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Energy storage and battery cost of a field failure
Cost of failure is humongous
Tier one suppliers shifted the research and testing focus on the automotive market. 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 are increasing concerns for the customers.
Case Study: What problem is this solving for you?
"Our company does a lot of cycling testing and field telemetry: charge the batteries up and discharge them to zero for six months or longer at a time. We also perform load tests based on product needs these tests to generate a lot of data. Batteries are cells but also have electronics around them. Electronics generate relevant data that sampled every minute. Every minute over six months means that a lot of data is being generated. We use data to plot and analyze things such as whether the battery is good for liability reasons or the product life cycle. Normally our team has had homegrown tools to analyze the data. Still, the company wanted to use a more standardized tool to measure the data, as well as to collect the data generated from tests in different locations around the world. Energsoft was one of the companies that we thought could help. When Energsoft came to our Company, Energsoft helped build it up to our requirements and compliant standards, and are continuing to do so. The battery data analytics platform enables data-driven decisions and improved productivity. It also supports internal communication and partnerships by enabling easy, secure data sharing."
“Everybody would like to get off Excel files if they can. Our team wanted a database, prediction, and fault analytics tool that gets the data faster. We don’t have to invest in a software team to do this. Fundamentally, battery analytics is very useful for a lot of things other than just a collection of data: how to throttle a system if something is going bad, how to add more capacity when needed, or when the battery is running low how to extend the battery. Data analytics tools like Energsoft are critical for that and historical data. Voltaiq a more established company, but they are also charging a few times more without any unique features. Voltaiq wanted to sell its existing solution but our Company wanted a lot more customizations. Energsoft gave that option and customized data analysis on the platform. Energsoft customer service level: it’s been good. They have a support help desk, emails, and conference calls. technical issues are getting resolved in a good amount of time.”
Battery Analytics Challenges
Field failure is 15 times more in Tesla, Boeing, and 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. Different parties involved and data tracking needed along the whole value chain.
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. No standard for battery state of health or remaining battery value. How can I choose the best cell, pack, and operation strategy?
How do you know your cell supplier?
Supplier cell quality is critical to battery safety, foreign materials, and particulate contamination. 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 sufficient room for cell expansion. Soldering of pouch cell terminals not recommended. Why do my batteries die? Can I optimize my operation strategy to maximize my lifetime?
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
- Battery state of health
- Remaining battery value
Common lithium-ion cell operating window problems
Scarcity of Resources
Narrow Operating Windows
Narrow Operating Windows
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
Narrow Operating Windows
Narrow Operating Windows
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
Narrow Operating Windows
Breakdown of Electrolyte
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
Solid Electrolyte Interface
Breakdown of Electrolyte
Another possible problem venting, exothermic breakdown of electrolyte, the release of flammable gases, pressure and temperature increases, and separator melts.
Solid Electrolyte Interface
Solid Electrolyte Interface
Solid Electrolyte Interface
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
Solid Electrolyte Interface
Solid Electrolyte Interface
Copper anode current collector dissolves cathode breakdown short circuit. Lithium plating during charging. Copper particulate contamination on battery electrode is a rare case too.
Research and usage continue to boost the energy storage capability of lithium-ion batteries (LIBs) leading to expanding applications and consumer use. Higher energy plus increased use leads to higher risk. Therefore, accurate tests and models are critical for predicting and controlling the complex electrochemical, thermal, and mechanical behavior of LIBs. Additionally, regulations to promote protection and information derived from forensic investigations to enhance prevention are required. The task of implementing effective safety strategies falls on R&D scientists (chemical, electrical, material, and software engineers), battery manufacturers, regulatory authorities, forensic scientists, and the public.
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.
Learn More
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.