Universität Stuttgart
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Item Open Access Comprehensive study of failure mechanisms of field-aged automotive lead batteries(2023) Conradt, Rafael; Schröer, Philipp; Dazer, Martin; Wirth, Jonathan; Jöris, Florian; Schulte, Dominik; Birke, Kai PeterModern vehicles have increasing safety requirements and a need for reliable low-voltage power supply in their on-board power supply systems. Understanding the causes and probabilities of failures in a 12 V power supply is crucial. Field analyses of aged and failed 12 V lead batteries can provide valuable insights regarding this topic. In a previous study, non-invasive electrical testing was used to objectively determine the reasons for failure and the lifetime of individual batteries. By identifying all of the potential failure mechanisms, the Latin hypercube sampling method was found to effectively reduce the required sample size. To ensure sufficient confidence in validating diagnostic algorithms and calculating time-dependent failure rates, all identified aging phenomena must be considered. This study presents a probability distribution of the failure mechanisms that occur in the field, as well as provides insights into potential opportunities, but it also challenges diagnostic approaches for current and future vehicles.Item Open Access Analytic free-energy expression for the 2D-Ising model and perspectives for battery modeling(2023) Markthaler, Daniel; Birke, Kai PeterAlthough originally developed to describe the magnetic behavior of matter, the Ising model represents one of the most widely used physical models, with applications in almost all scientific areas. Even after 100 years, the model still poses challenges and is the subject of active research. In this work, we address the question of whether it is possible to describe the free energy A of a finite-size 2D-Ising model of arbitrary size, based on a couple of analytically solvable 1D-Ising chains. The presented novel approach is based on rigorous statistical-thermodynamic principles and involves modeling the free energy contribution of an added inter-chain bond DAbond(b, N) as function of inverse temperature b and lattice size N. The identified simple analytic expression for DAbond is fitted to exact results of a series of finite-size quadratic N N-systems and enables straightforward and instantaneous calculation of thermodynamic quantities of interest, such as free energy and heat capacity for systems of an arbitrary size. This approach is not only interesting from a fundamental perspective with respect to the possible transfer to a 3D-Ising model, but also from an application-driven viewpoint in the context of (Li-ion) batteries where it could be applied to describe intercalation mechanisms.Item Open Access Modeling and experimental investigation of the interaction between pressure-dependent aging and pressure development due to the aging of lithium-ion cells(2023) Avdyli, Arber; Fill, Alexander; Birke, Kai PeterIn order to meet the increasing demands of the battery in terms of range, safety and performance, it is necessary to ensure optimal operation conditions of a lithium-ion cell. In this thesis, the influence of mechanical boundary conditions on the cell is investigated theoretically and experimentally. First, fundamental equations are derived that lead to coupled models that can be parameterized based on specific cell measurements and predict the pressure evolution due to capacity aging and vice versa. The model is used to derive optimal operating points of the cell, which can be considered in the module design.Item Open Access A performance and cost overview of selected solid-state electrolytes : race between polymer electrolytes and inorganic sulfide electrolytes(2021) Karabelli, Duygu; Birke, Kai Peter; Weeber, MaxElectrolytes are key components in electrochemical storage systems, which provide an ion-transport mechanism between the cathode and anode of a cell. As battery technologies are in continuous development, there has been growing demand for more efficient, reliable and environmentally friendly materials. Solid-state lithium ion batteries (SSLIBs) are considered as next-generation energy storage systems and solid electrolytes (SEs) are the key components for these systems. Compared to liquid electrolytes, SEs are thermally stable (safer), less toxic and provide a more compact (lighter) battery design. However, the main issue is the ionic conductivity, especially at low temperatures. So far, there are two popular types of SEs: (1) inorganic solid electrolytes (InSEs) and (2) polymer electrolytes (PEs). Among InSEs, sulfide-based SEs are providing very high ionic conductivities (up to 10−2 S/cm) and they can easily compete with liquid electrolytes (LEs). On the other hand, they are much more expensive than LEs. PEs can be produced at less cost than InSEs but their conductivities are still not sufficient for higher performances. This paper reviews the most efficient SEs and compares them in terms of their performances and costs. The challenges associated with the current state-of-the-art electrolytes and their cost-reduction potentials are described.Item Open Access Impedance based temperature estimation of lithium ion cells using artificial neural networks(2021) Ströbel, Marco; Pross-Brakhage, Julia; Kopp, Mike; Birke, Kai PeterItem Open Access Pressure characteristics and chemical potentials of constrained LiFePO4/C6 cells(2018) Singer, Jan Patrick; Kropp, Timo; Kuehnemund, Martin; Birke, Kai PeterConstraining lithium-ion cells increases the cyclic lifetime. However, depending on an expected volume expansion during charge and discharge cycling, defining the optimal constraining pressure range is not straightforward. In this study, we investigate a lithium iron phosphate/graphite pouch cell at four initial constraining pressure levels. As a function of C-Rate, the thermodynamic principle of the non-monotonic pressure curve during full charge and discharge cycles is evaluated. Using the rubber balloon model to calculate the chemical potential of lithium iron phosphate and discussing the relationship between the chemical potential and pressure, we illustrate the pressure curve qualitatively. By applying differential pressure analysis, we evaluate the resulting pressure curves of a single graphite stage. Approaching a fundamental understanding of reduced cycling lifetime of full cells with unknown material composition, we allocate the stages and stage transitions of graphite as well as the phase transition of lithium iron phosphate. Local extreme values in the differential pressure analysis indicate phase and stage transitions. These values can identify critical operating conditions that should be considered for defining the optimum