battery cycling automation...sli vehicules electric appliances small batteries mobiles stationary...

Automated Battery

Cycling System

by: Robert J. Laurin - AVESTOR

& Michel Daigle - Hatch

Confidential

http://images.google.ca/imgres?imgurl=http://www.callisto.si.usherb.ca/~ti/images/Laurin.jpg&imgrefurl=http://www.callisto.si.usherb.ca/~ti/RLaurin.htm&h=237&w=200&sz=8&tbnid=YSp8U3SRMBYJ:&tbnh=103&tbnw=87&hl=fr&start=15&prev=/images%3Fq%3DRobert%2Blaurin%26hl%3Dfr%26lr%3D%26sa%3DG

http://images.google.ca/imgres?imgurl=http://www.callisto.si.usherb.ca/~ti/images/Laurin.jpg&imgrefurl=http://www.callisto.si.usherb.ca/~ti/RLaurin.htm&h=237&w=200&sz=8&tbnid=YSp8U3SRMBYJ:&tbnh=103&tbnw=87&hl=fr&start=15&prev=/images%3Fq%3DRobert%2Blaurin%26hl%3Dfr%26lr%3D%26sa%3DG

© 2005 AVESTOR - Hatch & Associates

Agenda

• AVESTOR corporate overview

• Battery cycling process description

• Alpha cycling system overview

• Battery cycling model (ISA S-88 structure)

• HMI process surveillance

• Quality assessment, reporting and automation

• Next steps, lessons learned, conclusion

• Questions & answers


AVESTOR

Corporate Overview


Overview 250+ Employees

Partnership between Hydro-Québec and Kerr McGee (50:50)

R&D Building in Boucherville PQ

Coating Plant, expansion in progress

Commercial Production Plant

Lithium Vanadium Oxide (LVO) plant in Soda Springs, Idaho

APEX, Nevada (30 min from Las Vegas) for LVO additional Plant and future battery plants


Corporate Milestones1979 Development started

1993 First USABC contract for EV

1994 AVESTOR is established

1997 GM contract for HEV

1999 First telecom field test

2000 EVS-17 demonstrations EV and HEV

2001 Kerr McGee and Hydro-Quebec partnership

2002 Inauguration of the world first LMP commercialplant

2003 First commercial delivery

2004 Ramping up of ALPHA plant

2005 Industrial sales


AVESTOR Alpha LMP Plant


Applications

Stationary

Automotive

Telecommunications

Electric Utilities


Other Stationary Markets

Signaling

Renewable

Oil and Gas


Other Stationary Markets

Data Center Installation


LMP Electrochemistry


Battery Specifications

Voltage: 48 Vcc

Capacity: 63 Ah (3 kWh)

Weight: 28 kg

Length: 400 mm

Width: 200 mm

Height: 272 mm


Battery Construction

18 cells connected in series


Main Characteristics

Stable electrochemical system

• Long life (10 years guaranty )

• High temperature tolerance (-40 ºC to +75 ºC)

• Improved Safety (solid electrolyte)

Light and small

• 1/3 the volume of lead-acid and 1/5 the weight

Predictable

• Remote and local monitoring of battery parameters

Smart

• Integrated thermal management system

• State of health and state of charge calculation


Markets

Rechargeable

batteries

Large Batteries

SLI

Vehicules

Electric

AppliancesSmall Batteries

Mobiles

Stationary

UPS

(AC Back-Up Power)

DC Back-Up Power

Transport

Telco

Industrial/Utilities

IT

Industrial

Utilities

Airport

Railways

Telephony

Wireless

CATV

Recreational

Utility Vehicules

EV

HEV

Other

Aerospace

Military

Telco

Mining

First markets targeted by AVESTORSecond markets targeted by AVESTOR

Future markets targeted by AVESTOR


Field Installations


Battery cycling

process description


About Hatch

• ISO-9001 2000 certified

• Head office located in Mississauga, Ontario; over 60 global offices on all continents

• 6,000 professionals worldwide

• Manages over US $20 Billion dollars in programs and projects annually

• Work with OSIsoft since 1996

• Founded in 1955: worldwide leader in consulting, information systems, project management and construction and engineering


The Battery Cycler


Cycling Process Objectives

•Go through the battery operational

cycles:

• Floating (no charge, no discharge)

• Discharging

• Charging

•Level the « electrochemistry »

behaviour of the battery and to control

the quality of the final product


Battery cycling phases• Main data collected and analysed during the battery

cycling is the various EC (Electrochemical Cells) voltages

• Battery cycling can be split in 6 major phases. Each phase could be divided into one or more steps (depending on the cycling protocol used).

