Browse Topic: Thermal runaway

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Integrating for Safety – A Proposed Approach to the Integration of Propulsion Battery Systems in Hybrid Electric Aviation2025-01-0148To be published on 04/25/2025
In the last year we have witnessed a notable surge in the designs and in the guidance material for electric and hybrid aircraft. FAA and EASA have continued to evaluate the safety of Propulsion Battery Systems (PBS), with a focus on thermal runaway containment testing. As a result, a harmonization white paper was issued to provide a certification path for Thermal Runaway (TR) Hazards, followed by an EASA certification memorandum on the acceptable approaches for the certification of Electric/Hybrid Propulsion Systems (EHPS). And just recently, an FAA Advisory Circular (draft) was issued for the “powered-lift” aircraft that feature these propulsion battery systems. In spite of the advances made by electric/hybrid aircraft manufacturers and the aviation authorities, there is still a missing piece of the puzzle. Mainly, we are still not confident in our ability to properly integrate the PBS into the EHPS architecture, in such a way where safety is never compromised, no matter the hazard
Hanna, Michael, Walker, Cherizar
Technical Paper
A framework for modeling mechanically induced thermal runaway in lithium-ion batteries2025-01-8134To be published on 04/01/2025
Battery safety is a paramount concern in the development of electric vehicles (EVs), as failures can lead to catastrophic consequences, including fires and explosions. With the rapid global adoption of EVs, understanding how battery cells perform under extreme conditions such as mechanical or thermal abuse is crucial for ensuring vehicle safety. This study investigates the abuse response of lithium-ion batteries under high-speed mechanical loading. Our research systematically examines the response of these cells at different states of charge (SOC) through controlled dynamic tests. These tests offer insights into the failure response of the cells. By analyzing the data, we gain a deeper understanding of the conditions that could trigger thermal runaway under mechanical abuse loadings, representative of EV crashes, a critical safety concern in EV battery systems. The experimental setup and methodologies are presented in this paper, alongside key findings that highlight the importance of
Patanwala, Huzefa, Kong, Kevin, Challa, Vidyu, Darvish, Kurosh, Sahraei, Elham
Technical Paper
Experimental Analysis of Battery Thermal Management Techniques for Electric Vehicle Lithium-Ion Batteries Using MATLAB Simulink, Simscape, and Stateflow Simulations2025-01-8165To be published on 04/01/2025
The integration of lithium-ion batteries into electric vehicles represents a significant advancement in the automotive industry. These batteries are widely utilized in energy storage systems. The extended life cycle, low self-discharge rates, high energy density, and eco-friendliness of lithium-ion batteries are well-known. However, Lithium-ion batteries are highly sensitive to temperature, adversely affecting their performance, lifespan, and safety. Therefore, effective thermal management is critical to ensuring optimal operating conditions and mitigating the risk of thermal runaway. To address this, experimental study was conducted on various battery thermal management techniques, including active, passive, and hybrid approaches. These techniques were investigated for their cooling efficiencies under different operating conditions. The study utilized MATLAB Simulink, Simscape, and Stateflow to simulate the electro-thermal behavior of cylindrical lithium-ion battery cells, battery
Thangaraju, Shanmuganathan, N, Meenakshi, Ganesan, Maragatham
Technical Paper
Effectiveness of Nail Penetration for Thermal Propagation Test in Battery Packs and Vehicles2025-01-8128To be published on 04/01/2025
The number of electric vehicles (EVs) has increased significantly in recent years. Consequently, incidents of EV fires have been reported. To protect passengers and evaluate battery robustness, thermal propagation tests are conducted. Typically, these tests initiate a cell in a battery pack using either a heater or a nail. While the heater method is commonly used, the nail method faces restrictions when selecting an initiation cell, especially for battery pack and vehicle testing. For battery pack testing, vertical penetration against the vehicle's travel direction does not have cell selection restrictions. However, for horizontal penetration, the initiation cells are limited to the outermost cells in the battery pack. In vehicle testing, horizontal penetration is unfeasible, whereas vertical penetration from bottom to top is possible. To demonstrate the feasibility of the nail method for battery pack and vehicle testing, especially in vehicles, nail tests were conducted on an electric
Maeda, Kiyotaka, Takahashi, Masashi
Technical Paper
Investigation of Impedance Evolution for Lithium Plating Detection during Multi-Stage Constant Current Fast Charging of Lithium-Ion Batteries2025-01-8124To be published on 04/01/2025
The lengthy charging time of lithium-ion batteries for electric vehicles (EVs) significantly affect their acceptance. Reducing charging time requires high-power fast charging. However, such fast charging can trigger various side reactions, leading to safety and durability issues. Among these, lithium plating is a major concern as it can reduce battery capacity and potentially cause internal short circuits or even thermal runaway. Currently, multi-stage constant current charging (MCCC) protocols are widely adopted. However, the difficulty in effectively detecting lithium plating during the MCCC process significantly limits the charging power. Therefore, it is urgent to explore a method to detect lithium plating during the MCCC process. In this study, the impedance evolution during the MCCC procedure was first investigated. Then a method based on the impedance variation patterns was proposed to detect lithium plating. Besides, the reason for the behavior of impedance changes was further
Shen, Yudong, Wang, Xueyuan, Wu, Hang, Wei, Xuezhe, Dai, Haifeng
Technical Paper
Research on heat dissipation of cabinet of electrochemical energy storage system2025-01-8193To be published on 04/01/2025
