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Computer-Aided Engineering for Electric-Drive Vehicle Batteries (CAEBAT)

Graphic of a 24-cell module battery prototype.

GM pack-level validation of CAEBAT tool using prototype for 24-cell module. Left: CAD geometry model. Right: FLUENT simulations. Images: Courtesy of GM

Graphic of stack pouch, wound cylindrical, and wound prismatic battery cells.

NREL enhancements to the framework functionality of cell domain models provided complete tool sets for CAEBAT partner simulation of all major cell form-factors (from left to right): stack pouch, wound cylindrical, and wound prismatic cells. Images: NREL

Graphic showing external battery case and two variations of wound prismatic cell configuration.

CD-adapco model construction showing external battery case and two variations of wound prismatic cell configuration for combined flow, thermal, and electrochemical simulation using CAEBAT tools. Images: Courtesy of CD-adapco

Graphic showing a range of wound prismatic battery cell configurations.

NREL's MSMD model quantifies the impacts of electrical/thermal pathway design on uneven charge-discharge kinetics in a wide range of large-format wound prismatic cells. Images: NREL

Graphics of Li-ion battery cells and packs.

Thermal-electrochemical models of Li-ion battery cells and packs. Wound electrode cell performance simulation (top left); time evolution of short in a prismatic cell (top right); pack simulation with cooling (bottom). Images: Courtesy of EC Power

The Computer-Aided Engineering for Electric-Drive Vehicle Batteries (CAEBAT) project is accelerating the development and lowering the cost of lithium-ion (Li-ion) batteries for next-generation electric-drive vehicles (EDVs). CAEBAT efforts focus on:

  • Developing engineering tools to design battery cells and packs
  • Shortening the battery prototyping and manufacturing processes
  • Improving overall battery performance, safety, and lifespan
  • Reducing expenses related to battery development and production.

The Vehicle Technologies Office (VTO) of the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy initiated the CAEBAT project in 2010 to facilitate the development of computer-aided engineering tools based on battery models developed by the national laboratories.

NREL brings its predictive computer simulation of Li-ion batteries, known as a multi-scale multi-dimensional (MSMD) model framework, to the CAEBAT project. MSMD's modular, flexible architecture connects the physics of battery charge/discharge processes, thermal control, safety, and reliability in a computationally efficient manner. This allows independent development of submodels at the cell and pack levels.

CAEBAT Industry Teams

NREL coordinates CAEBAT activities with battery, vehicle, and software industries to develop the first generation of electrochemical-thermal CAEBAT tools for the design and simulation of battery cells and packs.

After a competitive selection process, NREL awarded subcontracts worth $7 million to the following three industry teams:

Each CAEBAT team is working independently to develop and validate modeling and design tools for EDV batteries, with an emphasis on integrating electrochemical, electrical, mechanical, and thermal physics. Teams are also exploring different chemistries, cell geometries, and battery pack configurations.

These industry partners are contributing 50% of project costs, bringing the overall CAEBAT budget to $14 million for three years.

In support of the CAEBAT project, Oak Ridge National Laboratory (ORNL) is developing an open-architecture software interface to link the models developed by different teams into the CAEBAT suite of tools. ORNL is also developing input-output interfaces to allow utilization of models across different platforms.

Phase 1 CAEBAT Publications

NREL's Publications Database offers a wide variety of documents related to the development of batteries and energy storage systems for EDVs. The following publications document CAEBAT project activities:

NREL Team

Multi-physics Modeling for Improving Li-Ion Battery Safety. Pesaran, A.; Kim, G.-H.; Santhanagopalan, S.; Yang, C. (2015).

Significant Enhancement of Computational Efficiency in Nonlinear Multiscale Battery Model for Computer Aided Engineering 
. Kim, G.; Pesaran, A.; Smith, K.; Graf, P.; Jun, M.; Yang, C.; Li, G.; Li, S.; Hochman, A.; Tselepidakis, D.; White, J. (2014).