initial constraining pressure range.Item Open Access Non-uniform circumferential expansion of cylindrical Li-ion cells - the potato effect(2021) Hemmerling, Jessica; Guhathakurta, Jajnabalkya; Dettinger, Falk; Fill, Alexander; Birke, Kai PeterThis paper presents the non-uniform change in cell thickness of cylindrical Lithium (Li)-ion cells due to the change of State of Charge (SoC). Using optical measurement methods, with the aid of a laser light band micrometer, the expansion and contraction are determined over a complete charge and discharge cycle. The cell is rotated around its own axis by an angle of α=10° in each step, so that the different positions can be compared with each other over the circumference. The experimental data show that, contrary to the assumption based on the physical properties of electrode growth due to lithium intercalation in the graphite, the cell does not expand uniformly. Depending on the position and orientation of the cell coil, there are different zones of expansion and contraction. In order to confirm the non-uniform expansion around the circumference of the cell in 3D, X-ray computed tomography (CT) scans of the cells are performed at low and at high SoC. Comparison of the high resolution 3D reconstructed volumes clearly visualizes a sinusoidal pattern for non-uniform expansion. From the 3D volume, it can be confirmed that the thickness variation does not vary significantly over the height of the battery cell due to the observed mechanisms. However, a slight decrease in the volume change towards the poles of the battery cells due to the higher stiffness can be monitored.Item Open Access Optimization of disassembly strategies for electric vehicle batteries(2021) Baazouzi, Sabri; Rist, Felix Paul; Weeber, Max; Birke, Kai PeterVarious studies show that electrification, integrated into a circular economy, is crucial to reach sustainable mobility solutions. In this context, the circular use of electric vehicle batteries (EVBs) is particularly relevant because of the resource intensity during manufacturing. After reaching the end-of-life phase, EVBs can be subjected to various circular economy strategies, all of which require the previous disassembly. Today, disassembly is carried out manually and represents a bottleneck process. At the same time, extremely high return volumes have been forecast for the next few years, and manual disassembly is associated with safety risks. That is why automated disassembly is identified as being a key enabler of highly efficient circularity. However, several challenges need to be addressed to ensure secure, economic, and ecological disassembly processes. One of these is ensuring that optimal disassembly strategies are determined, considering the uncertainties during disassembly. This paper introduces our design for an adaptive disassembly planner with an integrated disassembly strategy optimizer. Furthermore, we present our optimization method for obtaining optimal disassembly strategies as a combination of three decisions: (1) the optimal disassembly sequence, (2) the optimal disassembly depth, and (3) the optimal circular economy strategy at the component level. Finally, we apply the proposed method to derive optimal disassembly strategies for one selected battery system for two condition scenarios. The results show that the optimization of disassembly strategies must also be used as a tool in the design phase of battery systems to boost the disassembly automation and thus contribute to achieving profitable circular economy solutions for EVBs.Item Open Access A high frequency alternating current heater using the advantages of a damped oscillation circuit for low voltage Li-ion batteries(2024) Oehl, Joachim; Gleiter, Andreas; Manka, Daniel; Fill, Alexander; Birke, Kai PeterIn many cases, batteries used in light e-mobility vehicles such as e-bikes and e-scooters do not have an active thermal management system. This poses a challenge when these batteries are stored in sub-zero temperatures and need to be charged. In such cases, it becomes necessary to move the batteries to a warmer location and allow them to acclimatize before charging. However, this is not always feasible, especially for batteries installed permanently in vehicles. In this work, we present an internal high-frequency AC heater for a 48 V battery, which is used for light electric vehicles of EU vehicle classes L1e and L3e-A1 for a power supply of up to 11 kW. We have taken advantage of the features of a damped oscillating circuit to improve the performance of the heater. Additionally, only a small inductor was added to the main current path through a cable with three windings. Furthermore, as the power electronics of the heater is part of the battery main switch, fewer additional parts inside the battery are required and therefore a cost and space reduction compared to other heaters is possible. For the chosen setup we reached a heating rate of up to 2.13 K min -1 and it was possible to raise the battery temperature from -10 °C to 10 °C using only 3.1% of its own usable capacity.Item Open Access Comparison of aqueous- and non-aqueous-based binder polymers and the mixing ratios for Zn//MnO2 batteries with mildly acidic aqueous electrolytes(2021) Fitz, Oliver; Ingenhoven, Stefan; Bischoff, Christian; Gentischer, Harald; Birke, Kai Peter; Saracsan, Dragos; Biro, DanielConsidering the literature for aqueous rechargeable Zn//MnO2 batteries with acidic electrolytes using the doctor blade coating of the active material (AM), carbon black (CB), and binder polymer (BP) for the positive electrode fabrication, different binder types with (non-)aqueous solvents were introduced so far. Furthermore, in most of the cases, relatively high passive material (CB+BP) shares ~30 wt% were applied. The first part of this work focuses on different selected BPs: polyacrylonitrile (PAN), carboxymethyl cellulose (CMC), styrene butadiene rubber (SBR), cellulose acetate (CA), and nitrile butadiene rubber (NBR). They were used together with (non-)aqueous solvents: DI-water, methyl ethyl ketone (MEK), and dimethyl sulfoxide (DMSO). By performing mechanical, electrochemical and optical characterizations, a better overall performance of the BPs using aqueous solvents was found in aqueous 2 M ZnSO4 + 0.1 M MnSO4 electrolyte (i.e., BP LA133: 150 mAh·g-1 and 189 mWh·g-1 @ 160 mA·g-1). The second part focuses on the mixing ratio of the electrode components, aiming at the decrease of the commonly used passive material share of ~30 wt% for an industrial-oriented electrode fabrication, while still maintaining the electrochemical performance. Here, the absolute CB share and the CB/BP ratio are found to be important parameters for an application-oriented electrode fabrication (i.e., high energy/power applications).