Lead-Acid Batteries for Future Automobiles

669 Pages·2017·40.05 MB·English

by  Jürgen Garche

LeadeAcid
Batteries for
Future
Automobiles
Edited by
Ju¨rgen Garche
Eckhard Karden
Patrick T. Moseley
David A.J. Rand
Elsevier
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List of Contributors
J. Albers
JohnsonControlsAutobatterieGmbH&Co.KGaA,Hannover,Germany
J. Badeda
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
IRWTHAachenUniversity,Aachen,Germany
M. Bremmer
RobertBoschGmbH,Leonberg,Germany
C. Chumchal
Ford-WerkeGmbH,Ko¨ln,Germany
M. Denlinger
FordMotorCompany,Research&InnovationCentreDearborn,Dearborn,MI,UnitedStates
J.P. Douady
ExideTechnologies,Gennevilliers,France
S. Fouache
ExideTechnologies,Gennevilliers,France
J. Furukawa
TheFurukawaBatteryCo.,Ltd.,Yokohama,Japan
J. Garche
FuelCellandBatteryConsulting,Ulm,Germany
M. Gelbke
AkkumulatorenfabrikMollGmbHþCo.KG,BadStaffelstein,Germany
T. Hildebrandt
JohnsonControlsAutobatterieGmbH&Co.KGaA,Hannover,Germany
M. Huck
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
J. Kabzinski
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
E. Karden
FordMotorCompany,Research&InnovationCentreAachen,Aachen,Germany
A. Kirchev
FrenchAtomicandAlternativeEnergyCommission(CEA-LITEN),LeBourgetduLac,France
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List of Contributors
J. Kizler
RobertBoschGmbH,Leonberg,Germany
M. Ko¨nigsmann
RobertBoschGmbH,Leonberg,Germany
B. Kronenberg
RobertBoschGmbH,Leonberg,Germany
M. Kuipers
ForschungszentrumJu¨lich,Aachen,Germany
D. Kurzweil
Ford-WerkeGmbH,Ko¨ln,Germany
P. Kurzweil
UniversityofAppliedSciences,Amberg,Germany
M. Kwiecien
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
L.T. Lam
CSIROEnergyFlagship,ClaytonSouth,VIC,Australia
N. Maleschitz
ExideTechnologies
E. Meissner
JohnsonControlsAutobatterieGmbH&Co.KGaA,Hannover,Germany
A.H. Mirza
RSRTechnologies,Inc.,Dallas,TX,UnitedStates
C. Mondoloni
PSAPEUGEOTCITROE¨N,CentreTechniqueLaGarenne-Colombes,LaGarenne-Colombes,
France
P.T. Moseley
TheAdvancedLeadeAcidBatteryConsortium,Durham,NC,UnitedStates
T.J. Moyer
EastPennManufacturingCompany,Inc.,LyonStation,PA,UnitedStates
A. Osada
BatteryAssociationofJapan(BAJ),Tokyo,Japan
S. Peng
LeochInternationalTechnologyLtd,FoothillRanch,CA,UnitedStates
K. Peters
GlenBank,Worsley,Manchester,UnitedKingdom
R.D. Prengaman
RSRTechnologies,Inc.,Dallas,TX,UnitedStates
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List of Contributors
D.A.J. Rand
CSIROEnergyFlagship,ClaytonSouth,VIC,Australia
M. Ruch
RobertBoschGmbH,Leonberg,Germany
J.F. Sarrau
ExideTechnologies,Gennevilliers,France
D.U. Sauer
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
IRWTHAachenUniversity,Aachen,Germany
C. Schmucker
RobertBoschGmbH,Leonberg,Germany
E. Schoch
RobertBoschGmbH,Leonberg,Germany
J. Scho¨ttle
RobertBoschGmbH,Leonberg,Germany
P. Schro¨er
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
K. Smith
EastPennManufacturingCo.,Inc.,LyonStation,PA,UnitedStates
R. Wagner
AkkumulatorenfabrikMOLL,BadStaffelstein,Germany
A. Warm
FordMotorCompany,Research&InnovationCentreAachen,Aachen,Germany
J. Wirth
RWTHAachenUniversity,Aachen,Germany
Ju¨lichAachenResearchAlliance,Ju¨lich,Germany
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About the Editors
Ju¨rgen Garche
Jürgenreceivedhis PhDwithworkintheoret-
ical electrochemistry from the Dresden
UniversityofTechnology(DUT)inGermanyin
1970 and the Dr. Habil for research in applied
electrochemistry by the same university in
1982.
He worked from 1970 to 1990 as senior
researcher for batteries and fuel cells at the
DUT. From 1991 to 2004, he was head of the
Electrochemical Energy Storage and Energy
Conversion Division of the Center for Solar
Energy and Hydrogen Research in Ulm,
Germany. After his pension, he founded the
consulting office Fuel Cells and Batteries
(FCBAT)inUlm,whereheisstillactive.
He was visiting professor at the Shandong
University (China)and SapienzaUniversity of
Rome (Italy), and is currently senior professor at the Ulm University. He has
morethan300publicationsand10patents,andisco-editoroffivebooksand
twojournals.
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About the Editors
Eckhard Karden
Eckhardreceivedhisdiplomainphysicsin1995
andhisPhDinelectricalengineeringin2001from
Rheinisch-Westfälische Technische Hochschule
(RWTH)AachenUniversityofTechnologywith
projectsonCAEmodellingandelectrochemical
impedance spectroscopy of leadeacid batte-
ries.Havingspent2.5yearsasseniorengineerat
InstitutfürStromrichtertechnikundElektrische
Antriebe (ISEA) Institute for Power Electronics
andElectricalDrivesofthesameuniversity,he
joined Ford Motor Company in the newly
established Research and Innovation Center
(RIC)inAachen,Germany.Hehasbeenfocussing
onbatteriesforlow-voltagepowersupplyand
micro- and mild hybrid applications. As a Technical Specialist, he is working
closely with Ford’s global engineering centres and has been involved in the
