Electric Vehicles Emerging Technologies

LITHIUM-ION BATTERY FAILURE CAUSES

 

LITHIUM-ION BATTERY FAILURE CAUSES

LITHIUM-ION BATTERY FAILURE CAUSES

1. External short circuit and cell failure
2. Due to External pressure - Machanical damage
3. Internal short circuit - due to chemical reaction, high C-rate or manufacturing faults
4. Crush - by external cause - deformation of the cells
5. Effects of internal short circuit due to - Dendrit growth, Separator damage
6. Heat generation, Thermal abuse - Thermal Runway stage

LiBs are sensitive to high power charging (fast charging), a too high or too low operating temperature, and mechanical abuse which eventually leads to capacity fade, short-circuiting, and the hazard of thermal runaway. Mitigation strategies are critical to reducing the risk of failures in LiBs.

As a crucial problem for the large-scale application of lithium-ion batteries, the safety issue attracts many concerns from consumers and manufacturers.

The failure mechanism is still unclear for some specific abuse behaviors, especially the damage evolution in cells or battery systems during the long-term operation. Based on the failure mechanism, some parameters and features can be used as signals for fault diagnosis and electric management. Safety designs in cells and battery systems can be employed to avoid more damage induced by abuse behaviors.

EV Battery pack assembly line course Topic are not limited to the items below, more related to battery failure mechanism and protection will be considered:

1. Battery failure mechanism and modeling
2. Safety design
3. Fault diagnosis and prognosis
4. Thermal and electric managements for better safety
5. Advanced materials for improving intrinsic safety

degrade of battery pack cycle

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Lithium-ion Battery

 

Li-ion Cylindrical Battery Fabrication

Step 1 Electrode Sheet Preparation

1. Furnace: raw active material (Cathode & Anode)
2. Milling Machine: grind & normalize the sintered material
3. Mixer: mix active, conductive, and binder material into slurry under vacuum
4. Coater: apply layer(s) of slurry onto current collector and dry it with an attached heater
5. Rolling Press (calendar): compress the electrode to a desired thickness/density

Step 2 Cell Assembly

Winding Method

1. Slitting Machine: slit/cut electrode sheet to strips of desired size
2. Ultrasonic Welding Machine: joining of multi-layer electrodes, and/or tabs to collectors
3. Winding Machine: form layers of Anode, Separator, and Cathode into a cell core
4. Short-circuit Detector: test for integrity of the cell
5. Vacuum Oven: remove any moister within the cell

Step 3 Case Sealing

1. Spot Welding Machine: allow contact to be made from cell to bottom of case (grounding)
2. Grooving machine: create indent on the neck of case to allow for proper seal (after inserting the cell core)
3. Welding Machine: attach cell to cap (positive)
4. Electrolyte Filling: inject the case with electrolyte under suitable environment within glove box 
5. Sealing Machine (Crimper): align cap with the open end of case and seal case inside glove box under suitable environment 
6. Recommend: wrap the newly finished battery with heat-shrinkable PVC for isolation of positive and negative terminals
7. Battery Analyzer: charge/discharge the assembled battery for cell activation

Step 4 Battery Testing 

Battery Analyzer to test the battery’s performance and Resistance Tester to measure battery’s internal resistance 

Electric Vehicle and EV Lithium-ion Battery Training Courses 

EV EVSE Business Management Course for Entrepreneurs 

This Techno Commercial course: Throughout this training session, AEVT bridges the needs of startups so that candidate can understand the technology from basic of EV to EVSE equipment like Lithium-ion battery, Battery pack assembly process, EV Motor, Charger, charging station development and all others parts/ equipment's calculation, selection, building a Legal Foundation, Understanding Finance Basics, Business Planning and Fundraising.

Lithium Battery Pack Assembly course 

Lithium Battery Pack Assembly course will cover li-ion cell to battery characteristic's, different parameters, EV battery Pack design aspect, calculation, assembly line unit detailing with financial aspects ,govt guidelines ,policies etc.

