Battery Engineering Symposium

Building Better Batteries

28-29 January 2019


With new improvements in battery chemistries, battery engineers are working to create high-energy, cost-effective, and reliable batteries that fully utilize the battery’s chemistry. To achieve this goal, engineers must consider materials and cell engineering, mechanical, electrical, and thermal design and integration of packs, as well as output, safety, and durability of the key designs. Battery Engineering will bring together engineering representatives from top OEM companies, the battery supply chain, and top academic institutions to discuss the recent advancements in battery technology. This symposium will encompass both cell and pack engineering and how advancements in these areas are not only building better, but safer and more robust batteries.

Final Agenda

Monday, 28 January

8:00 Symposium Registration and Morning Coffee

BATTERY SAFETY

9:30 Chairperson’s Opening Remarks

Gregory Offer, PhD, Senior Lecturer, Mechanical Engineering, Imperial College London

9:35 Thermal Runaway Propagation in Li-Ion Batteries

Andreas Pfrang, PhD, Scientific Officer, Joint Research Centre, Directorate for Energy, Transport and Climate, European Commission

If thermal runaway occurs in a single cell inside battery assemblies, the heat generated typically cannot be easily dissipated and will lead to a temperature increase in adjacent cells. Such thermal runaway can cascade through the whole battery module or pack leading to significant heat and gas release. In this presentation, a model describing thermal runaway based on thermal data of reactions taking place in cells during thermal runaway is shown and thermal runaway initiation methods are compared. Finally, an overview of current standards on thermal propagation is given.

9:55 Calorimeters to Advance Thermal Management and Safety of Batteries

Carlos Ziebert, PhD, Head, Battery Safety Center, IAM-AWP, Karlsruhe Institute of Technology (KIT)

This talk will show how the calorimeters allow studying of the thermal runaway propagation to develop and qualify suitable countermeasures, such as heat protection barriers, which is currently becoming a very "hot topic." The acquired data are essential on all levels of the value chain, from safe design on materials level up to thermal management and adaptation of safety systems, or implementation into modelling and simulation tools.

10:15 Enhancing Cooling System Durability for Battery Packs and Fuel Cells

Michael Harenbrock, Business Development Manager, Mann+Hummel GmbH

Air and Liquid Cooling is required to keep Li Ion Battery Systems at the right temperature range to maintain system performance and to avoid system failure. The presentation will give an overview of the different cooling methods established – open and closed air cooling systems, direct and indirect cooling systems for battery systems. Failure modes caused by coolant contamination will be explained, and technical solutions for particle filtration, water adsorption and ion exchange will be highlighted.

10:35 Networking Coffee Break with Poster Viewing

11:05 Components to Improve Lithium Battery Safety

Peter Kritzer, PhD, Senior Application Manager, Sales Automotive, Freudenberg Sealing Technologies

The presentation will give an overview of products and approaches to improve battery safety. Beside cell separators, specially developed overpressure valves and heat shields, new concept ideas will be presented, which could improve battery safety on a higher level. Besides this, we will produce components enabling a reliable function of the batteries under normal operation.

11:25 Preventing Lithium Ion Battery Failure During High Temperatures by Externally Applied Compression

Gregory Offer, PhD, Senior Lecturer, Mechanical Engineering, Imperial College London

Lithium-ion cells can unintentionally be exposed to temperatures outside manufacturers' recommended limits without triggering a full thermal runaway event. The question addressed in this paper is: Are these cells still safe to use? In this study, externally applied compression has been employed to prevent lithium ion battery failure during such events.

DOW Corning(2)11:45 How Silicone Materials are Answering the Performance and Assembly Requirements of EV Battery Packs

Julien Richeton, PhD, Technical Service & Development Scientist, Dow Performance Silicones, Dow Silicones Deutschland GmbH

High-energy density, more compact batteries requires gap fillers with higher thermal conductivity but also higher flow to fill intricate geometry. Thanks to their highly-tunable properties, silicone materials are in a position to offer the right balance between a long-term performance and a simplified assembly process.

12:05 Q&A

12:30 Networking Lunch

PACK ENGINEERING

13:55 Chairperson’s Remarks

Wenzel Prochazka, Battery Manager, Battery Benchmarking Program, AVL List GmbH

14:00 Smart Sensing for Future Batteries

Yue Guo, PhD, Project Manager, Deputy Head, Energy Innovation Centre, WMG, The University of Warwick

A more effective battery thermal and structural deformation monitoring system by applying distributed optical fibre sensing techniques has been proposed and demonstrated in this paper, to meet the challenge hindering the mass adoption of lithium-ion or more advanced chemistries in future battery applications.

