DESIGN AND TESTINGOF A LOW-COST LEAD-CARBON REPLACEMENT BATTERY PACK

FOR A HONDA CIVIC

D. Karner, T. Grey, R. Newnham

Work Conducted for theAdvanced Lead Acid Battery Consortium

And TheU.S. Department of Energy

Project Overview

• Furukawa Ultra Battery has shown promise in mild HEV applications

• East Penn Manufacturing has licensed Ultra Battery technology for US production

• US Department of Energy and ALABC are interested in evaluating the East Penn Ultra Battery in a mild HEV application

• Electric Transportation Applications has been engaged to evaluate the East Penn Ultra Battery in a Honda Civic HEV

Project Objectives

• Convert a Honda Civic HEV to operate using an Ultra Battery manufactured by East Penn

• Retain an 800 pound vehicle payload• Provide packaging favorable to battery life• Maintain vehicle fuel economy performance • Maintain vehicle emissions performance• To obtain an "Experimental Vehicle" permit• Maintain vehicle FMVSS certification• To evaluate vehicle performance/durability

Progress

• Development and testing of Simulated Honda Civic HEV profile (HCHEVP)

• Characterization of Ultra Batteries from Furakawa (FUB) Capacity at various rates Discharge resistance at various SOCs Performance of FUB and standard lead-

acid (STLA) under HEV screening test Full HPPC analysis of FUB and STLA

Progress

• Preliminary optimization of HCHEVP• Operation of FUB under HCHEVP• Vehicle Preparation

Design of battery compartment Evaluation of vehicle safety features Design of Battery Management System

Analog/Digital/Analog converter Emulation software

Honda Civic

East Penn Ultra Battery Pack

Preliminary packaging with extension, but without thermal management

Development and Testing of HCHEVP

• Battery data logged during field and dyno (UDDS, HWFET) operation

• Information obtained on affects of air conditioning, hill climbing, etc.

• Profile based on one pass through UDDS and HWFET schedules

• Data from five individual passes through both profiles used to obtain an average

• UDDS schedule = 1380 s, 7.5 miles, 19.5 mph • HWFET schedule = 760 s, 10.2 miles, 48.5 mph

Development of simulated profile

Battery current and vehicle speed on dyno.

Development and Testing of HCHEVP

HCHEVP – one pass through UDDS followed by one pass through HWFET

Battery voltage (STLA) over seven passesand one pass through the HCHEVP

Development and Testing of HCHEVP

25

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0 2000 4000 6000 8000 10000 12000 14000

Time (s)

Vo

lta

ge 25

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10566 10966 11366 11766 12166 12566

Time (s)

Vo

lta

ge

Development and Testing of HCHEVP

Battery current (STLA) over seven passesand one pass through the HCHEVP

-80

-60

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0 2000 4000 6000 8000 10000 12000 14000

Time (s)

Cu

rre

nt

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10566 10966 11366 11766 12166 12566

Time (s)

Cu

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Development and Testing of HCHEVP

• 3 months of cycling provides >64,000 miles of simulated HEV driving

• Energy/power levels of profile equivalent to that experienced in the field and on dyno

• One pass through the HCHEVS – battery delivers and accepts 2.89 Ah. Over the design life of the vehicle (160,000 miles), the battery would deliver 26,000 Ah, the equivalent of 4,000, 100% cycles

• Comparative calculations performed for a Toyota Prius battery pack indicate the delivery of almost 6,000, 100% cycles over the same distance.

Application of simulated profile

FUB Characterization - Capacity

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1 10 100 1000

Discharge current (A)

Dis

ch

arg

e t

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(h

)

Values from thisstudy

CSIRO values

Dischargecurrent

(A)

End-of-discharge

voltage (V)

Temp at end-of-discharge

(C)

Capacity(Ah)

1.33 10.5 25.0 9.631.33 10.5 25.0 9.431.33 10.5 25.0 9.741.33 10.5 25.0 9.792.19 10.5 25.5 9.452.19 10.5 25.5 9.472.19 10.5 25.5 9.506.65 10.5 28.0 8.156.65. 10.5 28.0 8.056.65 10.5 28.0 8.0739.9 9.6 34.5 4.8839.9 9.6 35.0 4.6539.3 9.6 34.5 4.56

FUB Characterization – Discharge Resistance

SOC

% Resistance of module (ohm)

Resistance per cell (m-ohm)

90 0.015 2.4 80 0.015 2.4 70 0.015 2.5 60 0.016 2.6 50 0.016 2.7 40 0.018 2.9 30 0.019 3.1 20 0.022 3.6 10 0.026 4.4 0 0.045 7.5

FUB Characterization – HEV Screening

(i) Discharge at 1C for 30 min (to ~ 50% SOC nominal)(ii) Rest for 10 s(iii)Charge at 2C for 60 s (to ~ 53% SOC nominal)

terminate test if voltage hits 17.5 V;(iv)Rest for 10s(v) Discharge at 2C for 60 s (to ~ 50% SOC nominal). (vi)If voltage during (v) drops to 11.5 V (~ 40% SOC), then

recharge an additional 5% SOC over the next 100 cycles.

STLA Characterization - HEV Screening

FUB Characterization - HEV Screening

STLA Characterization - HPPC Testing

FUB Characterization - HPPC Testing

Conclusions

• Simulated HCHEVP complete and validated • Furakawa has been characterized• Preliminary vehicle design complete –

continuing work on thermal management• Next steps

Characterize EPUB modules Cycle full EPUB pack under HCHEVP for 3

months (64 000 miles equivalent)