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Mechanism of internal thermal runaway propagation in blade batteries

Journal of Energy Chemistry 2024年第2期89卷 184-194,I0005页

作者： Xuning Feng Fangshu Zhang Wensheng Huang Yong Peng Chengshan Xu minggao ouyang School of Vehicle and Mobility Tsinghua UniversityBeijing 100084China

Blade batteries are extensively used in electric vehicles,but unavoidable thermal runaway is an inherent threat to their safe use.This study experimentally investigated the mechanism underlying thermal runaway propagation within a blade battery by using a nail to trigger thermal runaway and thermocouples to track its propagation inside a cell.The results showed that the internal thermal runaway could propagate for up to 272 s,which is comparable to that of a traditional battery module.The velocity of the thermal runaway propagation fluctuated between 1 and 8 mm s^(-1),depending on both the electrolyte content and high-temperature gas diffusion.In the early stages of thermal runaway,the electrolyte participated in the reaction,which intensified the thermal runaway and accelerated its propagation.As the battery temperature increased,the electrolyte evaporated,which attenuated the acceleration effect.Gas diffusion affected thermal runaway propagation through both heat transfer and mass transfer.The experimental results indicated that gas diffusion accelerated the velocity of thermal runaway propagation by 36.84%.We used a 1D mathematical model and confirmed that convective heat transfer induced by gas diffusion increased the velocity of thermal runaway propagation by 5.46%-17.06%.Finally,the temperature rate curve was analyzed,and a three-stage mechanism for internal thermal runaway propagation was proposed.In Stage I,convective heat transfer from electrolyte evaporation locally increased the temperature to 100℃.In Stage II,solid heat transfer locally increases the temperature to trigger thermal runaway.In StageⅢ,thermal runaway sharply increases the local temperature.The proposed mechanism sheds light on the internal thermal runaway propagation of blade batteries and offers valuable insights into safety considerations for future design.

关键词： Lithium-ion battery Blade battery Thermal runaway Internal thermal runaway propagation

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Key Technologies and Prospects for Electric Vehicles Within Emerging Power Systems: Insights from Five Aspects

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CSEE Journal of Power and Energy Systems 2024年第2期10卷 439-447页

作者： Yalun Li minggao ouyang C.C.Chan Xueliang Sun Yonghua Song Wei Cai Yilin Xie Yuqiong Mao Department of Electrical Engineering and School of Vehicle and MobilityTsinghua UniversityBeijing 100084China School of Vehicle and Mobility Tsinghua UniversityBeijing 100084China Department of Electrical and Electronic Engineering The University of Hong KongHong Kong 999077China Department of Mechanical and Materials Engineering University of Western OntarioLondonON N6A 3K7Canada State Key Laboratory of Internet of Things for Smart City University of MacaoTaipaMacao 999078China Department of Electrical Engineering Tsinghua UniversityBeijing 100084China School of Electrical and Electronic Engineering Harbin University of Science and TechnologyHarbin 150080China

The energy revolution requires coordination in energy consumption, supply, storage and institutional systems.Renewable energy generation technologies, along with their associated costs, are already fully equipped for large-scale promotion.However, energy storage remains a bottleneck, and solutions areneeded through the use of electric vehicles, which traditionallyplay the role of energy consumption in power systems. Toclarify the key technologies and institutions that support EVsas terminals for energy use, storage, and feedback, the CSEEJPES forum assembled renowned experts and scholars in relevantfields to deliver keynote reports and engage in discussions ontopics such as vehicle–grid integration technology, advancedsolid-state battery technology, high-performance electric motortechnology, and institutional innovation in the industry chain.These experts also provided prospects for energy storage andutilization technologies capable of decarbonizing new powersystems.

关键词： Electric vehicles engineering philosophy highpower density motor new power system solid state batteries vehicle grid integration.

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Effect of preload forces on multidimensional signal dynamic behaviours for battery early safety warning

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Journal of Energy Chemistry 2024年第5期92卷 484-498页

作者： Kuijie Li Jiahua Li Xinlei Gao Yao Lu Depeng Wang Weixin Zhang Weixiong Wu Xuebing Han Yuan-cheng Cao Languang Lu Jinyu Wen Shijie Cheng minggao ouyang School of Electrical and Electronic Engineering Huazhong University of Science and TechnologyWuhan 430074HubeiChina State Key Laboratory of Automotive Safety and Energy Tsinghua UniversityBeijing 100084China Energy and Electricity Research Center Jinan UniversityZhuhai 519070GuangdongChina Department of Mechanical Engineering Imperial College LondonLondon.SW7:2AZ.UK

