Field Sustainment Power Conditioning #TA3-040-5

Brad Lehman, Northeastern UniversityKhalil Shujaee, Clark Atlanta UniversityWes Tipton, Army Research Laboratories

Presented by: Florent Boico

Dept. Elect. & Comp. Engin.

Northeastern University

May 31 2005

Motivation/Background• Background

– Dept. Army recently mandated that all training exercises must use rechargeable batteries;

– Estimated to save $70M annually (versus non-rechargeable);– Soldiers like rechargeable batteries so much that they are bringing them into

combat also;– About 75% of Army rechargeable batteries are BB390 NiMH (4lbs). (BB390 has

2 x 12V legs and can be used as either 24V or 12V battery.)

• Motivation for Solar Chargers

– Soldiers carry four BB390 batteries (= 16 lbs) for portable electronic equipment;

– Forward field observers, scouts, special ops, are constrained to stay within 10 miles of TOC (Tactical Operation Center where there is a charging facility shelter);

– Portable solar arrays carried by soldier (~1lb) reduce number of batteries carried and eliminate the need to stay near TOC.

TOC

Operation area

10 mi.

Spare batteries, generator ,Chargers, shelter, etc.

Soldiers using batteries

Motivation/Background• Portable Solar Chargers

– Being field tested by CERDEC C2D Army Power Division;

– Best solution: soldier directly connects solar array to battery and lets charge all day while on a mission;

– Companies have attempted and failed to build power electronic charge regulators to control the charging.

• Issues when Solar Charging– Experiments show reduced battery

capacity;– Batteries sometimes overheat and

vent: can no longer be used;– Batteries are constantly being

recharged by soldier, even if battery lightly discharged

• Leads to reduced life cycle of battery.

Three different portable solar arrays charging three NiMH

batteries.

(Picture courtesy of Dennis Lane, CERDEC, C2D, Army Power Division)

NiMH Overcharge Detection

Conventional (known) NiMH charge control algorithms stop charging (or switch to trickle charge) when battery voltage begins to decrease or when rate of cell temperature begins to substantially rise.

Full State Of ChargeFull State Of Charge

Solar Charging BB390

– Companies have attempted to work with CERDEC to build solar chargers: • Chargers failed: They falsely terminate charging before completion;• CERDEC refuses to use any of these chargers.

– Known charging algorithms are applicable to constant power source: • Termination for “dumb” NiMH batteries (BB390) occurs based on battery V, dV/dt,

time, and sometimes temperature T or dT/dt.– Solar arrays produce varying current sources depending on clouds

• Fast charge Slow charge Fast charge …– How to correctly predict charge termination for DUMBDUMB batteries like BB390 (basic research)?

I V

Typical sunny day measurement

The negative voltageslope shows that the battery is overcharging

Changes in the solar array current cause changes in the battery voltage.

Typical cloudy day(scattered clouds)

Conventional charge control algorithm falsely terminate charging !

0 50 100 150 200 250 300 350 400 45024

26

28

30

32

34

36

38

40

42Temperature inside the battery pack

Time (min)

Variation of Temperature Throughout the Day

Large variations of the temperature can falsely trigger charge termination on temperature based algorithms.

PIC µC

ADCBatterythermistors

voltage leg 1&2

leg1

leg2

BB390leg1 leg2

Serial connection for data logging (optional)

Prototype

charging current

Phase 1 Charger Prototype (2004)

A prototype of the charger has been built.Its characteristics include :• charge monitoring by sensing : -voltage & current across

each leg- cell temperature

• clamps on the BB390 battery.

• optional RS-232 connection for data logging and evaluation by a computer.

• algorithm fully upgradable.