14:20 ANSYS Simulation Tools for Battery Development

Rolf Reinelt, PhD, Senior Application Engineer, Application Engineering, ANSYS Germany

ANSYS battery tools range from 3D field simulation (in CFD) to Reduced Order Model (ROM) extraction to system simulation. In particular it is possible to calculate the distribution of ohmic and electrochemistry sources in the battery. This allows us to accurately predict the temperature distributions in the battery and to assess the performance and durability. In our presentation we will give an overview of the underlying techniques and comprehensive system simulation methods for electric drivetrain and battery development.

14:40 Optimizing and Qualifying New Electrolyte Designs Faster with Advanced Analytics

Tal Sholklapper, PhD, CEO, Voltaiq

As global automotive OEMs race to electrify their fleets, there's a need for new electrolytes to enable safer, higher energy density batteries. In this presentation we will discuss how companies are putting together the data infrastructure and analytics environment that enables them to support electrification of the global automotive market.

15:00 Q&A

15:15 Refreshment Break with Poster Viewing

BENCHMARKING AND BMS

15:50 Chairperson’s Remarks

Wenzel Prochazka, Battery Manager, Battery Benchmarking Program, AVL List GmbH

15:55 Homogeneity of Lithium Analysis in Lithium-Ion Batteries – A Study on Half Cells, Full Cells and Parallel Connected Cells of the Tesla Model S 85

Friedrich Hust, Chief Engineer, Modelling, Analytics and Lifetime Prediction, RWTH-Aachen, Institut für Stromrichtertechnik und Elektrische Antriebe

In this work, the inhomogeneous distribution of lithium on the electrodes of lithium-ion batteries is assessed by analyzing the voltage response in half-cells, full-cells, and parallel connected cells. A set of experiments has been conducted ranging from differential voltage analysis to voltage relaxation measurements and electrochemical impedance spectroscopy. This submission summarizes the former stated experiments, derives and explains the theory of homogeneity of lithium distribution.

16:15 A Challenge of Reliable Circuit Protection in Automotive Applications

Liwu Wang, PhD, Director, Business Development, Sales & Marketing, AEM Components (USA), Inc.

This presentation highlights some potential safety concerns in circuit protection associated with EV applications. It demonstrates how advanced “Wire-in-Air” fuse technology could yield much more consistent and reliable performance. The newly developed solid, robust structure of CMF fuses assure the best safe power density in higher power applications.

16:35 Effective Battery Control Instead of Monitoring the Death of the Battery

Hans Harjung, CEO, e-moove GmbH

Monitoring and balancing is state-of-the-art in battery management (BMS) since decades. In fact, this means monitoring the death of the battery. Effective battery control (ebc) is controlling all cells according to their individual state-of-health (SoH) and aging parameters. This leads to a maximum lifetime and performance of the battery pack combined with highest safety.

16:55 Q&A

17:10 Welcome Reception with Poster Viewing

18:15 Dinner Tutorial Check-In*

20:30 Close of Day

Tuesday, 29 January

7:30 Symposium Registration and Morning Coffee

PACK ENGINEERING (CONT.)

8:30 Chairperson’s Opening Remarks

Uwe Wiedemann, PhD, Managing Director, Munich Electrification GmbH

8:35 BMS Technology and Cost

Uwe Wiedemann, PhD, Managing Director, Munich Electrification GmbH

8:55 Development of Cutting Edge Battery Packs Using Next-Generation Cell Chemistries

Wasim Sarwar, PhD, Senior Battery Systems Engineer, Williams Advanced Engineering

Williams Advanced Engineering is focused on the development of the world’s most power-dense and energy-dense batteries through the advancement and implementation of next-generation cell chemistries. This talk will explain how the design, monitoring and control of battery systems will evolve as we shift from typical transition-metal oxide, graphite + SiOx li-ion cells, to next-generation cells (Si-dominant anode & Semi-Solid-State Systems).

9:15 High Power and Safe Li-Metal Batteries Part II: The Forgotten Concept of Three-Phase Boundary

Slobodan Petrovic, PhD, Professor, XNRGI

The power loss in lithium batteries comes partially from poor electronic conduction and limited active surface area. A new electrode consisting of porous structure and silicon collector is used to enable effective and high-area three-phase boundary between active mass, electrolyte and electronic conductor.

CELL ENGINEERING

9:35 Digitalization as a Game Changer for Battery Cell and Battery Production

Kai Peter Birke, PhD, Electrical Engineering, University of Stuttgart

Many so-called developments in the field of Li-Ion battery cells and batteries still rely purely on trial and error. The reason is that some currently present battery cell production methods are extremely challenging to digitalize. Both new and modified production methods as well as digitalization can change the game and tremendously improve high volume production. However, digitalization counts on measurable values as well as a constant and optimized production flow. We will report and highlight examples of improving battery cell production by digitalization as well as sophisticated production flows.