Providing early safety warning for batteries in real-world applications is challenging.In this study,comprehensive thermal abuse experiments are conducted to clarify the multidimensional signal evolution of battery failure under various preload forces.The time-sequence relationship among expansion force,voltage,and temperature during thermal abuse under five categorised stages is revealed.Three characteristic peaks are identified for the expansion force,which correspond to venting,internal short-circuiting,and thermal runaway.In particular,an abnormal expansion force signal can be detected at temperatures as low as 42.4°C,followed by battery thermal runaway in approximately 6.5 min.Moreover,reducing the preload force can improve the effectiveness of the early-warning method via the expansion force.Specifically,reducing the preload force from 6000 to 1000 N prolongs the warning time(i.e.,227 to 398 s)before thermal runaway is triggered.Based on the results,a notable expansion force early-warning method is proposed that can successfully enable early safety warning approximately 375 s ahead of battery thermal runaway and effectively prevent failure propagation with module validation.This study provides a practical reference for the development of timely and accurate early-warning strategies as well as guidance for the design of safer battery systems.

关键词： Lithium-ion battery Thermal runaway Preload force Expansionforce Early warning Multidimensional signal

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Torque-based Optimal Acceleration Control for Electric Vehicle

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Chinese Journal of Mechanical Engineering 2014年第2期27卷 319-330页

作者： LU Dongbin ouyang minggao State Key Laboratory of Automotive Safety and Energy Tsinghua University

The existing research of the acceleration control mainly focuses on an optimization of the velocity trajectory with respect to a criterion formulation that weights acceleration time and fuel consumption. The minimum-fuel acceleration problem in conventional vehicle has been solved by Pontryagin＇s maximum principle and dynamic programming algorithm, respectively. The acceleration control with minimum energy consumption for battery electric vehicle（EV） has not been reported. In this paper, the permanent magnet synchronous motor（PMSM） is controlled by the field oriented control（FOC） method and the electric drive system for the EV（including the PMSM, the inverter and the battery） is modeled to favor over a detailed consumption map. The analytical algorithm is proposed to analyze the optimal acceleration control and the optimal torque versus speed curve in the acceleration process is obtained. Considering the acceleration time, a penalty function is introduced to realize a fast vehicle speed tracking. The optimal acceleration control is also addressed with dynamic programming（DP）. This method can solve the optimal acceleration problem with precise time constraint, but it consumes a large amount of computation time. The EV used in simulation and experiment is a four-wheel hub motor drive electric vehicle. The simulation and experimental results show that the required battery energy has little difference between the acceleration control solved by analytical algorithm and that solved by DP, and is greatly reduced comparing with the constant pedal opening acceleration. The proposed analytical and DP algorithms can minimize the energy consumption in EV＇s acceleration process and the analytical algorithm is easy to be implemented in real-time control.

关键词： permanent magnet synchronous motor（PMSM） field oriented control（FOC） efficiency model electric vehicle energy optimal acceleration

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Influence of Tire Dynamics on Slip Ratio Estimation of Independent Driving Wheel System

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Chinese Journal of Mechanical Engineering 2014年第6期27卷 1203-1210页

作者： LI Jianqiu SONG Ziyou WEI Yintao ouyang minggao State Key Laboratory of Automotive Safety and Energy Tsinghua University

The independent driving wheel system, which is composed of in-wheel permanent magnet synchronous motor（I-PMSM） and tire, is more convenient to estimate the slip ratio because the rotary speed of the rotor can be accurately measured. However, the ring speed of the tire ring doesn’t equal to the rotor speed considering the tire deformation. For this reason, a deformable tire and a detailed I-PMSM are modeled by using Matlab/Simulink. Moreover, the tire/road contact interface（a slippery road） is accurately described by the non-linear relaxation length-based model and the Magic Formula pragmatic model. Based on the relatively accurate model, the error of slip ratio estimated by the rotor rotary speed is analyzed in both time and frequency domains when a quarter car is started by the I-PMSM with a definite target torque input curve. In addition, the natural frequencies（NFs） of the driving wheel system with variable parameters are illustrated to present the relationship between the slip ratio estimation error and the NF. According to this relationship, a low-pass filter, whose cut-off frequency corresponds to the NF, is proposed to eliminate the error in the estimated slip ratio. The analysis, concerning the effect of the driving wheel parameters and road conditions on slip ratio estimation, shows that the peak estimation error can be reduced up to 75% when the LPF is adopted. The robustness and effectiveness of the LPF are therefore validated. This paper builds up the deformable tire model and the detailed I-PMSM models, and analyzes the effect of the driving wheel parameters and road conditions on slip ratio estimation.

