design and development of battery management systems

IN PASSENGER ELECTRIC VEHICLES PROTOTYPE

By

Elroy FKP Tarigan 21952053

MASTER’S DEGREE in

MASTER OF MECHANICAL ENGINEERING – MECHATRONICS Concentration FACULTY OF ENGINEERING & INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia

January 2021

Revision After Thesis Defense on 27 January 2021

Elroy FKP Tarigan STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

Elroy FKP Tarigan

_____________________________________________

Student Date

Approved by:

Dena Hendriana, B.Sc., S.M., Sc.D.

__________________________________

Thesis Advisor Date

Ary Syahriar, Ph.D., DIC.

_____________________________________________

Thesis Co-Advisor Date

Dr. Maulahikmah Galinium, S.Kom., M.Sc

_____________________________________________

Dean Date

Elroy FKP Tarigan ABSTRACT

DESIGN AND DEVELOPMENT OF BATTERY MANAGEMENT SYSTEMS IN PASSENGER ELECTRIC VEHICLES PROTOTYPE

By

Elroy FKP Tarigan, Students

Dena Hendriana, BSc.,M.Sc., Ph.D, Advisor Ary Syahriar, Ph.D, DIC,. Co-Advisor

SWISS GERMAN UNIVERSITY

The development of battery management system in this study is in battery monitoring syatem and the implementation of smart charging system to the lead acid battery. This research objective is to design and develop an individual monitoring system of a battery in an electric vehicle and implementation of the new charger with a recovery feature through pulse signal. The methodology of this research is problem identification, literature review, determining the target, analysis and problem solving using various method. The result shows implementation of sensor for individual battery and send the data as a display and to the IoT cloud. The calibration has been done to the device with 1.5% accuracy. The calibration factor for all battery has been calculated and implemented. The pulse charging system has been used to improve the lead acid battery condition. Data verification has been done with the measurement outside the prototype.

The next step development of this study is the temperature determining charger and the different shape and frequency of charger signal.

Keywords: Electric Vehicle, Sensor Technology, IoT, Automotive, Calibration, Pulse Charging, Lead Acid Battery

Elroy FKP Tarigan DEDICATION

I dedicate this works for the future of the country I loved: Indonesia, My Family and Polman Astra

Elroy FKP Tarigan ACKNOWLEDGEMENTS

I Would like to thank to Mr. Dena Hendriana., BSc., M.Sc., Ph.D and Mr. Ary Syahriar,.

Ph.D,. DIC. and all Lecturers who have guided me while studying in Swiss German University, to Mr. Yohanes Climacus Sutama and the team in Automotive Department which I take the field of my thesis and to the management of Politeknik Manufaktur Astra who gave me the opportunity to take a master's degree.

Elroy FKP Tarigan TABLE OF CONTENTS

Page

STATEMENT BY THE AUTHOR ... 2

ABSTRACT... 3

DEDICATION ... 4

ACKNOWLEDGEMEN TS ... 5

TABLE OF CONTENTS ... 6

LIST OF FIGURES ... 8

LIST OF TABLES ... 10

CHAPTER 1 – IN TRODUCTION ... 11

1.1. Background ... 11

1.2. Research Problem ... 12

1.3. Research objectives ... 13

1.4. Significance to Study ... 13

1.5. Research Question ... 13

1.6. Hypothesis ... 13

CHAPTER 2 - LITERATURE REVIEW ... 14

2.1. Theoretical Perspectives ... 14

2.2. Previous Study ... 28

CHAPTER 3 – RESEARCH METHODS ... 31

3.1. Methodology ... 31

3.2. Electric Vehicle Prototype ... 31

3.2. Circuit Design ... 37

3.3. Materials and Equipment ... 40

3.4. Charging System... 46

3.5. Thinkspeak Platform... 47

3.6. Battery Measurement ... 48

3.7. Flowchart ... 56

CHAPTER 4 – RESULTS AND DISCUSSIONS... 57

4.1. Circuit Implementation ... 57

4.2. Programming ... 84

4.3. Data Analysis ... 85

4.4. Comparison of Economic Value... 86

CHAPTER 5 – CONCLUSIONS AND RECOMENDATIONS... 88

Elroy FKP Tarigan

5.2. Recommendations (Next Step) ... 88

GLOSSARY ... 89

REFERENCES ... 93

CURRICULUM VITAE ... 96

Elroy FKP Tarigan LIST OF FIGURES

Figure Page

Figure 1. 1 Renewable energy Chart (Fischer, 2014) ... 11

Figure 1. 2 EV Project Milestone Polman Astra (Sutama, 2020). ... 11

Figure 1. 3 EV prototype series 1.1 used in this research. ... 12

Figure 2. 1 energy diversification of EVs (Chau, 2015) ... 14

Figure 2. 2 Specific energy and specific power of various type of battery (Ziemann et al., 2013) ... 17

Figure 2. 3 Electrochemical process during charging and discharging (Fischer, 2014) ... 18

