Revolutionary Electric Vehicle Battery (REVB) - design and integration of novel state estimation/control algorithms & system optimisation techniques

Lead Research Organisation: Cranfield University
Department Name: Sch of Aerospace, Transport & Manufact

Abstract

The latest draft of the main application form (submitted by OXIS Energy on behalf of all collaborators) is attached. This
gives a fuller picture of the project, including detailed work package descriptions.
Cranfield's research is divided into six work packages:
WP CF1: High-Level Requirements Gathering
WP CF2: Architectural Design
WP CF3: Modelling and Estimation
WP CF4: Control and Optimization
WP CF5: Integration
WP CF6: Development of Reusable Software Tools
Detailed descriptions of each follow.
WP CF1: High-Level Requirements Gathering
In this work package, we will work with the other consortium members to determine the exact requirements that the
automotive battery pack needs to meet. We will understand the power requirements and other demands on the battery
system.
The ultimate end use of the technology would be in an electric vehicle. For the purpose of this project, the consortium is
planning to produce a hardware-in-the-loop 'technology demonstrator'. This will be developed by Lotus Engineering, and
Cranfield will use it to integrate and test state estimators and control algorithms. (The requirements for the hardware-in-the-loop simulator are directly analogous to those for a real electric vehicle, so we can be confident that our work has realworld
relevance.)
WP CF 2: Architectural Design
In this work package, we will work with one collaborator in particular (Lotus Engineering) to design the structure of the
demonstrator's Battery Energy Manager. (This is a computer control system that can be embedded in a vehicle, and we
will be using it to control the behaviour of the powertrain components.) We will first seek to understand Lotus's existing
controller in detail. After this, we will be able to produce detailed requirements for our controller and estimator, and then
design an architecture for it.
WP CF3: Modelling and Estimation
In this work package, we will develop low-order models of the battery suitable for embedding in the Battery Energy
Manager, and we will use these to design a novel state estimator that will give 'virtual measurements' for quantities that are
hard to measure directly. We will prepare an initial version of these in time to support Lotus's parallel software design
activities. We will then refine the algorithms, taking into account development in our collaborators' research activities.
The low-order models will also be used to design controllers in WP CP4.
WP CF4: Control and Optimization
In this work package, we will apply multi-objective system optimization techniques to the driveline as a whole. We will also
use advanced control techniques to develop a novel control algorithm for the Battery Energy Manager. We will prepare
initial versions of these in time to support Lotus's parallel software design activities. We will then refine the algorithms,
taking into account development in our collaborators' research activities.
WP CF5: Integration
In this work package, we will support Lotus as they integrate our estimation and control algorithms into their Battery Energy
Manager and hardware-in-the-loop technology demonstrator. We will simulate the behaviour in a virtual environment,
modify the algorithms if needed, and then support integration on the hardware-in-the-loop technology demonstrator itself.
WP CF6: Development of Reusable Software Tools
In this work package, we will take the software tools we develop in earlier work packages, and develop them to make them
robust enough to be useful to others who wish to apply similar techniques. (We will distribute our tools over the WWW.)

Planned Impact

The UK battery industry will benefit from the availability of the new technologies since it will be able to license the new
battery chemistry, and purchase cells manufactured using it. These are expected to be better value than current
technology, which will make UK suppliers more competitive. Given short development times in the industry, this will be
possible immediately.

The UK automotive sector will benefit from the knowledge gained during this exercise. The new technologies will make
electric vehicles more practicable. Having a knowledge-base in the UK will make it easy for UK automotive suppliers to
exploit these technologies, and therefore make them more competitive. Given short development times in the industry, this
will be possible immediately.
The technologies will contribute to the UK's commitments to transition to clean technologies: good automotive batteries are
a vital enabling technology for clean vehicles. The project will make clean vehicles more affordable, and therefore support
the UK's efforts to reduce CO2 emissions from motoring. This will begin to have an effect within a few years.

Publications

10 25 50
 
Description Lithium-sulfur (Li-S) batteries offer extreme light weight, which is very helpful for applications where weight (rather than, say, space) is the dominating constraint. Examples of applications where this can be important are light goods vehicle and buses, aircraft and marine vessels. Unfortunately, Li-S batteries are more difficult to monitor and operate than most other types: this is because there is not a straightforward relationship between the output voltage and the state of charge (i.e. remaining energy) in the battery; you cannot simply measure the total charge throughput, either, as Li-S batteries have a temporary 'history effects'. In the past, the only solution was to 'play it safe' and only partially discharge the batteries, but we have developed new methods that get round the problem.