关键词： electric vehicle （EV） driving wheel system tire dynamics slip ratio estimation characteristic frequency low-pass filter （LPF）

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Interaction of In-wheel Permanent Magnet Synchronous Motor with Tire Dynamics

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Chinese Journal of Mechanical Engineering 2015年第3期28卷 470-478页

作者： SONG Ziyou LI Jianqiu WEI Yintao XU Liangfei ouyang minggao State Key Laboratory of Automotive Safety and Energy Tsinghua University

Drive wheel systems combined with the in-wheel permanent magnet synchronous motor（I-PMSM） and the tire are highly electromechanical-coupled. However, the deformation dynamics of this system, which may influence the system performance, is neglected in most existing literatures. For this reason, a deformable tire and a detailed I-PMSM are modeled using Matlab/Simulink. Furthermore, the influence of tire/road contact interface is accurately described by the non-linear relaxation length-based model and magic formula pragmatic model. The drive wheel model used in this paper is closer to that of a real tire in contrast to the rigid tire model which is widely used. Based on the near-precise model mentioned above, the sensitivity of the dynamic tire and I-PMSM parameters to the relative error of slip ratio estimation is analyzed. Additionally, the torsional and longitudinal vibrations of the drive wheel are presented both in time and frequency domains when a quarter vehicle is started under conditions of a specific torque curve, which includes an abrupt torque change from 30 N·m to 200 N·m. The parameters sensitivity on drive wheel vibrations is also studied, and the parameters include the mass distribution ratio of tire, the tire torsional stiffness, the tire damping coefficient, and the hysteresis band of the PMSM current control algorithm. Finally, different target torque curves are compared in the simulation, which shows that the estimation error of the slip ratio gets violent, and the longitudinal force includes more fluctuation components with the increasing change rate of the torque. This paper analyzes the influence of the drive wheel deformation on the vehicle dynamic control, and provides useful information regarding the electric vehicle traction control.

关键词： I-PMSM,tire dynamics,slip ratio estimation,tire torsional vibrations,longitudinal vibrations

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Vehicle survival patterns in China

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Science China(Technological Sciences) 2011年第3期54卷 625-629页

作者： HAO Han WANG HeWu ouyang minggao CHENG Fei State Key Laboratory of Automotive Safety and Energy Tsinghua University Beijing 100084 China China Automotive Energy Research Center (CAERC) Tsinghua University Beijing 100084 China

The vehicle survival pattern describes the process that the survival ratio of vehicles decreases with the growth of vehicle age. Vehicle average life span and vehicle scrappage intensity are the key features of vehicle survival patterns and are important for the projection of China's vehicle scrappage and ownership. In this study, we modeled the vehicle survival patterns of nine classifications of vehicles in China by employing the Weibull distribution, and obtained the vehicle survival ratio functions. It is estimated that the average life spans of private passenger vehicles, government and business vehicles, non-operating buses, heavy duty, medium duty and light duty trucks are 14.5, 13.1, 11.5, 12.8, 10.1, and 8 years, respectively. The scrappage intensities of these vehicles are similar. Average life spans of taxis, transit buses and non-transit operating buses are 5, 9, and 5.5 years with the pattern of mandatory scrappage. Vehicle scrappages in China are mainly regulated by the upper limits of vehicle distances traveled specified by the compulsory scrappage standards.

关键词：生存模式汽车报废中国 Weibull分布报废车辆平均寿命汽车分类客运车辆

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Driving and Braking Control of PM Synchronous Motor Based on Low-resolution Hall Sensor for Battery Electric Vehicle

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Chinese Journal of Mechanical Engineering 2013年第1期26卷 1-10页

作者： GU Jing ouyang minggao LI Jianqiu LU Dongbin FANG Chuan MA Yan State Key Laboratory of Automotive Safety and Energy Tsinghua University

