the effective
Meng, ShunZhang, DongZhang, YuZhang, ChunyuYao, MingyaoQiu, LiangQian, Yejian
A full lithium-ion battery (LIB) pack has hundreds to thousands of cells, coolant flow lines and channels, and channel bends to control cell temperature within its operating window and minimize cell internal resistance, aging, and fire risk. A 75 kWh LIB pack has four modules, and each has 23–25 bricks. Two challenges in battery state predictions for hot and subzero temperatures are battery temperature (Tbatt ) and coolant flow within the whole pack. In this work, a 1D 75 kWh full-pack model with its thermal management system is developed using a holistic reverse-engineering method, which can predict Tbatt at any bricks/modules and inlet/outlet coolant flow characteristics. A Tesla Model Y equipped with dual e-motors is tested on an in-house state-of-the-art chassis dynamometer. The test data at V = 60–80 km/h, 100–150 A constant discharge, and Tbatt = −10°C to 40°C are used to develop the model. The 75 kWh pack model features 4000+ cylindrical cells (96S46P, Panasonic 21700-format
Sok, RatnakKusaka, Jin
The organizers of the most prominent Formula Student competitions have recently initiated a preliminary feasibility study on the application of hydrogen-based propulsion technologies in future single-seater race vehicles. These include electric powertrains with electrochemically converted hydrogen in fuel cell–powered vehicles, competing within the electric championship league. Based on the initial set of regulations, this study presents a model-based comparison between battery-powered (BEVs) and fuel cell–powered electric vehicles (FCVs) for Formula Student. The analysis is conducted using energy, power, and efficiency metrics from four candidate models of propulsion systems, implemented in an open and publicly available MATLAB script: two BEVs with varying battery capacities, and two FCVs employing different hybridization strategies. The aim of this study is to pinpoint and quantify the advantages and disadvantages of each technology for the Formula Student use case, and to identify
Martoccia, LorenzoBreda, SebastianoFontanesi, Stefanod’Adamo, Alessandro
As global demand for sustainable energy solutions increases, there is a push to develop alternatives to lithium-ion batteries, which face limitations in cost, resource availability, and safety. In particular, multivalent-ion batteries based on magnesium, calcium, zinc, and aluminum have emerged as promising candidates due to their ability to transfer multiple electrons per ion, offering higher volumetric energy density and greater material abundance. This review examines recent advances in electrode and electrolyte development for these systems, highlighting cathode innovations such as cobalt sulfides for magnesium, NASICON-type and redox-coupled materials for calcium, molybdenum trioxide frameworks for zinc, and organic and composite electrodes for aluminum. Electrolyte research has produced improved ionic transport and stability through solvation tuning, hybrid and polymer systems, and deep eutectic solvents. Interfacial engineering is identified as a key enabler for enhancing
Mittal, VikramShah, RajeshLi, Ivy
This article surveys the most recent data-driven methods of lithium-ion (Li-ion) battery state of health (SOH) estimation methods and dataset resources utilized in electrified vehicles (EV) and their potential adoption for automotive battery management systems. These include regression-based models, ensemble learners, deep neural networks, and physics-informed hybrid methods. The review describes estimation methods found in articles published between 2023 and 2025, and investigates their differences in terms of estimation accuracy, data requirement, interpretability, and real-time deployment ability. The article traverses the dataset space, focusing on laboratory aging datasets, vehicle field–based datasets, telematics-derived records, and synthetic or augmented datasets, to underline that model performance in the estimation of SOH cannot be disentangled from the quality of the data, the operating coverage, and the transfer conditions. Apart from the model design, this work reviews the
Nyachionjeka, KumbirayiBayoumi, Ehab H.E.
