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We propose algorithms to speed up physics-based battery lifetime simulations by one to two orders of magnitude compared to the state-of-the-art. First, we propose a reformulation of the Single Particle Model with side reactions to remove algebraic equations and hence reduce stiffness, with 3x speed-up in simulation time (intra-cycle reformulation). Second, we introduce an algorithm that makes use of the difference between the “fast” timescale of battery cycling and the “slow” timescale of battery degradation by adaptively selecting and simulating representative cycles, skipping other cycles, and hence requires fewer cycle simulations to simulate the entire lifetime (adaptive inter-cycle extrapolation). This algorithm is demonstrated with a specific degradation mechanism but can be applied to various models of aging phenomena. In the particular case study considered, simulations of the entire lifetime are performed in under 5 s. This opens the possibility for much faster and more accurate model development, testing, and comparison with experimental data.

 

Accurate tracking of the internal electrochemical states of lithium-ion battery during cycling enables advanced battery management systems to operate the battery safely and maintain high performance while minimizing battery degradation. To this end, techniques based on voltage measurement have shown promise for estimating the lithium surface concentration of active material particles, which is an important state for avoiding aging mechanisms such as lithium plating. However, methods relying on voltage often lead to large estimation errors when the model parameters change during aging. In this paper, we utilize the in-situ measurement of the battery expansion to augment the voltage and develop an observer to estimate the lithium surface concentration distribution in each electrode particle. We demonstrate that the addition of the expansion signal enables us to correct the negative electrode concentration states in addition to the positive electrode. As a result, compared to a voltage only observer, the proposed observer can successfully recover the surface concentration when the electrodes' stoichiometric window changes, which is a common occurrence under aging by loss of lithium inventory. With a 5% shift in the electrodes' stoichiometric window, the results indicate a reduction in state estimation error for the negative electrode surface concentration. Under this simulated aged condition, the voltage based observer had 9.3% error as compared to the proposed voltage and expansion observer which had 0.1% error in negative electrode surface concentration. 

Li-ion battery internal short circuits are a major safety issue for electric vehicles, and can lead to serious consequences such as battery thermal runaway. An internal short can be caused by mechanical abuse, high temperature, overcharging, and lithium plating. The low impedance or hard internal short circuit is the most dangerous kind. The high internal current flow can lead to battery temperature increase, thermal runaway, and even explosion in a few seconds. Algorithms that can quickly detect such serious events with a high confidence level and which are robust to sensor noise are needed to ensure passenger safety. False positives are also undesirable as many thermal runaway mitigation techniques, such as activating pyrotechnic safety switches, would disable the vehicle. Conventional methods of battery internal short detection, including voltage and surface temperature based algorithms, work well for a single cell. However, these methods are difficult to apply in large scale battery packs with many parallel cells. In this study, we propose a new internal short detection method by using cell swelling information during the early stages of a battery heating caused by an internal short circuit. By measuring cell expansion force, higher confidence level detection can be achieved for an internal short circuit in an electric vehicle scale battery pack.