conceptual work, specifications, and component verification plans for the
enhancedfloodedbatteries,batterysensors,andchargingstrategiesthatwent
intoFord’sfirstgenerationsofmicrohybridvehicles.Heisanactivememberof
German,European,andinternationalstandardisationworkinggroupsforstop/
startandmicrohybridbatteries.
xxiii
About the Editors
Patrick T. Moseley
Pat was awarded a PhD for crystal structure
analysis in 1968 by the University of Durham,
UK, and a D.Sc. for research publications in
materials science, by the same university, in
1994.
He worked for 23yearsat the Harwell Labo-
ratory of the UK Atomic Energy Authority,
where he brought a background of crystal
structureandmaterialschemistrytothestudy
of leadeacid and other varieties of battery,
thus supplementing the traditional electro-
chemicalemphasisofthesubject.
From 1995, he was Manager of Electrochem-
istryattheInternationalLeadZincResearchOrganizationinNorthCarolina
and Program Manager of the Advanced Lead Acid Battery Consortium. In
2005,healsobecamePresidentoftheConsortium.Dr.Moseleywasoneof
theeditorsoftheJournalofPowerSourcesfor25yearsfrom1989to2014.In
2008,hewasawardedtheGastonPlantémedalbytheBulgarianAcademyof
Sciences.
xxiv
About the Editors
David A.J. Rand
Dr. David Rand, AM, PhD, ScD, Fellow of the
AustralianAcademyofTechnologicalSciences
and Engineering (FTSE), was educated at the
UniversityofCambridge,whereheconducted
research on fuel cells. In 1969, he joined the
AustralianGovernment’sCommonwealthSci-
entific and Industrial Research Organisation
(CSIRO) laboratories in Melbourne. After
furtherexplorationoffuelcellmechanismsand
thenelectrochemicalstudiesofmineralbene-
ficiation,DavidestablishedtheCSIROBattery
ResearchGroupinthelate1970sandremained
its leader until 2003. He was one of the six
scientiststhatestablishedtheAdvancedLeadeAcidBatteryConsortiumin1992
andservedasitsManagerin1994.AsaChiefResearchScientist,Davidbecame
CSIRO’sScientificAdvisoronhydrogenandrenewableenergyuntilhisretire-
ment in 2008. He remains active within the organisation as an Honorary
ResearchFellow,andhasservedastheChiefEnergyScientistoftheWorldSolar
Challengesinceitsinceptionin1987.DavidwasawardedtheFaradayMedalby
the Royal Society of Chemistry (UK) in 1991 and the UNESCO Gaston Planté
MedalbytheBulgarianAcademyofSciencesin1996.HebecameaFellowofthe
Australian Academy of Technological Sciences and Engineering in 1998, and
becameaMemberoftheOrderofAustraliain2013forservicetoscienceand
technologicaldevelopmentinthefieldofenergystorage.
xxv
Preface
More than 150years after its introduction by Gaston Planté in 1859, the
leadeacid battery is still the most employed of all rechargeable battery
systems;itaccountsforoverhalfofthedemandworld-wide.Overtheyears,
the performance of leadeacid technology has progressed steadily to keep
pacewiththeconcomitantincreaseinuserrequirements,andhasbecomea
globallystandardizedcommodityproduct.
The development of the valve-regulated leadeacid (VRLA) battery in the
1970sprovedtobeamajorbreakthrough.Eventually,inthe1990s,thisradical
new design found its way into demanding automotive applications. The
advances in science and technology that made VRLA batteries a success in
bothautomotiveandindustrialapplicationswerereviewedinValve-Regulated
LeadeAcid Batteries published by Elsevier in 2004, with three of us as
co-editorsandcontributors.Ratherthanundertakearevisededitionofthis
book,wehavedecidedtoproduceanewworkdirectedtowardsadvancesin
automotiveleadeacidbatteries.
Improved battery designs and materials have recently resulted in enhanced
flooded batteries (EFBs) that almost match performance and durability of
automotive VRLA batteries at substantially lower cost. Both technologies
haveallowedentry-levelpowertrainelectrificationinlargevolumes,andthus
significantreductionsinCO emissions,forbothdevelopedandemergingroad
2
transport markets. And innovation goes on, for example, the UltraBattery™
thatintegratesasupercapacitivefunction.
Furtherreductioninemissionsremainsinfocusfortheautomotiveindustry,
while a new effort is targeting autonomous driving. The latter will require
entirely new comfort and safety functions to be established. Interestingly,
bothtechnologytrendsrelyonelectrification,eitherofthepowertrainorof
chassis systems and vehicle controls, and both will add new technical
requirementstoautomotivebatteries.Togetherwiththechallengesimposed
by new vehicle technologies, the automotive leadeacid is now also con-
fronted with competition from other battery chemistries, especially given
thedevelopingmaturityoflithium-iontechnologyforthisdemandingappli-
cation.Indefiningthescopeforthisnewpublication,wehaveattemptedto
create a balance between the technology of the battery itself and engi-
neeringaspectsrelatedtovehicleintegration.
Wearegratefultohaveasauthorsnotonlyleadingbatterytechnologistsand
scientists but also experienced experts from the automotive industry. In
particular,wehaveenjoyedourmutuallearningexperiencewhileeditingthe
xxvii