In a traditional electric vehicle, managing its battery thermal performance is of prime importance. A well-designed battery thermal management system helps in extending its life and avoids safety-related issues like thermal runaways. A critical part of this thermal management is the battery cooling system (BCS), which can be air- or liquid-cooled. Based on the vehicle battery pack size, location, and its design complexity, the original equipment manufacturer can opt for either of the previous two methods. An air-cooled type of BCS system usually involves an active ventilation fan to dissipate the battery heat in the surroundings, which brings symbiotic noise into the picture. In an air-cooled BCS system, the primary source of noise is the cooling airflow over the heat exchanger caused by the fan. The airflow and noise performance characteristics of this fan are typically measured by the supplier in a standalone condition. These performance parameters deviate greatly when the fan is
Nomani, MustafaDupatti, DarshanNikam, KrishnaSasikumar, R.Kajagar, SureshPanchare, DattajiAgalawe, Kiran
Accurate modeling of battery temperature rise during fast charging is challenging due to uncertainty around cell heat generation and the thermal characteristics of the materials and interfaces which make up the battery pack. High fidelity thermal models are critical to attaining the best battery pack design, since they enable a multitude of cooling and packaging approaches to be considered prior to building a prototype. In this study, a 3D finite element analysis (FEA) thermal model of a production fast charging battery module is created. A loss model is parameterized as input for the FEA model. A key part of the loss model is the entropic heating coefficient (EHC), which is the change of open circuit voltage with respect to temperature. The EHC is measured by waiting for the cell voltage to reach steady state at various temperatures in 5% and 10% state of charge intervals over its capacity. This is then corrected numerically by accounting for unwanted discharge or rebounds. The EHC is
Thornton, JackKollmeyer, PhillipPanchal, SatyamGross, Oliver
State-of-charge (SOC) operating windows strongly affect lithium-ion battery degradation, while conventional aging tests require long durations to establish trends. Coulombic efficiency (CE), defined as the discharge-to-charge capacity ratio, provides an early-life diagnostic for parasitic reactions and long-term performance prediction. Eight 21700 NMC cells were cycled at 25 °C across four SOC windows (0–100%, 20–80%, 40–60%, and 80–100%) using conventional and ultra-high precision cyclers. Capacity retention, resistance growth, and CE were evaluated to quantify depth-of-discharge (DOD) effects. A non-linear aging behavior was observed, with accelerated initial capacity loss followed by stabilization. The 0–100% SOC window exhibited the highest degradation, with ~9% capacity loss per 100 EFC initially, stabilizing to ~3.3% per 100 EFC, corresponding to a projected 80% SOH life of ~440 cycles. In contrast, the 40–60% window showed stabilized fade of only 2.0% per 100 EFC, yielding a
Hussein, HudaArora, DipanPanchal, SatyamGross, OliverEmadi, AliKollmeyer, Phillip
Ambient and initial temperatures significantly impact the energy consumption rate (ECR) of battery electric vehicles (BEVs) due to auxiliary loads and the temperature dependence of battery efficiency. This study introduces a streamlined, physics-based thermal modeling approach within the FASTSim tool that bridges the gap between oversimplified constant-load models and computationally expensive high-fidelity simulations. By employing a lumped thermal mass framework, the model captures fundamental energy balances and critical non-linear energy penalties while maintaining the computational efficiency required for expansive sensitivity studies. The simulations evaluated a compact BEV hatchback with a resistive heater over city (UDDS) and highway (HWFET) test cycles. Compared to a 22°C initial and ambient temperature baseline, a -7°C initial/ambient temperature resulted in a 221% increase in the ECR for the city cycle and a 100% increase for the highway cycle. Conversely, a 45°C initial
Baker, ChadSteuteville, RobinHolden, JakeGonder, JeffreyCarow, Kyle
Towing imposes substantial efficiency penalties on both battery-electric vehicles (BEVs) and internal combustion engine (ICE) vehicles, reducing range by 30-50%. This paper presents a proof-of-concept embedded control architecture for distributed trailer propulsion that actively regulates drawbar force to reduce towing loads. Unlike proprietary e-trailer systems requiring specialized hardware, the proposed implementation demonstrates feasibility using commercial off-the-shelf (COTS) components and open-source software. The distributed architecture employs dual Raspberry Pi 4B single-board computers communicating via ROS 2 at 20 Hz. The trailer-mounted controller executes a Simulink-generated control node coordinating load cell acquisition (HX711 ADC), motor CAN bus telemetry, and throttle commands to a 5 kW BLDC traction motor powered by a 5 kWh LiFePO4 battery pack. A vehicle-mounted controller logs OBD-II/CAN validation data. The control pipeline implements cascaded EWMA/Hampel