Figure 2. 4 Arduino boards (what is arduino?, 2018) ... 21

Figure 2. 5 Voltage divider principle ... 23

Figure 2. 6 Fluke 325 series (www.fluke.com) ... 25

Figure 2. 7 Facom 714A (www.facom.com) ... 27

Figure 2. 8 Portable refractometer ... 28

Figure 3. 1 Previous battery monitoring system ... 32

Figure 3. 2 Electrical drive process... 34

Figure 3. 3 General main wiring diagram (Dewi, 2018)... 35

Figure 3. 4 Headlamp electrical flow... 35

Figure 3. 5 Headlamp Electrical Circuit (Dewi, 2018) ... 36

Figure 3. 6 Voltage monitoring circuit ... 38

Figure 3. 7 Relay Circuits ... 39

Figure 3. 8 Battery balancing circuit... 40

Figure 3. 9 Arduino Mega Pinout (ARDUINO, 2018) ... 41

Figure 3. 10 ESP 8266 pinout and component (ESP8266 - WiFi Module, 2018) ... 42

Figure 3. 11 Voltage sensor (Voltage Sensor Module, 2020) ... 44

Figure 3. 12 LCD module ... 45

Figure 3. 13 I2C module ... 46

Figure 3. 14 Pulse charging signal ... 46

Figure 3. 15 Thinkspeak methodology (Thingspeak, 2020) ... 47

Figure 3. 16 Battery preparation ... 48

Figure 3. 17 Battery internal resistance ... 49

Figure 3.18 Voltage Measurement Process ... 50

Figure 3. 19 Voltage measurement result ... 51

Figure 3. 20 Capacitance measurement ... 52

Figure 3. 21 Specific gravity measurement ... 53

Figure 3. 22 Capacitance measurement 2 ... 54

Figure 3. 23 Capacitance measurement 3 ... 55

Figure 3. 24 Flowchart for microcontroller ... 56

Figure 4. 1 Experimental setup of voltage monitoring system ... 57

Figure 4. 2 Experimental setup of voltage sensor arrangements ... 58

Figure 4. 3 Experimental setup of microcontroller and board ... 59

Figure 4. 4 Experimental setup of LCD voltage result ... 59

Figure 4. 5 Battery arrangements of voltage measurement process ... 60

Elroy FKP Tarigan

Fluke voltage measurements ... 61

Figure 4. 7 Cell 1 Sensor Reading ... 62

Figure 4. 8 Cell 1 Averaging... 63

Figure 4. 9 Cell 1 complete graph... 63

Figure 4. 10 Cell 1 with 12 V input ... 64

Figure 4. 11 Cell 1 with 14 V input ... 65

Figure 4. 12 Cell 1 calibration factor ... 66

Figure 4. 13 Cell 2 with 10 V input ... 67

Figure 4. 14 Cell 2 with 12 V input ... 67

Figure 4. 15 Cell 2 with 14 V input ... 68

Figure 4. 16 Cell 2 Calibration Factor ... 69

Figure 4. 17 Cell 3 with 10 V input ... 70

Figure 4. 18 Cell 3 with 12 V input ... 70

Figure 4. 19 Cell 3 with 14 V input ... 71

Figure 4. 20 Cell 3 calibration factor ... 72

Figure 4. 21 Cell 4 with 10 V input ... 73

Figure 4. 22 Cell 4 with 12 V input ... 73

Figure 4. 23 Cell 4 with 14 V input ... 74

Figure 4. 24 Cell 4 calibration factor ... 75

Figure 4. 25 Experimental setup of IoT implementation ... 76

Figure 4. 26 IOT display ... 76

Figure 4. 27 Another graph from free Thinkspeak platform ... 77

Figure 4. 28 Experimental setup of charger ... 78

Figure 4. 29 Pulse charger experiment... 78

Figure 4. 30 48 V Charger circuit ... 79

Figure 4. 31 Experimental setup of all battery charging ... 79

Figure 4. 32 Pulse charger test ... 80

Figure 4. 34 Normal and pulse charging graph... 82

Figure 4. 35 All cell charging graph. ... 83

Figure 4. 36 All charging and invidual pulse charing ... 84

Figure 4. 37 Programming serial monitor result ... 85

Figure 4. 38 All cell calibration factor ... 86

Elroy FKP Tarigan LIST OF TABLES

Table Page

Table 1. 1 Specific battery parameter ... 16

Table 2. 1 Fluke 325 Specification (Corp., 2013)... 25

Table 2. 2 Facom 714A specification ... 26

Table 2. 3 Internal resistance measurement ... 27

Table 3. 1 EV prototype dimensions (Dewi, 2018) ... 32

Table 3. 2 EV prototype drivetrain (Dewi, 2018) ... 33

Table 3. 3 Voltage and distance data (Dewi, 2018) ... 36

Table 3. 4 Battery performance test (Dewi, 2018)... 37

Table 3. 5 EV Prototype Drivetrain (Dewi, 2018) ... 37

Table 3. 6 Arduino mega 2560 specification (ARDUINO, 2018) ... 41

Table 3. 7 ESP8266 pinout (ESP8266 - WiFi Module, 2018) ... 43

Table 3. 8 Arduino voltage sensor Pin (Voltage Sensor Module, 2020)... 45

Table 3. 9 LCD specifications (https://www.futurlec.com/) ... 45

Table 3. 10 Internal resistance value... 49

Table 3. 11 Capacitance result ... 54

Table 4. 1 Cell 1 Measurement value ... 65

Table 4. 2 Cell 2 Measurement Value... 68

Table 4. 3 Cell 3 Measurement Value... 71

Table 4. 4 Cell 4 measurement value ... 74

Table 4. 5 Experimental data of pulse charger... 80

Table 4. 6 Normal and pulse charging result ... 81

Table 4. 7 Cell 1 to 4 averaging data ... 85

Table 4. 8 Experimental setup price Estimation ... 87