Design and Application of Battery Systems Ken Arnold r 4/21/00

(Primary and Secondary Cells)

The widespread use of primary (non-rechargeable) and secondary (rechargeable) batteries has resulted in a proliferation of battery designs, and the demand for higher performance energy storage. Recent advances in battery chemistry, such as metal hydride and Lithium ion cells, have increased the options available to the designer of energy storage systems. This diverse selection of battery technologies, coupled with improvements in manufacturing technology, power management, charging and control techniques, has increased the options available to the designer of energy storage systems. This seminar is intended to give the student a basic understanding of battery system design and application. The seminar covers two aspects of system design: battery chemistry and application design. The topics covered in the battery chemistry section include: chemical-energy storage theory, primary and secondary cell types, commercially available products, failure mechanisms, and safety considerations. Application design topics include system design requirements, maintenance, advanced charging techniques, performance optimization, support circuit design, fault condition handling, supervisory controls, and future trends in battery powered systems. Practical design examples are used to illustrate the concepts covered in the seminar.

After completing the seminar, the student will be able to specify the requirements for battery systems, select appropriate batteries, and design an integrated system from commercially available components.

Ken Arnold is President of HiTech Equipment Corporation, where he supervises the design and development of battery powered systems such as security systems, pagers, and communications devices employing primary and secondary energy storage systems. Mr. Arnold is an instructor of Electrical and Computer Engineering courses at the University of California at San Diego, Extended Studies, where he has instructed eight different courses since 1982. Mr. Arnold is also a member of several curriculum development committees at UCSD. Mr. Arnold is author of the text "Embedded Controller Design," as well as numerous papers. He is also listed in "Who's Who in California."

 

Design and Application of Battery Systems

 

PART I -- Battery Design and Characteristics

1 Introduction

Background

Terminology

History

Taxonomy

Primary vs. Secondary Cells

Chemistry

Performance

Maintenance

 

2 Basic Electrochemistry

Electrochemical Activity

Electrolytes

Electrodes

Anode and Cathode Discharge Reactions

Charging Reactions

Secondary Chemical Reactions

 

3 Primary and Secondary Cells

Primary Cells

Carbon/Manganese Dioxide Zinc

Alkaline

Lithium

Mercury

Silver

Zinc/Air

Secondary Cells

Lead Acid

Nickel Cadmium

Lithium

Metal Hydride

 

4 Mechanical Construction

Electrodes

Barriers

Safety Mechanisms

  

5 Examples of Commercially Available Batteries

Applications

Manufacturers

Comparative Performance

Capacity

Density

Life

Cost

Example Battery Designs

 

6 Wear-out & Failure Mechanisms

Operating Lifetime

Deep Discharge

High Temperature Charging

Over Charging

Failure Modes

Cell Reversal

Shorted electrodes

Recovery

Venting

Overcharge

Over Temperature

High Temperature Charging Effects

Charge "Memory"

 

7 Safety Aspects

Storage

Operating

Discharge

Charge

Venting

Hazardous Materials

Disposal

Recycling

 

 

PART II -- Battery Operated System Design and Application

1 Systems Design

Specifying the Storage System Requirements

Battery Technology Selection

Design Considerations

Supervisory Circuits

Applications

Examples

 

2 Simple Charging Circuits

Constant Voltage

Constant Current

Isolation from Charging Source

 

3 Maintenance and Charging

Operating Temperature Effects

Charging Temperature Effects

Parametric Variations

Manufacturing Variations

Operating Life Variations

 

4 Charge and Discharge Cycles

Discharge Rate vs. Capacity Interaction

Temperature Effects on Cell Capacity

Normal Charge

Trickle Charging

High Charge Rate

 

5 Theoretical vs. Practical Performance

Output Voltage

Capacity

Energy Capacity (energy/mass)

Volumetric Efficiency (energy/volume)

Peak Output Current Limitations

Maximum Charging Current Limitations

 

6 Power Conversion Circuits

Voltage Conversion

Voltage Inverters

Power Source & Load Switching

Switching Supply Designs

Circuit Design Tools and Methods

Applications

 

7 Advanced Charging Circuits and Algorithms

Constant Current - Constant Voltage

Cell Temperature

Negative dV/dt

Pulsed

Charge Discharge

Intelligent Charging

 

8 Fault Detection and Prevention

Deep Discharge

High Temperature Charging

Over Charging

Failure Modes

Fault Tolerance & Redundancy

 

9 Design Examples

Portable Phones and Computers

Energy Density

Outdoor Power Source

Security

Solar Array Requirements

Environmental Requirements

Hybrid Power Systems

Un-interruptible Power Supplies

 

10 Summary

Battery Chemistry

Selection Criteria

Making the Decision

Charging Systems

 

11 Future Trends

Battery Technology

Power Conversions

Market Demands