We developed new models of the Li-S batteries using Equivalent Circuit Network (ECN) models, and we used these to develop two sets of algorithms virtual measurement of the remaining useful charge. One set was based on control theory, using techniques like the extended Kalman filter; the other set used a technique from computer science called the Adaptive Neuro-Fuzzy Interence System (ANFIS). We developed these in a laboratory setting using real Li-S cells and replicating driving conditions accurately. Both sets of algorithms were successful, and ran in real-time. We helped one of the industrial partners transfer one of our algorithms to their own battery management system computer.

We have also published the first reusable lithium-sulfur software models, which we made available for free through the MATLAB File Exchange from MathWorks.

We also began to do work on another set of models, based on fast electrochemical models, though we did not complete these during the timeframe of the project.
Exploitation Route Anyone wanting to use lithium-sulfur (Li-S) batteries will need a battery management system, and our algorithms could be a key part of this. Without our algorithms (or something equivalent), the benefits of Li-S are reduced; with our algorithms, the benefits can be realized.

At the time the project finished, there were still electrochemical issues that needed
ithium-sulfur (Li-S) batteries offer extreme light weight, which is very helpful for applications where weight (rather than, say, space) is the dominating constraint. Examples of applications where this can be important are light goods vehicle and buses, aircraft and marine vessels. The techniques we use will be reusable by automotive OEMs and suppliers.

One of the industrial partners is already working to deploy our algorithms. In addition, we are able to support potential collaborators through shared research and/or consultancy.
Sectors Aerospace, Defence and Marine,Electronics,Energy,Environment,Transport

 
Description The algorithms we developed have been used in further R&D work by several industrial partners from UK and EU, looking at hybrid electric passenger cars, buses, and high-altitude pseudo satellites. The algorithms have been incorporated into prototype Battery Management System (BMS) computers as part of developmental testing and product design. This work is continuing, and growing in maturity. As of 2021, practical realisation in marine and aerospace applications is very close. In all cases, these have supported the development of potential UK exports, as the cell developer(s) are UK-based.
First Year Of Impact 2017
Sector Aerospace, Defence and Marine,Transport
Impact Types Societal,Economic

 
Description Hosted a visiting student from a European university
Geographic Reach Europe 
Policy Influence Type Influenced training of practitioners or researchers
Impact Hosted a visiting PhD fellow from Aalborg university, transferring expertise in lithium-sulfur battery state estimation - with transferrable knowledge to batteries in general.
 
Description MSc research projects related to the REVB project
Geographic Reach Multiple continents/international 
Policy Influence Type Influenced training of practitioners or researchers
Impact From the REVB project, we were able to create opportunities for MSc researchers through individual research projects. These researchers came from an international background and are now working in various countries.
 
Description (ALISE) - Advanced Lithium Sulphur battery for xEV
Amount € 6,852,301 (EUR)
Funding ID 666157 
Organisation European Commission 
Sector Public
Country European Union (EU)
Start 06/2015 
End 05/2019
 
Description Aerospace Technology Institute - Strategic Research and Development Projects
Amount £3,644,446 (GBP)
Funding ID TS/P003818/1 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 11/2016 
End 02/2020
 
Description Developing the Isothermal Control Platform (ICP) as the Basis of New Proposed Standards for the Testing of Lithium Batteries for Use in Electric Vehicles.
Amount £447,619 (GBP)
Funding ID 105297 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 06/2019 
End 06/2021
 
Description EPSRC Impact Acceleration Account
Amount £17,999 (GBP)
Organisation Cranfield University 
Sector Academic/University
Country United Kingdom
Start 09/2017 
End 12/2017
 
Description Faraday Challenge: Innovation - research and development
Amount £6,866,040 (GBP)
Funding ID TS/R013780/1 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 04/2018 
End 07/2021
 
Description H2020-NMBP-ST-IND-2018-2020 (Industrial Sustainability)
Amount € 7,920,588 (EUR)
Funding ID 8144471 
Organisation European Commission H2020 
Sector Public
Country Belgium
Start 01/2019 
End 07/2022
 
