Energy storage and battery cost of a field failure

Cost of failure is humongous

Battery Reliability for Tier 1 suppliers with battery scarcity due to focus on the automotive market. The growing use of cells for increased form factor flexibility and less mechanical protection with less observed quality lower by a factor.  The sale and use of batteries require continuous testing and analysis to measure performance characteristics. Daily Gigabytes of data, Excel-based, Little analysis Distributed Teams, New Data Formats.  

Field failure rate is 15 times for Tesla, Boeing, Samsung

Field failure rate is 15 times for Tesla, Boeing, Samsung

Common battery cell operating window problems

The energy industry is transforming. Renewables are claiming their place, consumers of electricity are generating it as well, and added to this, an increasing number of electric vehicles plugin instead of filling up. The grid has evolved, with electricity now flowing both ways – to and from consumers. Here, at the ‘edge of the grid’ where consumers and utilities interact, is where we see the most disruption and innovation.

How do you do the following?
Supplier qualification, characterization of electrical performance non-destructive and destructive tear-down and environment analysis, development of incoming inspection protocols.

How do you know your cell supplier?
Supplier cell quality is critical to battery safety, foreign materials, particulate contamination, and manufacturing defects increase the risk of shorting and thermal runaways.

How good is your assembly process?
Pouch cells do not have the mechanical protection of metallic encased cells. It is critical the host device/assembly process not induce automatic stress points on the pouch cell, corners, surrounding electronics, sufficient room for cell expansion. Soldering of pouch cell terminals is not recommended.

Are you selecting characterization and test capability smartly?
Here are just a few critical tests: Microscopy and imaging, environmental testing, chemical characterization, component testing, sample preparation, mechanical characterization, and testing.

Here are the important reliability services that we would suggest

  •  Bench-marking of battery cell quality and design
  • Evaluation of battery management systems
  • Battery life prediction
  • Battery pack thermal solution and housing consultation
  • Test plan development
  • Design review and component selection 
  • Battery failure analysis, root cause identification and recommendation
  • Battery performance tests and a wide range of abuse condition

Common lithium-ion cell operating window problems

Scarcity of Resources

Energsoft Laboratory

Scarcity of expertise and resources. Lack of battery quality control, application integration issues, and proper storage procedures will push batteries outside the operating window.

Narrow Operating Windows

Energsoft and Tesla Goals

Narrow operating windows must be respected throughout the battery life cycle: manufacturing, application integration, battery storage, warehousing, transportation, and use. But the biggest issue is evaluations

Thermal runaway

Energsoft Laboratory for Clean Environment

Big Data can be used to prevent cells operating window problems that could consist of thermal runaway issue with death and lawsuits, cathode active material breakdown oxygen release and ignition. 

Breakdown of Electrolyte

Electrification in Transportation

 Another possible problem venting, exothermic breakdown of electrolyte, the release of flammable gases, pressure and temperature increases, and separator melts.  

Solid Electrolyte Interface

Battery Pack Improvements

 Breakdown of solid electrolyte interface (SEI)  Layer and Temperature rise. Lithium plating during charging, capacity loss overheating.  Cascading failure occurs in the battery module without an aluminum heat sink.

Breakdown Short Circuit

Software Analytics Dashboards

Copper anode current collector dissolves cathode breakdown short circuit. Lithium plating during charging. Copper particulate contamination on battery electrode is a rare case too.

$M Losses Samsung 5000, Swagway 200, Sony 400, Boeing 600

Shanghai parking lot fire

Tesla Model S Spontaneously on Fire in Los Angeles 

Exploding Phone Batteries from Samnsung

Battery explosions in the Galaxy Note 7

Samsung recall in 2016

Boeing 787 Dreamliner battery problems

 The FAA is worried rechargeable lithium batteries may trigger catastrophic fires in the cargo holds of passenger jets. Safety analysts warn this kind of fire could take down a plane 

Anatomy of Cell Failure

Anatomy of Cell Failure

Battery Industry Problems

Energsoft is on top of advanced battery R&D work across the globe and highlights the most promising materials and cell technologies that will enable advances in battery technology expansion. Safety concerns arise when batteries are abused, used outside the design’s operational space, poorly designed, or beyond useful life. Heat generation and gas generation are the most common responses of batteries to abusive conditions--the most serious consequences occur when the stored energy is rapidly released in an unintended manner, triggering thermal runaway. This report presents the fundamentals of battery safety and abuse tolerance. It discusses materials, cells, and battery system design, manufacturing, applications, and validation, as well as the lessons learned from recent failures. 

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Energsoft Inc. optimizes the use of their battery engineering department, companies can make strategic investments in battery data analytics software. Energy storage analytics can track a battery throughout its life-cycle, providing full trace-ability and an overview of the battery’s history.