Charge, n=n+1sense Vbatt(n)

& Ibatt(n)

|dV/dt|>thsld1

Imax- Imin>thsld2

Reset : Vmax=0dpos=0

Vmax- Vbatt>0.1V& dpos=1

Trickle charge

dV/dt>thsld3

dpos=1

yes

yes

yes

no

no

yes

Vmax=Vbatt(n) Vbatt(n)>Vmaxyes

no

no

no

Initialisation :Vmax=0dpos=0

Voltage Charge Control Algorithm (2004)

If the voltage suddenly drops or if strong discrepancies in the current is detected, the algorithm is reset to prevent false overcharge detection

Minimum and maximum current over a period of 5 minutes

After reset the algorithm waits for a positive voltage slope to allow overcharge detection

2005 Results :

•Refined Maximum Power Point Tracker

•Differential temperature based charge control algorithm developed

Phase II: Maximum Power Point Tracking (MPPT)

We have built preliminary Phase II chargers that include MPPT:

• Adjusting the duty ratio of the Up-Down converter forces the solar array to operate at its maximum producing power point; • MPPT adaptively optimize charging to different NiMH batteries (12V, 24V, 9.6V, etc.)• Bypass switch improves power efficiency when MPPT not needed.

µ controller

Up-Down converter

ADCd

CurrentSensingresistor

DPWM

Iout

filter

PV array

Bypassswitch

µ controller

Up-Down converter

ADCd

CurrentSensingresistor

DPWM

Iout

filter

PV array

Bypassswitch

Battery Voltage

Current when solar array is directly connected to the battery

Current when the proposed charger with MPPT is used.

4.8V 660 mA 720 mA

12V 310 mA 310 mA

24V 0 mA 160 mA

Higher Charging Current is Achieved with MPPT

New Charge Charge Control Algorithm

Developed in 2005: Differential Temperature Method

• The algorithm is based on measuring the difference in the temperature of each of the two legs of the BB390.

• When overcharge occurs in one leg, it can be detected by comparison with the other leg.

• Method gives improved robustness Not sensitive to changing illumination conditions Not sensitive to changing ambient temperatures 100% success rate after dozens of experiments!

When battery overcharges, it heats up.

2005 - Differential Temperature Algorithm

Battery or leg

• The algorithm is based on measuring the difference in the temperature of each of the two legs of the BB390.

• When overcharge occurs in one leg, it can be detected by comparison with the other leg.

C

Battery can also heat up due to external causes (e.g. : sun) but is not fully charged yet.

2005 - Differential Temperature Algorithm

C

How can one differentiate between overcharging and external heating ?

2005 - Differential Temperature Algorithm

C C

Supposing one leg is charged and the other is left open :• In case of overcharge the temperature will rise in one leg only• If the pack is heated from outside, the temperature will rise in both legs

2005 - Differential Temperature Algorithm

thermistors

Two Independent Legs

2005 Differential Temperature Algorithm

thermistors

T1-T2> threshold T1-T2< threshold

Overcharge No Overcharge

C C

•The algorithm functions as follows :

-Detects a rise in temperature in any of the legs.-Keep charging the leg that has been detected as potentially overcharging-Measure the slope of differential temperature measurement to detect overcharge-After a certain time if no overcharge is detected, charge is resumed in both legs.

•The differential sensing of the temperature reduces the effect of external heating and ambient temperature on the measurement.

• Overcharging detection of one leg via temperature using this method is more robust.

•Thresholds are current dependant.

2005 - Differential Temperature Algorithm

Charge leg 1&2

dT1/dt > thsld1

Charge leg 1Stop leg 2timer1=0

d(T1-T2)/dt>thsld2

Timer1>10min increment timer

dT2/dt > thsld1

Charge leg 2Stop leg 1timer1=0

d(T2-T1)/dt>thsld2

Timer1>10minincrement timer

leg1 fully charged leg2 fully charged

no

yes

no

nono

nono

yes yes

yes

yes yes

Switch to trickle charge in each leg

External heatingNormal charge resumed,Internal balancing takes place.

Thsld reached,Entering potential overcharge.

Overcharge detected on leg1,Charging process over.

Algorithm based on simple derivative fails

New algorithm delivers accurate full SOC detection

Thsld reached,Entering potential overcharge mode.

Experimental Results2005 - Differential Temperature Algorithm

dt

dT1

dt

TTd )( 21

1T

I

V

External heating does not fool new algorithm

Conclusion

•More robust voltage charge control algorithm (2004)

•Differential temperature charge control algorithm (2005)

•Maximum Power Point Tracker (2004-2005)

•Algorithms are being implemented inside theprototype charger.

• The phase one prototype is stand alone and mechanicaly compatible with BB390 batteries