Three Dimensional Thermal-, Electrical-, and Electrochemical-Coupled Model for Cylindrical Wound Large Format Lithium-ion Batteries. Lee, K. J.; Smith, K.; Pesaran, A.; Kim, G. H. (2013).

Three-Dimensional Multi-Physics Model for a Li-Ion Battery. Guo, M.; Kim, G. H.; White, R. E. (2013).

Progress of the Computer-Aided Engineering of Electric Drive Vehicle Batteries (CAEBAT). Pesaran, A. (2013).

Multi-Scale Multi-Physics Lithium-Ion Battery Model with Multi-Domain Modular Framework. (Preprint). Kim, G. H. (2013) NREL Report No. CP-5400-60847.

Battery Capacity Estimation of Low-Earth Orbit Satellite Application. Jun, M.; Smith, K.; Wood, E.; Smart, M. C. (2012).

Accelerating Electric Vehicle Battery Innovation with Multiphysics Simulation. Pesaran, A.; Kim, G.-H.; Smith, K.; Santhanagopalan, S. (2012).

Accelerating Development of EV Batteries Through Computer-Aided Engineering. Han, T. (General Motors Research and Development Center); Kim, G-H. (NREL); Collins, L. (ANSYS, Inc.) (2012).

Overview of Computer-Aided Engineering of Batteries and Introduction to Multi-Scale, Multi-Dimensional Modeling of Li-Ion Batteries. Pesaran, A.; Kim, G.-H.; Smith, K.; Santhanagopalan, S.; Lee. K.-J. (2012).

Computer-Aided Engineering of Batteries for Designing Better Li-Ion Batteries. Pesaran, A.; Kim, G.-H.; Smith, K.; Lee, K.-J.; Santhanagopalan, S. (2012).

Modeling Detailed Chemistry and Transport for Solid Electrolyte Interface (SEI) Films in Li-ion Batteries. Colclasure, A. M.; Smith, K. A.; Kee, R. J. (2011).

Computer-Aided Optimization of Macroscopic Design Factors for Lithium-Ion Cell Performance and Life. Smith, K.; Kim, G.-H.; Pesaran, A. (2010).

Computer-Aided Engineering for Electric Drive Vehicle Batteries (CAEBAT). Pesaran, A.; Kim, G.-H.; Smith, K.; Santhanagopalan, S.; Lee. K.-J. (2011).

A Three-Dimensional Thermal-Electrochemical Coupled Model for Spirally Wound Large-Format Lithium-Ion Batteries. Lee, K.-J.; Smith, K.; Kim, G.-H. (2011).

Integrated Lithium-Ion Battery Model Encompassing Multi-Physics in Varied Scales: An Integrated Computer Simulation Tool for Design and Development of EDV Batteries. Kim, G.-H.; Smith, K.; Lee, K.-J.; Santhanagopalan, S.; Pesaran, A. (2011).

Multi-Domain Modeling of Lithium-Ion Batteries Encompassing Multi-Physics in Varied Length Scales. Kim, G. H.; Smith, K.; Lee, K. J.; Santhanagopalan, S.; Pesaran, A. (2011).

Accelerating Design of Batteries Using Computer-Aided Engineering Tools. Pesaran, A.; Kim, G.-H.; Smith, K. (2010).

3D Thermal and Electrochemical Model for Spirally Wound Large Format Lithium-ion Batteries. Lee, K. J.; Kim, G. H.; Smith, K. (2010).

Computer-Aided Engineering Automotive Batteries. Pesaran, A.; Kim, G.-H.; Smith, K.; Neubauer. J. (2010).

CD-adapco Team

Press releases:

Publications:

Presentations:

EC-Power Team

Zhao, W., Luo, G., and Wang, C.Y. (2015). "Modeling Internal Shorting Process in Large-Format Li-Ion Cells," J. Electrochem. Soc., 162(7), A1352-A1364.

W. Zhao, G. Luo and C.Y. Wang, "Modeling Nail Penetration Process in Large-Format Li-ion Cells," J. Electrochem. Soc., 162 (1) A207-A217 (2015).