When lithium batteries are charged and discharged in electrochemical energy storage systems, significant internal electrochemical reactions occur, generating substantial heat and causing a rise in battery temperature. This can adversely affect battery performance and lifespan, and in severe cases, lead to thermal runaway, threatening the safety of the entire system. Research on the thermal modeling of lithium-ion batteries, accurate description and prediction of temperature rise, and the design of thermal management systems based on numerical heat flow simulations are crucial for ensuring safe and reliable battery operations. These efforts are vital for advancing new energy technologies. However, most existing research on heat dissipation in energy storage systems focuses solely on single air-cooled or liquid-cooled systems, which often have simple structures and poor heat dissipation effects. Based on the actual size of an energy storage products, this thesis establishes a
Chen, Jianxiang, Li, Liping, Zhou, Fupeng, Li, Chuncheng, Shangguan, Wen-Bin
Technical Paper
Experimental and Simulation-Based Characterization of Thermal Runaway in Lithium-Ion Batteries Using Altair SimLab2025-01-8146To be published on 04/01/2025
Thermal runaway is a critical phenomenon in lithium batteries, characterized by a self-sustaining process due to internal chemical reactions, that is triggered once a certain temperature is reached within the cell. This event is often caused by overheating due to charge and discharge cycles and can lead to fires or explosions, posing a significant safety threat. The aim of this study is to induce thermal runaway on single cells in different ways to characterize the phenomenon and validate the simulation models present in Altair SimLab. The work was conducted in several key phases. Initially, an experimental test was performed in a calorimeter (EV ARC HWS test) to collect temperature data of the Molicel 21700 P45B cell during thermal runaway under adiabatic conditions. These data were used for a simulation on a single cell, allowing a detailed comparison with the experimental results. Subsequently, a test was conducted on a single cell under operational conditions, overheated using a
Giuliano, Luca, Scrimieri, Luigi, Reitano, Simone, Berti Polato, Davide, Ferraris, Alessandro, Comerford, Andrew, Bhatnagar, Saakaar
Technical Paper
Numerical Model of the Heat-Wait and Seek and Heating Ramp Protocol for the Prediction of Thermal Runaway in Lithium-Ion Batteries2025-01-8127To be published on 04/01/2025
Interest in Battery-Driven Electric Vehicles (EVs) has significantly grown in recent years due to the decline of traditional Internal Combustion Engines (ICEs). However, malfunctions in Lithium-Ion Batteries (LIBs) can lead to catastrophic results such as Thermal Runaway (TR), posing serious safety concerns due to their high energy release and the emission of flammable gases. A better understanding of this phenomenon is essential for reducing risks and mitigating its effects. In this study, a digital twin of an Accelerated Rate Calorimeter (ARC) under a Heat-Wait-and-Seek (HWS) procedure is developed using a Computational Fluid Dynamics (CFD) framework. The CFD model simulates the heating of the cell during the HWS procedure, pressure build-up within the LIB, gas venting phenomena, and the exothermic processes within the LIB due to the degradation of internal components. The model is validated against experimental results for an NCA 18650 LIB under similar conditions, focusing on LIB
Gil, Antonio, Monsalve-Serrano, Javier, Marco-Gimeno, Javier, Guaraco-Figueira, Carlos
Technical Paper
Multiphysics-Multiscale Reduced Order Model Based Design Optimization of an Immersion Cooled Battery System2025-01-8185To be published on 04/01/2025
A vital aspect of Ultra-Fast Charging (UFC) Li-Ion battery packs is their thermal management system, which directly influences safety, performance, and cell longevity. Immersion cooling technology offers superior effectiveness compared to indirect cold plate cooling, as it allows for faster heat dissipation and has the potential to significantly mitigate thermal runaway propagation, enhance overall pack performance, and extend cell life. To achieve faster design optimization and deeper insights, high-fidelity Multiphysics-Multiscale simulations are essential. In this study, Equivalent Circuit Model (ECM) based electro-thermally coupled CFD simulations are utilized to optimize an innovative busbar design that facilitates the removal of individual cells. Additionally, high-fidelity 3D transient flow-thermal simulations have been employed to optimize coolant flow direction, inlet positions, cell spacing, and separator design, ensuring efficient flow distribution within the module. While
Tyagi, Ramavtar, Negro, Sergio, Baranowski, Alex, Atluri, Prasad
Technical Paper
Impact of Thermal Gradients on Calorimetry Testing of Battery Cells2025-01-8175To be published on 04/01/2025
Detailed modeling of battery thermal runaway and propagation often requires a source term that represents the chemical heat release of the cell as a function of temperature. The shape of this heat release trend typically comes from cell testing data. Accelerating rate calorimetry (ARC) tests provide concise information on cell self-heating, since the cell is kept nearly isothermal and adiabatic. Also, compared to differential scanning calorimetry (DSC) tests of battery component materials, it contains all interactions between components. Converting the temperature rise rate data to heat release rate is theoretically very simple, only requiring the heat capacity of the cell. Practically, however, careful analysis is required to avoid artifacts arising from limitations of the test setup. This study uses a simple one-dimensional transient heat transfer model to illustrate the runaway process inside a cell and describe two error sources present in many ARC tests. As the cell temperature
Vanderwege, Brad, Petersen, Ben
Technical Paper
Extreme-Fast Charging Performance Optimization of Immersion-Cooled Battery Systems with Cylindrical Cells2025-01-8169To be published on 04/01/2025