Joshi, GauravAdelman, IanLiu, JunDonnaway, Ruthie
Modern battery management systems have a critical need for highly accurate battery terminal voltage models, which are a key component of algorithms that estimate or predict power capability, range, temperature, and other factors. While electro-chemical and equivalent circuit models are widely used for this purpose, they typically struggle to model efficiently the complex, non-linear dynamics inherent in real-world battery operation. This study proposes a robust, data-driven approach for terminal voltage estimation using a feed-forward neural network (FNN) machine learning model. Characterization and drive cycle tests were performed on a 60 Ah prismatic cell from a Fiat 500e at temperatures ranging from -20 °C to 40 °C. The collected data was used to train and test the models, with model error reported for HWFET, UDDS, US06, and LA92 cycles. Model size was swept between around 100 and 35,000 trainable parameters for an FNN with three inputs – unfiltered power, state of charge, and
Dehury, BiswanathNahidmobarakeh, LucasMohammed, Kamran AhmedPanchal, SatyamGross, OliverKollmeyer, Phillip
Predicting battery self-discharge across wide temperature ranges and extended durations remains a significant challenge due to the scarcity of physical test data, which is typically limited to a few temperature points and short observation windows. This limitation complicates generalization and increases the risk of inaccurate extrapolation. To address this, the paper introduces a machine learning–based framework designed to predict self-discharge behavior under diverse thermal conditions and longtime horizons. Multiple modeling strategies are examined, including feedforward neural networks, long short-term memory (LSTM) architectures, synthetic data generation, and physics-informed integration of governing equations. Particular emphasis is placed on hybrid and physics-regularized models that embed first-principles relationships to guide extrapolation beyond the observed data domain. This approach mitigates the inherent instability and potential errors associated with purely data
Chavare, SudeepZeng, YangbingMuppana, Sai SiddharthaMiao, YongXu, Simon
As the automotive industry increasingly adopts high-energy-density batteries, ensuring vehicle safety against catastrophic thermal runaway (TR) has become paramount. Predicting the complex failure sequence of prismatic cells, requires high-fidelity simulation tools that can capture tightly coupled physical phenomena. This paper presents a comprehensive, three-dimensional multi-physics Computational Fluid Dynamics (CFD) framework designed to simulate the entire TR event. The simulation originates with a multi-step Arrhenius chemical kinetics model to calculate the heat and gas generated by the primary exothermic reactions. This process drives a rapid increase in internal temperature and pressure, which is resolved by the model’s fluid dynamics solver. The initial vent opening is triggered when this internal pressure exceeds a predefined mechanical burst threshold, simulating a realistic seal rupture. Concurrently, a Conjugate Heat Transfer (CHT) analysis calculates the temperature
Mukherjee, SwarnavaSchlautman, JeffSrinivasan, Chiranth
Parasitic inductance and capacitance of the battery pack can affect the performance of the electric powertrains. Characterizing these parasitic phenomena in an automotive battery pack is therefore crucial to ensuring performance and reliability. In this work, geometric models of a production automotive battery pack are developed to simulate the parasitic inductance of the busbar system, the parasitic inductance of individual modules, and other critical components. For these simulations, several assumptions and simplifications are introduced to reduce model complexity, while preserving the main electromagnetic behavior of the system. The impact of the different components on the battery pack impedance is investigated to evaluate parasitic capacitances, thereby simulating the worst-case scenario. Laboratory procedures are developed to accurately measure parasitic impedance, providing a reliable comparison between experimental data and analytical models and supporting the overall validity
Misley, MarcoD'Arpino, MatildeZhu, DiZhang, Liwen