W. Zhao, G. Luo, and C.Y. Wang, "Effect of Tab Design on Large-Format Li-ion Cell Performance," Journal of Power Sources 257 70-79 (2014).

G.S. Zhang, L. Cao, S. Ge, C.Y. Wang, C. E. Shaffer, C. D. Rahn, "In Situ Measurement of Temperature Distribution in a Cylindrical Li-ion Cell," to be submitted (2014).

Kalupson, J., Luo, G., and Shaffer, C., "AutoLion™: A Thermally Coupled Simulation Tool for Automotive Li-ion Batteries," SAE Technical Paper 2013-01-1522, 2013, doi: 10.4271/2013-01-1522. SAE International World Congress and Exhibition, April 16, 2013, Detroit, MI.

Ji, Y., Zhang, Y., and Wang, C.Y. (2013). "Li-Ion Operation at Low Temperatures," J. Electrochem. Soc., 160(4), A636-A649.

Zhang, G., Shaffer, C. E., Wang, C. Y., & Rahn, C. D. (2013). "In-Situ Measurement of Current Distribution in a Li-Ion Cell," J. Electrochem. Soc., 160(4), A610-A615.

Ji, Y., Wang, C.Y. (2013). "Heating Strategies for Li-Ion Batteries Operated from Subzero Temperatures," Electrochimica Acta, 107, 664-674.

Guangsheng Zhang, Christian E. Shaffer, Chao-Yang Wang, and Christopher D. Rahn, "Effects of Non-uniform Current Distribution on Energy Density of Li-ion Cells," J. Electrochem. Soc., 160 A2299-A2305 (2013).

G.S. Zhang, L. Cao, S. Ge, C.Y. Wang, C. E. Shaffer, and C. D. Rahn, "In Situ Measurement of Li-Ion Battery Internal Temperature," 224th ECS Meeting, Abstract #538, San Francisco, CA, USA, Oct. 27 - Nov. 01, 2013.

G. Luo and C.Y. Wang, A Multi-dimensional, Electrochemical-Thermal Coupled Li-ion Battery Model, Chap.6 in Lithium-Ion Batteries: Advanced Materials and Technologies, CRC Press, 2012.

Yang, Xiao Guang, Miller, Ted, and Yu, Paul, Ford Motor Company, "Li-Ion Electrochemical Model," 2012 Automotive Simulation World Congress, October 30-31, 2012, Detroit, MI.

Shaffer, C.E., Wang, C.Y., Luo, G. and Zhao, W., "Safety Analysis Design of Lithium-ion Battery EV Pack through Computer Simulation," Battery Safety 2012, Knowledge Foundation Conference, December 6-7, 2012, Las Vegas, NV.

Shaffer, C.E., and Wang, C.Y., "Thermal Management for Start-up of Li-Ion Batteries," 222nd Meeting of The Electrochemical Society (PRiME 2012), Honolulu, HI, October 7-12, 2012.

Luo, Gang, Shaffer, C.E. and Wang C.Y., "Electrochemical-thermal Coupled Modeling for Battery Pack Design," 222nd Meeting of The Electrochemical Society (PRiME 2012), Honolulu, HI, October 7-12, 2012.

Wei Zhao, C.Y. Wang, Gang Luo, Christian E. Shaffer, "New Findings on Large Li-ion Battery Safety through Computer Simulation," Battery Safety 2011 - Advancements in System Design, Integration, & Testing for Safety & Reliability, November 9-10, 2011, Las Vegas, NV.

GM Team

Saeed Asgari, Xiao Hu, Michael Tsuk, Shailendra Kaushik, "Application of POD plus LTI ROM to Battery Thermal Modeling: SISO Case," to be presented in 2014 SAE World Congress.

Xiao Hu, Scott Stanton, Long Cai, Ralph E. White, "A Linear Time-Invariant Model for Solid-Phase Diffusion in Physics-Based Lithium-Ion Cell Models," Journal of Power Sources 214 (2012) 40-50.