Efficient and robust optimization frameworks are essential to develop and parametrize battery management system (BMS) controls algorithms. In such multi-physics application, the tradeoff between fast-charging performance and aging degradation needs to be solved while simultaneously preventing the onset of thermal runaway. To this end, a multi-objective optimization framework was developed for immersion-cooled battery systems that provides optimal charging rates and dielectric flowrates while minimizing aging and charging time objectives. The developed production-oriented framework consists of a fully coupled, lumped electro-thermal-aging model with core-to-surface and immersion-cooling heat transfer, the latter controlled by the dielectric fluid flowrate. The modeled core temperatures are inputs to a semi-empirical aging degradation model, in which a fast-aging solver computes the updated capacity and internal resistance over multiple timescales, and feedback into the electrical and
Suzuki, Jorge, Tran, Manh-Kien, Tyagi, Ramavtar, Meshginqalam, Ata, Zhou, Zijie, Nakhla, David, Atluri, Prasad
Technical Paper
Biobased Phase Change Material for Electric Vehicle Battery Thermal Management using Copper Fins: A numerical Investigation2025-01-8171To be published on 04/01/2025
Electric vehicles (EVs) are gaining popularity due to their zero tailpipe emissions, superior energy efficiency, and sustainable nature. EVs have various limitations, and crucial one is the occurrence of thermal runaway in the battery pack. During charging/discharging of EV battery pack which consists Li-ion cells generates significant amount of heat; thermal runaway in the battery pack happens due to excessive heat accumulation inside the cell because of ineffective cooling of the Li-ion cell/battery pack. It necessitates for the development of an effective EV battery thermal management system. In the present work thermal management of a 26650 Lithium iron phosphate (LFP) cell using natural air cooling, composite biobased phase change material (CBPCM) and its combination with copper fins is numerically investigated using multi-scale multi dimension - Newman, Tiedenann, Gu and Kim (MSMD-NTGK) battery model in Ansys Fluent at an ambient temperature of 306 K. Natural air cooling was
Srivastav, Durgesh, Patil, Nagesh Devidas, Shukla, Pravesh Chandra
Technical Paper
Multiscale Modeling and Validation of Thermal Runaway Propagation in Immersion-Cooled Battery Systems with Full-Scale Application2025-01-8166To be published on 04/01/2025
Thermal management is a critical challenge in the design and operation of lithium-ion batteries (LIBs), particularly under high-stress conditions that can lead to thermal runaway (TR). Immersion cooling technology offers a promising solution by providing uniform cooling across all battery cells, thereby reducing the risk of hotspots and thermal gradients that can trigger thermal runaway. However, accurately modeling the thermal behavior of such systems, especially under the complex conditions of immersion cooling, presents significant challenges. This study introduces a comprehensive multiscale and multiphysics modeling framework to analyze thermal runaway and its propagation (TRP) in battery systems cooled by immersion in dielectric fluids. The model integrates 1D and 3D simulations, with a focus on the detailed calibration of energy terms at the single-cell level using 3D Computational Fluid Dynamics (CFD). This calibration includes thorough analysis of cell chemistries, exothermic
Negro, Sergio, Tyagi, Ramavtar, Kolaei, Amir, Pugsley, Kyle, Atluri, Prasad
Technical Paper
Battery Thermal Runaway Propagation: A CFD Approach to Cell and Module Analysis2025-01-8164To be published on 04/01/2025
This Paper will focus on simulating thermal runaway propagation within a battery cell and module. The thermal runaway model parameters are derived from accelerating rate calorimeter (ARC). The simulation involves a thermal runaway propagation model that converts the stored energy of the battery materials into thermal energy, thereby simulating the propagation of thermal runaway. The initiation of thermal runaway is modelled through a nail penetration event, represented by a heat profile in the nail region. The resulting temperature rise in this area triggers the short propagation model, leading to the spread of thermal runaway. For the single-cell simulation, the 1-equation thermal runaway model is used, focusing on the direct energy conversion and propagation within the cell. In contrast, the module simulation involves a more complex scenario. Here, an initial temperature rise near the nail region activates a short propagation model, which subsequently triggers the 4-equation thermal
Wakale, Anil, Ma, Shihu, Hu, Xiao
Technical Paper
3D Modeling of Thermal Runaway in Pouch Cells: Effects of Surface Heating and Heating Rates2025-01-8559To be published on 04/01/2025
Thermal runaway in battery cells presents a critical safety concern, emphasizing the need for a thorough understanding of thermal behavior to enhance battery safety and performance. This study introduces a newly developed AutoLion 3D thermal runaway model, which builds on the earlier AutoLion 1D framework and offers significantly faster computational performance compared to traditional CFD models. The model is validated through simulations of the heat-wait-search mode of the Accelerating Rate Calorimeter (ARC), accurately predicting thermal runaway by matching experimental temperature profiles from peer-reviewed studies. Once validated, the model is employed to investigate the thermal behavior of 3D LFPO cells under controlled heating conditions, applying heat to one or more surfaces at a time while modeling heat transfer from non-heated surfaces. The primary objective is to understand how these localized heating patterns impact temperature profiles, including average core temperatures
Hariharan, Deivanayagam, Gundlapally, Santhosh
Technical Paper
Battery Pack VentingJ3325_202503 (Current)03/05/2025
The scope of this information report is battery packs containing lithium-ion battery cells with liquid electrolyte, focusing on automotive applications like passenger cars and trucks. Considering different operating conditions as well as durability and safety requirements, some of its contents might provide guidance for other applications. The same applies to battery cell chemistries not covered in this report (e.g., sodium-ion or solid-state battery cells).