Techno-Commercial Feasibility Report for startups

Electric Vehicle Charging Station Design, Installation

Certificate EV Charging Station Installer Training Program is a master courses that takes an Engineer, designe engineer, installer from site assessment, all the way through power-up and pinpointing. Installers who take this training will have all the information needed to efficiently and accurately assess, design and install charging stations.

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Electric vehicle charging per kilometre 60 paise

 

The Ministry of Power has previously announced new EV charging infrastructure standards and guidelines. In compliance with the rules, the state government has fixed the ceiling cost of service charges to be charged by electric vehicle public charging stations. It approved the Rs 12.06 + applicable GST service cost maximum for electric vehicle rates covered by State/Central subsidies.
it is still less expensive than petrol and diesel. “It costs Rs 300 if any four-wheeler takes 25 units to completely charge their cars.” “You can’t even get three litres of petrol with the same quantity of petrol,”

Car comparison between petrol, diesel and electric vehicles

If the price of petrol is considered at Rs 100 per litre and mileage is considered 16 km per litre, the cost of the car, per kilometre, will be about Rs 6.25.

If the price of diesel is considered at Rs 95 per litre and mileage is considered 22 km per litre, the cost of the car, per kilometre, will be around Rs 4.31. 

 Whereas, an electric vehicle requires 30.2 units of electricity on being full charged, therefore if we consider Rs. 6 per unit as the electricity cost then it would cost Rs 181.2 for getting charged fully and then it would run for about 300km. In this way, its cost per kilometre will be close to 60 paise.

 The cost of charging an electric vehicle (EV) in Mumbai would work out to Rs 15 per unit, according to the Brihanmumbai Municipal Corporation (BMC). As per their calculations, an electric car would take anywhere between 20 and 30 units to be fully charged and it would cost the user Rs 200 to Rs 400.

 In Delhi, the government has fixed Rs 4.5 per unit for low tension charging of e-vehicles and Rs 5 per unit for high tension EVs. There would be a service charge based on the charging facility also. So it would cost anywhere between Rs 120 and Rs 150 for a fully charged EV.

 As per the infrastructure guidelines set by the government, it is compulsory to set an EV Charging station at every 3km in cities and 25kms on Highways on both sides. For long-range and heavy-duty vehicles, there should be a charging station at every 100kms on both sides of the road (mostly Highways).

 

Cost of Setting Electric Charging Station in India

            Cost of setting EV charging station in India varies from Rs. 1 Lakh to Rs. 40 Lakhs depending on the types of chargers and investment one is willing to make. However, considering a broader scenario and a supply of 250KVA EV Station below is the estimate.

Charger Type	CCS – 60kW	CHAdeMO – 60kW	Type 2 AC – 7/22kW	Bharat DC-001 – GB/T	Bharat AC-001
Approximate Cost	12,50,000	12,50,000	1,00,000	2,40,000	60,000

 

• New Electricity Connection (250 KVA): 7,50,000 /-
• Civil Works: 2,50,000 /-
• EVSE Management Software + Integration: 40,000 /-
• Technicians, Manpower, Maintenance etc: 3,50,000 /- yearly
• Advertising and Promotion: 50,000 /-
• Land Lease (if the land is at lease): 6,00,000 /- yearly

Total Approximate: Rs. 40,00,000 /- (First year including setup and if the land is at lease)
Annual maintenance from the second year: Rs. 10,00,000 /- (Including land lease)

Minimum Infrastructure Requirement for EV Charging Station

1. A transformer with subsequent substation must be installed along with safety equipment
2. For the purpose of metering/ termination, there should be a 33/11KV Cable with related equipment.
3. Appropriate Civil works should be there
4. There should be adequate space for charging and Entry / Exit of Vehicles
5. Necessary local certifications, if any required. (Varies state to state)

Understanding the Business (Revenue Model)

        Revenue projections are something which we do not have control on. But we can assume a scenario and work out a feasible projection for the next 5 years.

If we take the above investment of Rs. 40 Lakhs, we get approximate of 500-1000 kWh per day EV power for consumption.