9:55 Q&A

10:10 Grand Opening Coffee Break with Exhibit & Poster Viewing

11:00 Chairperson’s Remarks

Bob Spotnitz, PhD, President, Battery Design LLC

11:05 Roll-To-Roll Pre-Lithiation for Lithium Ion Battery Anodes

Jan Ronsmans, Technology Manager, Emerging Technologies, JSR Micro NV

This presentation will explain a new way for lithiation of lithium ion battery anodes. This method that can result in significant battery performance improvements and its applicability to an industrial mass manufacturing process is already demonstrated. The roll-to-roll pre-lithiation technique can be applied to a wide variety of anode materials and offers opportunities to reduce lithium ion battery manufacturing cost, such as excess loading of cathode due to low first-cycle efficiency of anode.

11:25 Next Generation of Primed Al/Cu Foils to Support the Battery Market Evolution

Thierry Dagron, Business Development Director, ARMOR Films for Batteries, ARMOR

In order to increase the energy density and cope with supply chain and safety regulations, most of the battery manufacturers look to develop nickel-rich cathodes, silicone-based anodes, higher voltages, water-based processes, etc. With such changes, new technical issues may occur at the interface between the electrode and the current collector. We demonstrate how primed current collectors (Al/Cu foils with a protective and conductive coating) solve these problems. ARMOR has developed specific primed Al/Cu foils for these new electro-chemistries. Benefits are longer cycle life, increased safety, fast charging, high power and energy density.

11:45 Continuous Mixing Process for LIB Electrode Slurries Contributes to Cost-Effective Cell Manufacturing

Philipp Stössel, PhD, Technologist Battery Solutions, Grinding & Dispersing, Bühler AG

The present production methods for lithium-ion battery (LIB) electrode slurries are largely based on batch processes. However, for the expected LIB market growth, especially in the automotive industry, these methods will no longer fulfill the requirements of the industry. Therefore, Bühler has developed a novel process based on a twin-screw mixer for fully continuous electrode slurry production. This process increases productivity per mixing line and eliminates batch-to-batch variations.

12:05 New Approaches in Battery Cell Production - From Standardization to Flexible and Agile Production Systems

Jürgen Fleischer, PhD, Manager, Machines, Equipment and Process Automation, Karlsruhe Institute of Technology

12:25 Q&A

12:40 Networking Lunch

13:55 Dessert Break with Exhibit & Poster Viewing

FAST CHARGING

14:40 Chairperson’s Remarks

Kevin Konecky, Battery Systems Consultant, Total Battery Consulting, Inc.

14:45 xEV Industry Trends of Charging & Battery Systems

Kevin Konecky, Battery Systems Consultant, Total Battery Consulting, Inc.

Lithium-ion battery systems are an enabling technology in the propagation of xEVs with longer range and higher-energy-density batteries. Further enabling public acceptance are convenient and time-effective charging options. This presentation will review many xEVs currently in production and discuss trends and diversity in the subsystem design choices that were implemented in each production system including charge capabilities. Different charging protocols and standards across the globe will be discussed with trends analyzed, as well as improvements to user convenience including faster DC-charging and wireless charging.

15:05 Charge Fast but Don’t Plate – How Validated Battery Models Can Solve the Dilemma

Michael Schoenleber, PhD, Co-Founder & CEO, Research & Development, Batemo GmbH

We will show that development time and effort can be drastically decreased by instead physically modelling a Lithium-Ion cell, proving the validity of the model in the whole operational range and subsequently using the model-predicted anode potential to investigate under which conditions Lithium-plating will start to occur. We will further show from that how charging strategies can be derived, that charge the battery truly as fast as possible while still avoiding Lithium-plating.

15:25 Presentation to be Announced

Peter Pichler, PhD, Manager, Samsung SDI Battery Systems

15:45 Electrical Parameters and Kinetics of Constrained Li-Ion Pouch Cells

Jan Singer, Electrical Energy Storage Systems, Institute for Photovoltaics, University of Stuttgart

Constraining Li-Ion pouch cells extends their cycling lifetime. The literature reports mechanical defects like delamination of the active material layers and localized deformation of the separator as well as surface film coverages on the anode as effects affecting the aging. Appling a light stack pressure on the electrodes housing helps to prevent the layer delamination. However, too high stack pressure accelerates the cyclic ageing due to enhanced delamination. In the first part of our presentation, we discuss the electrical parameters like internal cell resistances, usable capacity, coulombic and energy efficiency of constrained Lithium-ion pouch cells at different temperatures. The second part of the presentation provides the interfaces kinetics of constrained Lithium-ion pouch cells. We discuss tracking systems for battery stacks and look beyond possibilities for fast charging concepts using these tracking systems based on the electrical parameters and the kinetics of constrained Li-ion pouch cells.

16:05 Q&A

16:25 Networking Reception with Exhibit & Poster Viewing (Sponsorship Opportunity Available)

17:25 Dinner Tutorial Check-In*

17:25 Close of Day


Battery Packs

Battery Safety