• The 6 cycling phases are:

1. Pre discharge or charge (i.e. cells leveling)

2. Floating: to detect cells shortcuts

3. Discharge: at C/4 rate (fast) and C/8 rate (slow)

4. Charge

5. Cells topping (i.e. cells leveling)

6. Floating: to detect cells auto-discharge


Phases voltage evolution

1 2 3 4 5 6

C/4 Fast

C/8 Slow


Battery Parameters

• Followed parameters from the card Voltage of individual cells (x 18)

Battery voltage/current at the pole

Battery temperature (x4)

Operations, phases and steps

Operating times

Electronic ID, CAN Network ID, Model No

Battery’s alarms


Battery acceptance criteria

• Various acceptance criteria have to be met by the battery during the cycling to be accepted

• In general terms, a battery can have one of 3 quality status:

Green: The battery meets all criteria and can be shipped to customers;

Yellow: The battery does not meet certain non-severe criteria and a more thorough validation is required;

Red: The battery does not meet certain severe acceptance criteria and the battery has to be reworked or disposed


Alpha Cycling

System Overview


Technologies• Allen Bradleys Control Logix series of PLC

• Panel View/RS View HMI

• Control Net communication layer

• RS Linx OPC communication layer with « external » applications such as PI

• OSIsoft PI Systems real time data base

• PI ProcessBook for HMI and PI-OLE-DB for reporting through MS-Excel

• PI-Batch to « assemble » produced good data using serial numbers and using ISA S-88 standards

• PI-Batch generator interface for automatic batch creation

• Symbol handheld/wireless computer

• Portable applications on Windows CE

• Barcode reading (1D & 2D)

• IFS Enterprise ERP

• Used to get battery cycling approval

• Supply chain management


Process Schematic• 152 batteries that are

controlled independently

• 4 Power supplies (charging)

• 20 Electronic loads (discharging)

• Voltage and current measured at the loads and power supplies

• Temperature measured at each position

• The internal battery parameters collected by its electronic processor

• Communication between the battery’s electronic and the PLC by a CAN network (subset of Device NET)


Systems Architecture

Alpha Cycling Local Netw ork

Corporate Netw ork

RSLinx/OPC & CEFusion

Server

IFS/Oracle Server PI Server

RS-View

PC Workstation

Wireless router &

antenna

IEEE 802.11b Wireless Barcode readerMC9000 G

PANELVIEW

DISPLAY

PLC

• Spread over 2 levels of network for safety and integrity

• OPC Server-Client for PLC to PI interfacing

• Acquisition node with local buffering

• Interoperability with the ERP (IFS) with PI and handheld device

• Handheld computer that is used to initialize and start the cycling procedure

• Local wireless network for the handheld


System Architecture

• Batteries data acquisition was a

major burden:

• CAN is not a “process control”

standard: No Control Logix card

• Need fast/wide data acquisition

• Solution: Prosoft’s PC-56 acquisition

PC card for Control Logix:

• Foster the CAN connection hardware

• Developed a CAN communication

driver

• Developed OPC client talked with PI


Operation Procedure

1

23


PI Server Modules

BATCH

SQL

PERF

EQUATION

ALARM

PI-ACE

SERVER

Module

Database

Raw

Data

Recorded

Data

RtPM

PI SERVER

PI ProcessBook

Client

PI OLE DB

Interface

MS-Excel

PI BaGen

Interface

PI OPC Client

Interface

Rockwell

OPC Server

(RS Linx)

Control Network

Control Logix

PLX

PLANT AUTOMATION SYSTEM

ALPHA PLANT

CYCLING FACILITY


Battery Cycling

Model


ISA S-88 terminology

Each element of the battery cycling process can be

translated into a ISA S-88 Batch Standard equivalent:

•Battery cycling process= Batch process

•Cycling protocol = Control recipe

•Battery module = Batch

•Cycling position = Batch unit

The succession and duration of each operation and

phase (i.e. sub-operation) is defined by the cycling

protocol.