Title Method and apparatus for determining the state of health and state of charge of lithium sulfur batteries 
Description An apparatus for modelling a state of charge (SOC) of a secondary cell includes a cell model module 532 that correlates terminal voltage with an operational condition of the cell and a memory effect module 533 that provides a prediction of the usable capacity of the cell based on its operating history. The cell model module is adjusted based on the operating history of the cell to compensate for the prediction made by the memory effect module. The operational condition may be measured terminal voltage, open circuit voltage, current load, temperature and/or internal resistance. The cell may particularly be a lithium sulphur cell in which capacity can be lost due to reactant species becoming inactive in use. Also disclosed is a method of modelling a cell comprising using an equivalent circuit model with parameters corresponding to data generated from the behaviour of the cell in use. Further disclosed is a method for generating a memory model of a cell that establishes a set of rules relating to different chemical species in the cell, their reactions and reaction rates. 
IP Reference GB2537406 
Protection Patent application published
Year Protection Granted 2016
Licensed Commercial In Confidence
Impact Other patents applied for: WO/2016/166555,1020177033100 (Korea).
 
Title Simulink models from 'Multi-temperature state-dependent equivalent circuit discharge model for lithium-sulfur batteries 
Description This fileset contains a Simulink representation of the models developed in the paper 'Multi-temperature state-dependent equivalent circuit discharge model for lithium-sulfur batteries' accepted by the Journal of Power Sources on July 23, 2016. The data files can be opened with Simulink R2016a. 
Type Of Technology Software 
Year Produced 2016 
Impact This software tool has made it easier for potential end-users of lithium-sulfur to understand how these batteries behave in practical applications. 
URL https://doi.org/10.17862/cranfield.rd.c.3292031
 
Description Appearance in ITV News Anglia West 
Form Of Engagement Activity A broadcast e.g. TV/radio/film/podcast (other than news/press)
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact Appearance on ITV News Anglia West to talk about electric vehicles.
Year(s) Of Engagement Activity 2017
 
Description Battery Modelling for Industrial Applications Symposium (Warwick) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Representatives of several UK automotive firms and research establishments heard my presentation, which sparked questions and discussion afterwards.

I was invited to participate in an expert panel by the symposium organisers.
Year(s) Of Engagement Activity 2014
 
Description Computer Science and Electronic Engineering Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented work at a conference.
Year(s) Of Engagement Activity 2015
 
Description EMN Meeting on Batteries 2016 (California) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Supporters
Results and Impact This was an international conference on batteries, where I presented REVB work. We received requests from one industrial organisation and two academic organisations, plus interest from a second industry partner.
Year(s) Of Engagement Activity 2016
URL http://emnmeeting.org/batteries/
 
Description IEEE International Conference on Renewable Energy Research and Applications 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented work at a conference.
Year(s) Of Engagement Activity 2016
 
Description IET Hybrid and Electric Vehicles Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presented work at a conference.
Year(s) Of Engagement Activity 2013,2014
 
Description IET International Conference on Power Electronics, Machines and Drives 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Present at an international conference.
Year(s) Of Engagement Activity 2016
 
Description IFAC Symposium on Advances in Automotive Control 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented work at an international conference.
Year(s) Of Engagement Activity 2016
 
Description International Conference on Powertrain Modelling and Control: Testing, Mapping and Calibration 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented work at conference.
Year(s) Of Engagement Activity 2016
 
Description International Conference on Synthesis, Modeling, Analysis and Simulation Methods and Applications to Circuit Design 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented work at an international conference.
Year(s) Of Engagement Activity 2016
 
Description LiSM3 - Lithium Sulfur Batteries: Mechanisms, Modelling and Materials Conf. (London) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented REVB work at the inaugural LiSM3 conference, reaching academics and industry representatives from a wide international base. This resulted in some good questions and discussion and plans for follow-on activity.
Year(s) Of Engagement Activity 2016
URL http://www.lism3.org/
 
Description LiSM3 II - Lithium Sulfur Batteries: Mechanisms, Modelling and Materials Conf. (London) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented work at an international conference held in London attended by industry representatives from across the world.
Year(s) Of Engagement Activity 2017
URL http://www.lism3.org/
 
Description Participation in Trade Mission to India 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact Participated in a Trade Mission to India led by The Rt Hon Dr Vince Cable and presented project overview to Automotive Research Association of India (ARAI).

Many good discussions afterwards, particularly around battery management systems. Early-stage proposal for bilateral research with ARAI and other UK partners,.
Year(s) Of Engagement Activity 2014