Battery Pack Venting Committee
Information Report
Cooling Characteristics and Optimization of an Air-Cooled Battery Pack2025-01-701601/31/2025
Lithium-iron phosphate batteries are widely used in energy storage systems and electric vehicle for their favorable safety profiles and high reliability. The designing of an efficient cooling system is an effective means of ensuring normal battery operation, improving cycle life, and preventing thermal runaway. In this paper, we proposed a forced-convection air cooling structure aiming at uniform temperature distribution and reducing the maximum temperature. The initial step was constructing a heating model for a single LiFeO4 battery. A source function was derived from the experimental data, which described the variation in heating power with discharge depth. This function was then used to create a dynamic loading of the battery heating model. Subsequently, a three-dimensional model of a 7-series and 2-parallel battery pack was constructed. Seven schemes were designed on the basis of the traditional Z-shaped structure, with the position of the air inlet and outlet altered. The
Zhang, Junhong, Liu, Ting, Dai, Huwei, Lin, Jiewei
Technical Paper
Safety Analysis of Traction Batteries Based on Micro Internal Short Circuit Damage2025-01-701701/31/2025
The internal short circuit of a traction battery is one of the most typical failure mechanisms that can lead to thermal runaway, potentially triggering thermal propagation across the entire battery system. This phenomenon poses significant safety risks, especially in electric vehicles and large-scale energy storage systems. Therefore, it is essential to explore and understand the internal short circuit behavior to mitigate these risks. One of the most effective testing methods for reproducing an internal short circuit is the penetration test, where specific test conditions must be carefully designed based on the failure behavior. Among these conditions, the penetration step length plays a crucial role, as it directly influences the short circuit dynamics. Despite the importance of penetration step length, there is currently no standardized test procedure that dictates how to select the appropriate step size for different battery samples. This gap in standardization complicates the
Wang, Fang, Sun, Zhipeng, Ma, Tianyi, Dai, Xiaoqian, Dai, Ce, Yan, Pengfei, Ma, Xiaole, Chen, Liduo, Ma, Haishuo, Shen, Shaopeng
Technical Paper
Fusion Control Strategy Based on Rule and Dynamic Objective of Heat Pump Type Thermal Management System for Electric Vehicles2025-01-702301/31/2025
Thermal management system of electric vehicles (EVs) is critical for the vehicle's safety and stability. While maintaining the components within their optimal temperature ranges, it is also essential to reduce the energy consumption of thermal management system. Firstly, a kind of architecture for the integrated thermal management system (ITMS) is proposed, which can operate in multiple modes to meet various demands. Two typical operating modes for vehicle cooling in summer and heating in winter, which utilizes the residual heat from the electric drive system, are respectively introduced. The ITMS based on heat pump enables efficient heat transfer between different components. Subsequently, an ITMS model is developed, including subsystems such as the battery system, powertrain system, heat pump system and cabin system. The description of modeling process for each subsystem is provided in detail. The model is tested under world light vehicle test cycle (WLTC) condition of six different
Zhao, Luhao, Tan, Piqiang, Yang, Xiaomei, Yao, Chaojie, Liu, Xiang
Technical Paper
Prediction of Gear Defect Based on WPT & CEEMDAN & SVD2025-01-704801/31/2025
After the defected gears are determined, a novel method, combined with wavelet packet decomposition, complementary ensemble empirical mode decomposition with adaptive noise and singular value decomposition, is put forward. It is utilized to exclude disturbance of irrelevant signals that generated by the defect gears. Firstly, wavelet packet decomposition is used to extract the defect signals and retain original features. The processed signal is called S1 and the irrelevant frequency bands could be filtered out. Secondly, complementary ensemble empirical mode decomposition with adaptive noise decomposes S1 into a series of intrinsic modal functions. The correlations between S1 and intrinsic modal functions are analyzed. The intrinsic modal functions that are highly correlated with S1 are screened out and reconstructed into a new signal, called S2. The disturbance of irrelevant signals could be further filtered out, but some of them still disturb the judgement. Thirdly, singular value
Gu, Junqing, Zuo, Yueyun, Zhang, Ni, Deng, Feng, Wu, Xiaolong
Technical Paper
Multi-step Prediction of Battery Temperature and Thermal Fault Diagnosis Based on Informer2025-01-701901/31/2025
Lithium-ion batteries are prone to thermal failures under extreme conditions, leading to thermal runaway and safety risks such as fire or explosion. Therefore, effective temperature prediction and diagnosis are crucial. This paper proposes a thermal fault diagnosis method based on the Informer time series model. By extracting temperature-related features and conducting correlation analysis, a 9-dimensional input parameter matrix is constructed. Experimental results show that the model can maintain an absolute temperature prediction error within 0.5°C when predicting 10 seconds in advance, with higher accuracy than the LSTM model. Additionally, a three-level warning mechanism based on the forgetting coefficient further enhances diagnostic accuracy. Validation using test data and real vehicle data demonstrates that this method can efficiently diagnose and locate thermal faults in batteries, with low computational costs, making it suitable for online applications.
Sun, Yefan, Zhu, Xiaopeng, Zhang, Zhengjie, Peng, Zhaoxia, Yang, Shichun, Liu, Xinhua
Technical Paper
Experimental and Modeling Investigation on Thermal Runaway Propagation and Venting Gas in Cell-to-Chassis Lithium-Ion Battery System2025-01-701101/31/2025
Thermal runaway propagation (TRP) within lithium-ion batteries (LIBs) poses critical barriers to the safe operation and large-scale application of cell-to-chassis (CTC) batteries. Such events can lead to severe safety incidents, including explosions and fires, in systems utilizing these batteries. However, there is a lack of research on the thermal runaway model coupled with vented gases at the CTC systems. In this study, a thermal runaway coupling model for the battery pack system was established utilizing Star-CCM+ software, allowing for the examination of thermal runaway propagation characteristics and vented gas characteristics a within power battery systems based on the measured parameters of battery thermal safety characteristic. The simulation results indicated that once thermal runaway becomes uncontrollable, combustible flue gases escape through the exhaust hole located on the side plate of the cell, thereby facilitating heat transfer to adjacent cells. The primary components
Ma, Niya, Zhang, Anwei, Zhou, Wentai, Zhou, You, Jia, Yuan, Fan, Zehong
Technical Paper
Battery Development for Vehicles: Integration of 3D Finite Element Method and CFD for Effective Thermal Management2024-36-016312/20/2024