M. Guo and R. E. White, "Mathematical Model for a Spirally-Wound Lithium-Ion Cell," Journal of Power Sources 250 (2014), also presented at the ECS meeting, spring 2014, Orlando, FL.

R. Rebba, J. McDade, S. Kaushik, J. Wang, T. Han, "Verification and Validation of Semi-Empirical Thermal Models for Lithium Ion Batteries," 2014 SAE World Congress, Detroit, MI.

G. Li, S. Li, "Physics-Based CFD Simulation of Lithium-Ion Battery under a Real Driving Cycle," Presentation at 2014 ECS and SMEQ Joint International Meeting, Oct 5-9, 2014, Cancun, Mexico.

G. Li, S. Li, and J. Cao, "Application of the MSMD Framework in the Simulation of Battery Packs," Paper IMECE2014-39882, Proceedings of ASME 2014 International Mechanical Engineering Congress & Exposition, IMECM 2014, Nov 14-20, 2014, Montreal, Canada.

Y. Dai, L. Cai, and R. E. White, "Simulation and Analysis of Inhomogeneous Degradation in Large Format LiMn2O4/Carbon Cells," J. Electrochem. Soc., 161 (8), 2014.

T. Han, G. Kim, R. White, D. Tselepidakis, "Development of Computer Aided Design Tools for Automotive Batteries," ANSYS Convergence Conference, Detroit, MI, June 5, 2014.

T. Han, M. Fortier, L. Collins, "Accelerating Electric-Vehicle Battery Development with Advanced Simulation," Aug 21, 2014, Webcast seminar organized by SAE International, http://www.sae.org/magazines/webcasts.

Meng Guo, Ralph E. White, "A Distributed Thermal Model for a Li-Ion Electrode Plate Pair," Journal of Power Sources 221 (2013) 334-344.

Ralph E. White, Meng Guo, and Gi-Heon Kim, "A Three-Dimensional Multi-Physics Model for a Li-Ion Battery," Journal of Power Sources, 2013.

Taeyoung Han, Gi-Heon Kim, Lewis Collins, "Multiphysics Simulation Tools Power the Modeling of Thermal Management in Advanced Lithium-Ion Battery Systems," ANSYS Quarterly magazine Advantage, 2012.

Taeyoung Han, Gi-Heon Kim, and Lewis Collins, "Development of Computer-Aided Design Tools for Automotive Batteries-CAEBAT," Automotive Simulation World Congress (ASWC), Detroit, October 2012.

Xiao Hu, Scott Stanton, Long Cai, and Ralph E. White, "A Linear Time-Invariant Model for Solid-Phase Diffusion in Physics-Based Lithium Ion Cell Models," Journal of Power Sources 214 (2012) 40-50.

Xiao Hu, Scott Stanton, Long Cai, and Ralph E. White, "Model Order Reduction for Solid-Phase Diffusion in Physics-Based Lithium Ion Cell Models," Journal of Power Sources 218 (2012) 212-220.

CAEBAT 2

  • S. Santhanagopalan, C. Zhang, M. A Sprague, A. Pesaran, "A Representative-Sandwich Model for Simultaneously Coupled Mechanical-Electrical-Thermal Simulation of Lithium-Ion Battery Cell under Quasi-Static Indentation Tests," J. Power Sources, Submitted.

  • J. Marcicki, X.G.Yang, and P. Rairigh, "Fault Current Measurements During Crush Testing of Electrically Parallel Lithium-Ion Battery Modules," ECS Letters, Submitted.

  • C. Zhang, S. Santhanagopalan, M. A Sprague, A. Pesaran, "Coupled Mechanical-Electrical-Thermal Modeling for Short-Circuit Prediction in a Lithium-Ion Cell under Mechanical Abuse," J. Power Sources, 290, p. 102-113 (2015). http://dx.doi.org/10.1016/j.jpowsour.2015.04.162

  • S. Santhanagopalan, C. Zhang, A. Pesaran, E. Sahraei, Tomasz Wierzbicki, "Electrochemical-Thermal Behavior of Lithium-Ion Cells Subjected to Mechanical Crush." Presented at the AABC in Detroit MI (2015).