In the design of Rechargeable Energy Storage System (RESS) structures, including battery trays, module side plates, and end plates, there are multiple conflating factors, including: Mechanical requirements necessitating the use of electrically conductive materials (steel and aluminum); proximity between battery module structure and battery cells, necessitating the use of electrical isolation coatings; and, module and pack designs that retain cells via the use of Structural Adhesive Material (SAM). Inherently, with this design approach, organic coatings are placed in a new and perilous position. In a sense, the coating becomes a supplement to an adhesive. As Computer-Aided Engineering (CAE) virtual analysis tools become more sophisticated, there is increasing reliance on these tools to predict the occurrence of structural failures in various load cases. Factors in test method, paint pretreatment, and topcoat affecting adhesion of organic coatings in structural adhesive joints are
Moceri, CharlesHarper, Jared
Linear time-invariant (LTI) reduced-order models (ROMs) have been widely used in battery thermal management simulations due to their low hardware requirements, high computational efficiency, and good accuracy. However, the inherent assumption of LTI behavior limits their applicability in scenarios with varying coolant flow rates, where this assumption is no longer valid. To address this limitation, a novel ROM is developed by decomposing the entire battery thermal system into two subsystems. All solid components are modeled as a traditional LTI ROM, while the coolant channel is represented using Newton’s cooling law. The two subsystems are then coupled through the exchange of heat transfer rate and temperature at the fluid–solid interface between the coolant and the cold plate. Model fidelity is further enhanced by introducing a spatially distributed heat flux during the generation of the LTI ROM for solid components. Validation is performed against CFD simulations at both module and
Guo, JiaChen, GuijieMa, ShihuHu, XiaoLi, JingSong, ShujunHuang, Long
Achieving the stringent EPA CAFE 2032 standards for light-duty full-size trucks and sport-utility vehicles (SUVs) in North American poses significant challenges. While Battery Electric Vehicles (BEVs) offer a clear path to zero tailpipe emissions, their widespread adoption in this segment faces hurdles including range anxiety, payload/towing capabilities, and traditional truck/SUV use cases. This paper investigates a balanced approach, focusing on optimizing propulsion system design with appropriate hardware content, can effectively meet future fuel economy and emissions standards. This investigation examines advanced BEVs and hybrid electric vehicle architectures, including full hybrids (HEVs), and plug-in hybrids (PHEVs) tailored for full-size trucks and SUVs. Considerations include the optimal sizing of internal combustion engines, electric motors, and battery packs to deliver robust performance while maximizing energy efficiency. This paper analyzes the integration of technologies
Babcock, DillonRobinette, Darrell
Battery swapping technology has emerged as a promising alternative to conventional charging for electric bus fleets, offering rapid turnaround times and improved vehicle availability. This paper utilizes existing bus routing information to perform an initial site evaluation for battery swapping stations. A Seattle-based public transit agency—King County Metro, a partner on this project—is used as a case study. Using General Transit Feed Specification (GTFS) data from King County Metro, a MATLAB model was built to reconstruct blocks and layovers, extracts dwell-time opportunities, and performs block-distance and block-time analyses to understand operational rhythms. based bus model was developed that maps route mileage, efficiency, and layover availability for battery swap decisions, using a look-ahead rule that defers battery exchanges whenever the next feasible layover can still be reached while respecting a minimum state-of-charge. The workflow estimates how many swaps each block
Vadlapatla, Taraka RishiJankord, GregoryD'Arpino, Matilde
General Motors (GM) continues to advance its electrification strategy through the development of scalable Battery Electric Vehicle (BEV) and Battery Electric Truck (BET) platforms. This paper highlights GM’s latest BEV and BET products that leverage shared Drive Unit (DU), Rechargeable Energy Storage System (RESS), and integrated power electronic (IPE) components across multiple vehicle programs. By adopting a modular and commonized propulsion architecture, GM achieves significant benefits in manufacturing efficiency, cost optimization, speed to market, and product flexibility. The shared DU, RESS, and IPE components are engineered to meet diverse performance requirements while maintaining high standards of energy efficiency, thermal management, and durability. This approach enables rapid deployment of electrified solutions across various segments, from passenger vehicles to full-size trucks, without compromising on capability or customer experience. The paper outlines the technical
Liu, JinmingSevel, KrisAnwar, MohammadOury, AndrewWelchko, BrianGagas, Brent
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