With the growing demand for electric vehicles (EVs), ensuring the safety and efficiency of battery systems is critical. This paper presents a methodology integrating 3D Finite Element Methods (FEM) and Computational Fluid Dynamics (CFD) to analyze battery systems, effectively mitigating thermal runaway phenomena. By combining FEM and CFD, our methodology provides a comprehensive approach to assess thermal management strategies within battery systems. This integration enables engineers to accurately simulate thermal behavior, predict hotspots, and optimize cooling strategies, thereby mitigating the risk of thermal runaway. Furthermore, our methodology minimizes the reliance on costly and time-intensive physical prototypes and testing. By leveraging virtual simulations, engineers can rapidly iterate through design modifications, assess their impact on thermal performance, and make informed decisions early in the development process. This article demonstrates the efficacy and accuracy of
Melo, Caiuã Caldeira, Araujo, Pedro Henrique, Castro Orefice, Fabio, Cury, Davi Machado, Vieira, Tiago Augusto Santiago, Abdu, Aline Amaral Quintella, Monteiro, Henrique Carlos
Technical Paper
TOC99-06-06-0TOC12/16/2024
TOC
Tobolski, Sue
Journal Article
Synthesis and Characterization of Advanced Multi Nanoparticle Based Nanofluid Stabilized by Surfactants2024-28-013912/05/2024
Recently, there has been a growing emphasis on Thermal Management Systems (TMS) for Lithium-ion battery packs due to safety concerns related to fire risks when temperatures exceed operating limits. Elevated temperatures accelerate electrochemical reactions, leading to cell degradation and reduced electronic system performance. These conditions can cause localized hotspots and hinder heat dissipation, increasing the risk of thermal runaway due to high temperatures, flammable gases, and heat-producing reactions. To tackle these issues, many automotive manufacturers employ indirect liquid cooling techniques to maintain battery pack and electronic system temperatures within safe limits. Engineered nanofluids, particularly those containing multi-nanoparticles dispersed in water and ethylene glycol, are being explored to enhance electrical safety in case of accidental exposure to electrical systems in EVs. This paper focuses on the experimental characterization of nanofluid containing
Nahalde, Sujay, Honrao, Gaurav, More, Hemant
Technical Paper
A Predictive Controller for Battery Cooling and Air-Conditioning Systems to Tackle the Comfort-Safety-Efficiency Dilemma2024-28-014712/05/2024
The advent of electric vehicles has increased the complexity of air conditioning systems in vehicles which now must maintain the safety and comfort of occupants while ensuring that the high voltage battery temperature is kept within safe limits. This new task is critical due to the influence of the cell and battery pack temperature on the efficiency. Moreover, high temperatures within the battery pack can lead to undesirable effects such as degradation and thermal runaway. Classical solutions to this problem include larger air conditioning components to support worst case scenario conditions where the cooling request from the battery and the cabin happen at the same time. In such conditions, for the safety of the battery, the cooling request is assigned to battery system which may cause discomfort to the passengers due the significant temperature increase in the cabin during such events. The probability of such events happening is certainly dependent on the weather conditions but in
Palacio Torralba, Javier, Kulkarni, Shridhar Diliprao, Shah, Geet, Jaybhay, Sambhaji, Kapoor, Sangeet, Locks, Olaf
Technical Paper
Battery Digital Twin with Edge Deployment2024-28-012012/05/2024
Today's battery management systems include cloud-based predictive analytics technologies. When the first data is sent to the cloud, battery digital twin models begin to run. This allows for the prediction of critical parameters such as state of charge (SOC), state of health (SOH), remaining useful life (RUL), and the possibility of thermal runaway events. The battery and the automobile are dynamic systems that must be monitored in real time. However, relying only on cloud-based computations adds significant latency to time-sensitive procedures such as thermal runaway monitoring. Because automobiles operate in various areas throughout the intended path of travel, internet connectivity varies, resulting in a delay in data delivery to the cloud. As a result, the inherent lag in data transfer between the cloud and cars challenges the present deployment of cloud-based real-time monitoring solutions. This study proposes applying a thermal runaway model on edge devices as a strategy to reduce
Sarkar, Prasanta, Pardeshi, Rutuja, Kharwandikar, Anand, Kondhare, Manish
Technical Paper
Electric Battery Cell, Module, and Battery Pack FE Modeling for Multiphysics Simulation2024-28-015412/05/2024
Electrified powertrain is the essential need to meet the C02 and NOX emissions compliance. Thereby focus of automotive industry is shifting towards to Electric Vehicle (EV). Thermal Runaway (TR) is still a big challenge to the safety of the EV. The major cause of TR is internal short-circuit of batteries under external mechanical abuse. When Anode and cathode of the battery comes in contact and short circuit happens. Internal short circuit is causing high amount of current flow and energy generation which leads to high increase in temperature. The approach that is used till date by OEMs is to protect the battery pack from structural damage during crash resulting into overdesigning of the vehicle. In this paper, detailed FE modeling of the battery system is considered for evaluating internal short circuit and TR. Solid Randle circuit is used for Multiphysics coupling simulation in Ls-dyna. Solid Randle circuits solves this Multiphysics and derives these electrical and thermal parameters
Jain, Tripti, Bonala, Sastry, Dangare, Anand
Technical Paper
Battery Digital Twin for Electric Vehicle Deployed on Cloud2024-28-015312/05/2024
A BDT (Battery digital Twin) is a virtual representation of a vehicle's physical battery system, combining electrochemical and machine learning models to provide insights into key battery parameters like State of Charge (SOC), State of Health (SOH), Internal Resistance (IR), and Remaining Useful Life (RUL). This BDT model is calibrated using cell testing throughout its degradation process up to 80% SOH, alongside vehicle data for accurate predictions under diverse conditions. By continuously monitoring the battery under various operating scenarios, the BDT aids in effective battery management, identifying cells that degrade more quickly and the likely causes of this degradation. Current and temperature profiles offer insights into battery usage patterns. The BDT aggregates fleet-wide parameters and analyzes individual cell performance, providing critical information on SOC, SOH, IR, RUL, and voltage. Additionally, the BDT includes prognostic capabilities to alert users of potential
Sasi Kiran, Talabhaktula, Kondhare, Manish, Patil, Suyog, Nath, Subhrajyoti, CH, Sri Ram, Tank, Prabhu, Sarkar, Prasanta
Technical Paper
Researchers Unveil Scalable Graphene Technology to Revolutionize Battery Safety and PerformanceTBMG-5214112/01/2024
This breakthrough promises to significantly enhance the safety and performance of lithium-ion batteries (LIBs), addressing a critical challenge in energy storage technology.