Resolvers are normally employed for rotor positioning in motors for electric vehicles, but resolvers are expensive and vulnerable to vibrations. Hall sensors have the advantages of low cost and high reliability, but the positioning accuracy is low. Motors with Hall sensors are typically controlled by six-step commutation algorithm, which brings high torque ripple. This paper studies the high-performance driving and braking control of the in-wheel permanent magnetic synchronous motor （PMSM） based on low-resolution Hall sensors. Field oriented control （FOC） based on Hall-effect sensors is developed to reduce the torque ripple. The positioning accuracy of the Hall sensors is improved by interpolation between two consecutive Hall signals using the estimated motor speed. The position error from the misalignment of the Hall sensors is compensated by the precise calibration of Hall transition timing. The braking control algorithms based on six-step commutation and FOC are studied. Two variants of the six-step commutation braking control, namely, half-bridge commutation and full-bridge commutation, are discussed and compared, which shows that the full-bridge commutation could better explore the potential of the back electro-motive forces （EMF）, thus can deliver higher efficiency and smaller current ripple. The FOC braking is analyzed with the phasor diagrams. At a given motor speed, the motor turns from the regenerative braking mode into the plug braking mode if the braking torque exceeds a certain limit, which is proportional to the motor speed. Tests in the dynamometer show that a smooth control could be realized by FOC driving control and the highest efficiency and the smallest current ripple could be achieved by FOC braking control, compared to six-step commutation braking control. Therefore, FOC braking is selected as the braking control algorithm for electric vehicles. The proposed research ensures a good motor control performance while maintaining low cost and high reliability.

关键词： battery electric vehicle field oriented control low-resolution Hall sensor regenerative braking plug braking,six-step commutation braking

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Rule-based Fault Diagnosis of Hall Sensors and Fault-tolerant Control of PMSM

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Chinese Journal of Mechanical Engineering 2013年第4期26卷 813-822页

作者： SONG Ziyou LI Jianqiu ouyang minggao GU Jing FENG Xuning LU Dongbin State Key Laboratory of Automotive Safety and Energy Tsinghua University

Hall sensor is widely used for estimating rotor phase of permanent magnet synchronous motor(PMSM). And rotor position is an essential parameter of PMSM control algorithm, hence it is very dangerous if Hall senor faults occur. But there is scarcely any research focusing on fault diagnosis and fault-tolerant control of Hall sensor used in PMSM. From this standpoint, the Hall sensor faults which may occur during the PMSM operating are theoretically analyzed. According to the analysis results, the fault diagnosis algorithm of Hall sensor, which is based on three rules, is proposed to classify the fault phenomena accurately. The rotor phase estimation algorithms, based on one or two Hall sensor(s), are initialized to engender the fault-tolerant control algorithm. The fault diagnosis algorithm can detect 60 Hall fault phenomena in total as well as all detections can be fulfilled in 1/138 rotor rotation period. The fault-tolerant control algorithm can achieve a smooth torque production which means the same control effect as normal control mode (with three Hall sensors). Finally, the PMSM bench test verifies the accuracy and rapidity of fault diagnosis and fault-tolerant control strategies. The fault diagnosis algorithm can detect all Hall sensor faults promptly and fault-tolerant control algorithm allows the PMSM to face failure conditions of one or two Hall sensor(s). In addition, the transitions between health-control and fault-tolerant control conditions are smooth without any additional noise and harshness. Proposed algorithms can deal with the Hall sensor faults of PMSM in real applications, and can be provided to realize the fault diagnosis and fault-tolerant control of PMSM.

关键词： electric vehicle permanent-magnet synchronous motor(PMSM) Hall sensors rule-based fault diagnosis fault-tolerant control

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Progress review of US-China joint research on advanced technologies for plug-in electric vehicles

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Science China(Technological Sciences) 2018年第10期61卷 1431-1445页

作者： ouyang minggao DU JiuYu PENG Huei WANG HeWu FENG XuNing SONG ZiYou State Key Laboratory of Automotive Safety and Energy Tsinghua University University of Michigan Mechanical Engineering

The United States and China are the world's largest automobile markets and oil consumers, and both face a severe challenge to conserve energy and reduce tailpipe emissions. Thus, both countries urgently need to transform conventional internal combustion engines to electrified powertrains. Targeting the advanced core technologies of plug-in electric vehicles(PEVs), a joint research collaboration between China and the US, called the "Clean Vehicle Consortium"(CVC), was set up in 2010. Six years of collaboration on PEV technologies has resulted in significant progress in three technical areas. Based on CVC publications,we review herein the progress made by the CVC research efforts on three key advanced PEV technologies. This includes the development of a safe battery with an energy density of 260 W h kg^(-1) and a systematic method for designing safe traction battery systems. Thus, a breakthrough in high power density and efficient traction motor systems has occurred. In addition to discussing advanced electric-drive powertrains, we also discuss global energy management strategies that aim to improve PEV energy efficiency. This discussion covers scientific and comprehensive analysis methods to analyze energy systems, which include costbenefit analyses of plug-in hybrid electric vehicles, life-cycle assessments for evaluating vehicle emissions, and PEV-ownership projections.

关键词：车辆技术中国插件美国电池系统评论设计安全

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