Physical model

A V E S T O R

A lp h a P la n t

C y c lin g C o n ta in e r

“A ”

B a tte ry ra c k # 1

(7 6 B a tte r ie s )

B a tte ry ra c k # 2

(7 6 B a tte r ie s )

O d d C y c lin g

P o s it io n s

1 0 1 A ...1 1 9 H

E v e n C y c lin g

P o s it io n s

1 0 2 A ...1 1 8 H

C o n ta in

C o n ta in

C o n ta in

C o n ta in

C o n ta in

C o n ta in

} E n te rp r is e

} S ite

} A re a

} P ro c e s s C e ll

} U n it


Procedural control model

C y c lin g p ro to c o l

B a tte ry M o d u le

C h a ra c te r iz a tio n

C h a rg in g ,

F lo a tin g ,D is c h a rg in g a n d

Id le o p e ra tio n s

C h a rg in g ,

F lo a tin g ,D is c h a rg in g

s u b -o p e ra tio n s te p s

C o n s is ts o f a n o rd e re d s e t o f



} P ro c e d u re

} U n it P ro c e d u re

} O p e ra t io n s

} P h a s e s


Model in PI-Module DB

• Used to store the

batch structure

• Used to store

cycling protocols

(I.e. multi-

products cycling)

• Used to configure

the whole

unit/equipment

structure using

the ISA S-88

structure &

terminology


PI Batch Generator

• Capable to

manage batch,

operations &

phases

simultaneously for

152 positions !

• The new BaGen

configuration utility

(SMT 3.0) is very

efficient and ease

of use

• We use the S-88

structure in BaGen


HMI Process

Surveillance and

Batteries Tracking


HMI features• Available on all PC workstations connected to

AVESTOR corporate network (via Citrix)

• Provides constant status and alarms monitoring for all

cycling positions at one glance

• Further analysis of a battery process values using

drill-down (in real time)

• Displays trends for each cycling parameters (EC

voltage, module current/voltage and temperature)

during all process operations (in real time or in

playback mode)

• User friendly tree-view representation of operations

and phases for selected batteries


HMI Main Dashboard


Batteries Tracking

• Search filter

• Access to cycling

data per battery

serial number

• Access to

Operation and

Phase data

• Allow « batch » (i.e.

battery) status

change and

update batch and

sub-batch data


Voltage Analysis


Temperature Analysis


« Batch » HandlingModification of a batch (i.e. Battery), operation or phase


Quality Assessment,

Reporting &

Automation


Cycling report features• Automatic reconciliation between battery cycling

process model and raw data from PI

• Detailed list of operations and phases with

begin/end dates, elapsed time and duration for

each battery

• Error reporting stored in event log for problematic

batteries (future development)

• Automatic calculation of results allows QA personal

to perform quick and precise quality assessment

• Selectable list of positions for automatic calculation

and report printing


PI-ACE Usage• Use PI-ACE to compute the instantaneous energy

stored in a battery

• One instance per cycling position = 152 instances !

• Executed at the frequency of 15 seconds

• Monitor batteries status at the frequency of

5 seconds


Report Feature• Presented within MS-Excel

• Use PI-OLEDB to access the data quickly

• We access to more than 40 tags at the 15 seconds level

for 72 hours: NEED A FAST ACCESS INTERFACE

• PI-Datalink is not adequate for such a search

• Programming done in a MS-Excel AddIn using PI-SDK

• Compute the battery’s parameters

• Allow the user to automatically assign the quality

status to the battery (i.e. Red, Yellow, Green)

• Report automation features to compute/print

multiple positions at once


Reports Main Page


Report Operations/Phases


Report Plots


Report Data Extraction


Report Automation


Conclusion &

Next Steps


Increase automation• Compute ALL the quality parameters automatically

in PI-ACE (actually some in the Excel report)

Includes the data and curves « interpretation » without human intervention

Then, would assign the Green, Yellow, Red status automatically

• Increase the interoperability with the ERP to improve the batteries tracking and storing cycling results

• Reduce the cycling time and optimize the cycling process

• Increase real-time failover capacity

• Use PI-Process Template to track the cycling curves


Increase automation(Process Template) Batteries

Cycling

curves


Lessons Learned• PI implementation went well by using its full

functionality

• Some little « response time » problem with PI-OLEDB SOLVE BY PI-OLEDB 3.0 !

• The PLC/Control Strategy has been difficult since short schedule and complex control strategy

• OPC Server on the Rockwell side was still a problem: Last ARC Advisory Group survey shows that 87 % of OPC Server technology users aren’t satisfied

PI IS A POWERFUL TOOL TO MANAGE ANY BATCH & REAL TIME QUALITY DATA


Questions & Answers

Robert J. Laurin, [email protected], (450) 645-2135

Michel Daigle, [email protected], (514) 864-5558

battery cycling automation...sli vehicules electric appliances small batteries mobiles stationary...

Documents