Magazine Article
Heat Generation Behavior of LFP and NCM Batteries during Long-Term Storage: A Comparative Study2024-01-701111/15/2024
The life and safety of a battery are closely linked to temperature. Designing an effective thermal management system relies on a thorough understanding and analysis of the thermal properties and mechanisms of the battery. Over time, as batteries are used, their thermal characteristics change due to variations in internal SEI thickness, the deterioration of the active material structure, gas production, and electrolyte consumption, all of which are associated with the aging process. In this paper, experiments on both NCM and LFP batteries were made to measure the heat generation characteristics by adiabatic calorimeter. The results showed that the impact of calendar aging on battery heat generation exhibited completely different patterns for the lithium-ion batteries of the two material systems mentioned above. This paper provides guidance for the optimization of heat generation characteristics of battery and the calibration of heat source in the design of battery thermal management
Li, Haibin, Zhao, Hongwei, Liu, Dinghong, Hu, Qiaosheng
Technical Paper
Correlation between Cell Thickness Profile and Lithium Plating: Applications in Lithium Plating Detection and Capacity Rollover Diagnostics2024-01-700911/15/2024
In the realm of low-altitude flight power systems, such as electric vertical take-off and landing (eVTOL), ensuring the safety and optimal performance of batteries is of utmost importance. Lithium (Li) plating, a phenomenon that affects battery performance and safety, has garnered significant attention in recent years. This study investigates the intricate relationship between Li plating and the growth profile of cell thickness in Li-ion batteries. Previous research often overlooked this critical aspect, but our investigation reveals compelling insights. Notably, even during early stage of capacity fade (~ 5%), Li plating persists, leading to a remarkable final cell thickness growth exceeding 20% at an alarming 80% capacity fade. These findings suggest the potential of utilizing cell thickness growth as a novel criterion for qualifying and selecting cells, in addition to the conventional measure of capacity degradation. Monitoring the growth profile of cell thickness can enhance the
Zhang, Jian, Zheng, Yiting
Technical Paper
Ionization Based Sensor for Early Detection of Thermal Runaway Events in Lithium-Ion Batteries2024-01-432611/05/2024
Lithium-ion and lithium-metal battery cells are susceptible to a phenomenon known as thermal runaway under failure conditions. Given their widespread use in applications such as electric vehicles, portable electronics, and energy storage systems, early detection of thermal runaway is crucial for ensuring the safety of these battery systems. Thermal runaway entails a rapid escalation in battery cell temperature accompanied by the emission of flammable lithium ions, particulates, electrons, hydrocarbons, and hydrogen gases. These gases pose a significant ignition risk, potentially leading to fires and endangering occupants and bystanders. Therefore, the timely detection of thermal runaway is paramount for ensuring safety in proximity to such battery systems. Traditionally, thermal runaway sensors comprise intricate assemblies of pressure, temperature, and gas sensors, strategically positioned at the pressure relief valve of battery modules. Calibration of all sensors is essential to
Mansour, Youssef
Technical Paper
Letter from the Focus Issue Editors14-13-03-001610/08/2024
Letter from the Focus Issue Editors
Shen, Ruiqing, Wang, Qingsheng
Journal Article
CFD Modeling of 18650 Lithium-Ion Cell to Predict Cell Gas Venting and Gas Phase Reactions during Thermal Runaway Event2024-28-009109/19/2024
To understand effect of thermal hazards of LIBs during TR event, it is important to study flame propagation behaviour of LIBs during storage and transport applications. The process of flame propagation involves complex phenomena of gas phase behavior of LIBs. Present paper attempts a numerical investigation to portray this complex phenomenon. This paper investigates 18650 lithium cell considering two different chemistries NMC and LFP. A 3D numerical CFD model has been constructed to predict the gas phase behavior, threshold internal pressure, and cell gas venting of an 18650-lithium cell under thermal runaway conditions. The gas phase processes are modelled using the 4-equation thermal abuse model, while the cell's venting mechanism is modelled using Darcy's equation. Present work is divided into two parts: 1) Venting gas Internal pressure prediction 2) modeling thermal runaway event. Both procedures are implemented on two different cell chemistries to understand and evaluate following
Gudi, Abhay, Bonala, Sastry
Technical Paper
Analysis of Electric Vehicle Battery Safety Enhancement Techniques Using Python2024-28-005209/19/2024
Electric Vehicles numbers are increasing at a rapid pace in the Indian market. As per the different feedbacks from the customers and reports available in media, there is an increase in Electric Vehicle (EV) battery fire accidents. The same is because of increased EV numbers, malfunctioning of battery and improper handling of EV systems. EV industry is looking for a solution for preventing these mis happenings by using advanced safety technology. This includes improvement in existing safety system through advanced warning backed by artificial intelligence, programming tools using new computing languages such as Python, Java etc. In present work temperature which happens to be major contributor in battery fire cases is being monitored with the help of programming used in battery management systems. In this process algorithm is being developed with the help of python as programming language. The same was test run on the selected parameters for validation of the developed programs for
Vashist, Devendra, Sharma, Aryan, Anand, Aditya
Technical Paper
Modelling Approach of Thermal Runaway Propagation and Gas Venting Process in Lithium-Ion Batteries: A Comprehensive Review2024-28-006809/19/2024
With the growing popularity of electric vehicles (EVs) Lithium-ion batteries (LIBs) exhibit unique characteristics such as long life, high specific energy, significant storage capacity, and remarkable energy density. The continual difficulty temperature non-uniformity over the battery surface and inside the battery pack, remains a major barrier in battery technology, significantly contributing to the tendency towards Thermal Runaway (TR). The hot gases discharged from a lithium-ion cell’s safety vent during a thermal runaway event carry flammable elements. If ignited, these gases heighten the potential for thermal runaway to spread to other cells within a multi-cell pack configuration. The study scrutinizes the effects of TR on the venting process. It explores contemporary approaches to minimize it, employing a variety of modeling methodologies such as Multiphysics, Computational Fluid Dynamics (CFD), and electrochemical-thermal, in addition to experimental methods. The objective of
Nogdhe, Yogesh, Garg, Ravi, Singh, Shobit Kumar
Technical Paper
Numerical Approach for the Characterization of the Venting Process of Cylindrical Cells under Thermal Runaway Conditions2024-01-290005/06/2024
Increasing awareness of the harmful effects on the environment of traditional Internal Combustion Engines (ICE) drives the industry toward cleaner powertrain technologies such as battery-driven Electric Vehicles (EV). Nonetheless, the high energy density of Li-Ion batteries can cause strong exothermic reactions under certain conditions that can lead to catastrophic results, called Thermal Runaway (TR). Hence, a strong effort is being made to understand this phenomenon and increase battery safety. Specifically, the vented gases and their ignition can cause the propagation of this phenomenon to adjacent batteries in a pack. In this work, Computational Fluid Dynamics (CFD) is employed to predict this venting process in an LG18650 cylindrical battery. The shape of the venting cap deformation obtained from experimental results was introduced in the computational model. The ejection of the generated gases was considered to analyze its dispersion in the surrounding volume through a Reynolds
Gil, Antonio, Micó, Carlos, Marco-Gimeno, Javier, Castro Espín, Mar
Technical Paper
A Comparative Analysis of Thermal Runaway Propagation in Different Modular Lithium-Ion Battery Configuration2024-01-290105/06/2024
Thermal runaway is a critical safety concern in lithium-ion battery systems, emphasising the necessity to comprehend its behaviour in various modular setups. This research compares thermal runaway propagation in different modular configurations of lithium-ion batteries by analysing parameters such as cell spacing and applying phase change materials (PCMs) and Silica Aerogel. The study at the module level includes experimental validation and employs a comprehensive model considering heat transfer due to thermal runaway phenomena. It aims to identify the most effective modular configuration for mitigating thermal runaway risks and enhancing battery safety. The findings provide valuable insights into the design and operation of modular lithium-ion battery systems, guiding engineers and researchers in implementing best practices to improve safety and performance across various applications.