  • A. Pesaran, G.H. Kim, S. Santhanagopalan, "Coupled Mechanical-Electrochemical-Thermal Modeling For Accelerated Design of EV Batteries," 28th Electric Vehicle Symposium, Kintex, Korea (2015). http://www.nrel.gov/docs/fy15osti/63701.pdf

  • M. Jun, K. Smith, P. Graf, "State-Space Representation of Li-Ion Battery Porous Electrode Impedance Model with Balanced Model Order Reduction," J. Power Sources, 273(1), p.1226-1236 (2015). http://dx.doi.org/10.1016/j.jpowsour.2014.02.063

  • C. Zhang, S. Santhanagopalan, M.A. Sprague, A. A. Pesaran, "Short-Circuit Simulation of Lithium-Ion Battery," 13th US National Congress on Computational Mechanics, San Diego, CA (2015).

  • G.H. Kim, C. Yang, K. Smith, A. Pesaran, "Integrated Multiscale Multiphysics Modeling of Safety Response in Lithium-Ion Batteries." Presented at the AABC in Detroit, MI (2015).

  • A. Pesaran, T. Wierzbicki and E. Sahraei, S. Dajka and G. Li, S. Santhanagopalan, C. Zhang, G.H. Kim, M.A. Sprague, "Coupling Mechanical with Electrochemical-Thermal Models for Batteries under Abuse." Presented at the 2015 DOE Annual Merit Review, Washington, D.C. (2015).

  • G.H. Kim, A. Pesaran, K. Smith, P. Graf, M. Jun, C. Yang, G. Li, S. Li, A. Hochman, D. Tselepidakis, "Significant Enhancement of Computational Efficiency in Nonlinear Multiscale Battery Model for Computer Aided Engineering." Presented at the 2015 DOE Annual Merit Review, Washington D.C. (2015).

  • S. Santhanagopalan, C. Zhang, M.A. Sprague, A. Pesaran, Jim Marcicki, P. Rairigh, X.G.Yang, Alex Bartlett, "Crash Propagation in Automotive Batteries: Simulations and Validation." Presented at the 2015 DOE Annual Merit Review, Washington D.C. (2015).

  • P. Barai, K. Smith, C.-F. Chen, G.-H. Kim, P.P. Mukherjee. (2014). "Reduced Order Modeling of Mechanical Degradation Induced Performance Decay in Lithium-Ion Battery Porous Electrodes," J. Electrochem. Soc. 162 (9) A1751-A1771, http://dx.doi.org/10.1149/2.0241509jes.

  • D.R. Diercks, M. Musselman, A. Morgenstern, T. Wilson, M. Kumar, K. Smith, M. Kawase, B.P. Gorman, M. Eberhart, C.E. Packard, "Evidence for Anisotropic Mechanical Behavior and Nanoscale Chemical Heterogeneity in Cycled LiCoO2," J. Electrochem. Soc., 161(11): F3039-F3045; doi:10.1149/2.0071411jes (2014). http://dx.doi.org/10.1149/2.0071411jes

  • K. An, P.Barai, K. Smith, P.P. Mukherjee, "Probing the Thermal Implications in Mechanical Degradation of Lithium-Ion Battery Electrodes," J. Electrochem. Soc., 161(6): A1058-A1070, (2014). http://dx.doi.org/10.1149/2.069406jes.

  • C. Yang, G.H. Kim, S. Santhanagopalan, A. Pesaran, "Multi-Physics Modeling of Thermal Runaway Propagation in a Li-Ion Battery Module." Presented at the 225th ECS Meeting, Orlando, FL. (2014).

CAEBAT Contact

For more information on CAEBAT activities, contact Gi-Heon Kim, 303-275-4437.