Garcia, Antonio, Monsalve-Serrano, Javier, Dreif, Amin, Guaraco-Figueira, Carlos
Technical Paper
Low-Temperature Aging Effect on Safety of Lithium-Ion Batteries Subjected to Intrusion: A Comparative Study of 18650 and Pouch Cells2024-01-206304/09/2024
This study investigates the impact of cycling aging on the safety performance of lithium-ion batteries, specifically 18650 cells and pouch cells. These cells are cycled at 0 °C with charging rates of 2 C and 0.8 C, respectively, upon reaching different states-of-health, and their mechanical-electrical-thermal responses are analyzed post-indentation tests. The compressive behavior of anodes and cathodes at different states-of-health is also examined. The failure mechanisms of battery components are discussed based on indentation results at cell level, compression results of components, electrochemical impedance spectroscopy, and visual observations. The study reveals that aged 18650 cells exhibit increased stiffness (evidenced by left-shifted force-displacement curves) during cell indentation, while the compressions test results of aged electrodes show decreased stiffness (right-shifted force-displacement curves) which is similar to the stiffness behavior of the pouch cells. As aging
Spettmann, Christopher, Shin, Jonghyeon, Qu, Yunlong, Liu, Yuanjie, Xia, Yong
Technical Paper
Numerical Investigation of a Single Cell (Li-Ion) Combined with Phase Change Material and Additives for Battery Thermal Management2024-01-266604/09/2024
Li-ion batteries are commonly used in Electric Vehicles (EVs) due to its high-power density and higher life cycle performance. Individual cells in such battery packs may sometimes lead to thermal runaway conditions under the effect of localized heat generation and faults. Battery liquid cooling methods are normally being employed to resolve this problem with limitations of limited temperature operating range and difficulty in reaching the intricate spaces between the cells. Introducing phase change material (PCM) can mitigate these limitations. The present study deals with a detailed numerical study of a single (Li-ion) cell in ANSYS Fluent using multi-scale multi dimension (MSMD) - Newman, Tiedenann, Gu and Kim (NTGK) model. The single cell model is investigated for the evaluation of its temperatures at varying air velocity surrounding the cell at higher C-rating (load) values. It was observed that the maximum cell surface temperatures were as 322.6, 319.8, 318.1, 316.9, 314.4 and
Srivastav, Durgesh, Patil, Nagesh Devidas, Shukla, Pravesh Chandra
Technical Paper
Development and Validation of a Reduced Chemical Kinetic Mechanism of Dimethyl Carbonate and Ethylene Carbonate2024-01-208504/09/2024
With the rapid development of electric vehicles, the demands for lithium-ion batteries and advanced battery technologies are growing. Today, lithium-ion batteries mainly use liquid electrolytes, containing organic compounds such as dimethyl carbonate and ethylene carbonate as solvents for the lithium salts. However, when thermal runaway occurs, the electrolyte decomposes, venting combustible gases that could readily be ignited when mixed with air and leading to pronounced heat release from the combustion of the mixture. So far, the chemical behavior of electrolytes during thermal runaway in lithium-ion batteries is not comprehensively understood. Well-validated compact chemical kinetic mechanisms of the electrolyte components are required to describe this process in CFD simulations. In this work, submechanisms of dimethyl carbonate and ethylene carbonate were developed and adopted in the Ansys Model Fuel Library (MFL). Further improvements were made to enhance the kinetic consistency
Zhang, Kuiwen, Puduppakkam, Karthik, Shelburn, Anthony
Technical Paper
Recent Progress on Mechanism of Mechanical Abuse2024-01-240504/09/2024
With the rapid development of electric vehicles (EVs), lithium-ion batteries (LIBs) with high energy and power density have been widely applied as the power producer of EVs. However, the range of EVs has been criticized. To meet consumer demand for high power and long driving distances, the energy and power density of LIBs are getting higher and higher. However, LIBs with higher energy density are more prone to catastrophic thermal runaway (TR). In recent years, EV accidents due to TR of LIBs have been frequently reported, which makes consumers lose confidence in EVs. To solve the problem, we must understand the mechanism of LIBs TR, thereby reducing the likelihood of TR in EVs. However, the induction mechanism of LIB TR induced by mechanical abuse is sophisticated. This paper focuses on recent advances in the study of thermal TR characteristics of batteries caused by mechanical abuse, including bending, collisions, and penetration. The impact of various mechanical abuses on the TR
Hao, Wang Zhi, Tang, Xuan, Zhou, Youhang
Technical Paper
Enhancing Battery Thermal Management in Electric Vehicles through Reduced Order Modeling and Predictive Control for Quick Charging2024-01-266404/09/2024
In the realm of electric vehicles (EVs), effective battery thermal management is critical to avert thermal runaway, overheating, and extend the operational lifespan of batteries. The process of designing thermal management systems can be substantially expedited through the utilization of modeling and simulation techniques. However, the high-fidelity 3D computational fluid dynamics (CFD) simulations often demand significant computational resources to provide comprehensive results under varying conditions. In this paper, we develop a reduced order model (ROM) to capture the battery thermal dynamics employing a sub-space method. To construct this ROM, we use high-fidelity CFD simulations to generate step responses of battery temperature with respect to the heat generation and cooling power. These step responses are subsequently used as training data for the ROM. To minimize computational expenses while preserving accuracy, we determine the minimal dimensionality of the ROM through the
Hu, Qiuhao, Ding, Peiran, Jiang, Weiran, Fung, Kenny
Technical Paper
Modeling of Vent Gas Composition during Battery Thermal Runaway2024-01-219904/09/2024
The growing global adoption of electric vehicles (EVs) emphasizes the pressing need for a comprehensive understanding of thermal runaway in lithium-ion batteries. Prevention of the onset of thermal runaway and its subsequent propagation throughout the entire battery pack is one of the pressing challenges of lithium-ion batteries. In addition to generating excess heat, thermal runaway of batteries also releases hazardous flammable gases, posing risks of external combustion and fires. Most existing thermal runaway models in literature primarily focus on predicting heat release or the total amount of vent gas. In this study, we present a model capable of predicting both heat release and the transient composition of emitted gases, including CO, H2, CO2, and hydrocarbons, during thermal runaway events. We calibrated the model using experimental data obtained from an 18650 cell from the literature, ensuring the accuracy of reaction parameters. We employ this developed model to investigate
Hariharan, Deivanayagam, Gundlapally, Santhosh
Technical Paper
Fire Safety of Battery Electric Vehicles: Hazard Identification, Detection, and Mitigation14-13-03-002403/21/2024
Battery electric vehicles (EVs) bring significant benefits in reducing the carbon footprint of fossil fuels and new opportunities for adopting renewable energy. Because of their high-energy density and long cycle life, lithium-ion batteries (LIBs) are dominating the battery market, and the consumer demand for LIB-powered EVs is expected to continue to boom in the next decade. However, the chemistry used in LIBs is still vulnerable to experiencing thermal runaway, especially in harsh working conditions. Furthermore, as LIB technology moves to larger scales of power and energy, the safety issues turn out to be the most intolerable pain point of its application in EVs. Its failure could result in the release of toxic gases, fire, and even explosions, causing catastrophic damage to life and property. Vehicle fires are an often-overlooked part of the fire problem. Fire protection and EV safety fall into different disciplines. To bridge the gap between these two disciplines and summarize the
Shen, Ruiqing, Quan, Yufeng, McIntosh, James D., Salem, Asad, Wang, Qingsheng
Journal Article
An Adapted ARP-Based Approach for the System Safety Assessment of Electric-Propulsion Thermal Runaway Hazards2024-01-191903/05/2024
The global electric and hybrid aircraft market utilizing lithium-ion Energy Storage Systems (ESS) as a means of propulsion, is experiencing a period of extraordinary growth. We are witnessing the development of some of the most cutting-edge technology, and with that, some of the most complex challenges that we as an industry have ever faced. The primary challenge, and the most critical cause of concern, is a phenomenon known as a “Thermal Runaway”, in which the lithium-ion cell enters an uncontrollable, self-heating state, that if not contained, can propagate into a catastrophic fire in the aircraft. A Thermal Runaway (TR) can be caused by internal defects, damage, and/or abuse caused by an exceedance of its operational specifications, and it is a chemical reaction that cannot be stopped once the cell has reached its trigger temperature. There are many technical papers that explore the characteristics of battery cells and the TR as a failure mode, but the failure mechanism(s) are still
Hanna, Michael, Walker, Cherizar
Journal Article
Verification Process for Thermal Runaway Mitigation in Large Electrical Energy Storage Powertrain Systems in Normal Category Aircraft and RotorcraftARP7131 (Current)02/16/2024
This SAE Aerospace Recommended Practice (ARP) is an industrial collaboration with regulatory bodies like the European Aviation Safety Agency (EASA) and the Federal Aviation Administration (FAA) to determine the worst-case credible thermal runaway (TR) condition (energy released and maximum temperature) for the design of an aviation large propulsion battery system to quantitatively verify TR in lieu of battery level RTCA DO-311A testing with protections disabled. The ARP considers the three stages of TR within a cell and defines the two critical temperatures for a specific cell design. These temperatures are key to understanding the layers of monitoring necessary to determine the severity of a TR event. Different trigger methods can be used to quantify the heating characteristics and resultant energy profile releases as a function of time. Results show three general phases of the event critical temperature (see 1.5) corresponding with the reaction between the cell’s solid electrolyte
AE-7D Aircraft Energy Storage and Charging Committee
Recommended Practice
TOC99-06-01-0TOC02/12/2024
TOC
Tobolski, Sue
Journal Article
Thermal Analysis of Components and Traces on Printed Circuit Boards2024-26-027901/16/2024
High currents flowing through various traces of a printed circuit boards (PCB) causes thermal run away and PCB warpage due to the occurrence of high heat density. The present study discusses on steady state thermal analysis performed in a PCB kept inside an enclosure. Thermal analysis allows PCB designer to quickly move and confirm the component’s placement by examining the temperature plots predicted on the PCB surface. A PCB particularly designed for automated manual transmission (AMT) application employed in Ashok Leyland electric vehicle (EV) trucks is used for this present study. The performed simulations are preliminary level and carried out with commercially available software Altair Simlab ElectroFlo 2022.3. Simlab is a PCB level EDA (Electronic Design Automation) software suite used for design and analysis, and thus helps in minimizing the development cycles. The power dissipation for each and every component and the component analysis power level plays a significant role in
Rajasekharan, Jayakrishnan, Prasad, Suryanarayana, ML, Sankar. T
Technical Paper
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