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Overview
Information is Power
Functionality
Maintenance
Identifies unhealthy batteries for replacement
Facilitates Condition-Based Maintenance (CBM)
Cost-Efficiency
Single BFG per system vs. multiple BFGs per system
Simple configuration reduces install, operation, and maintenance
Powerful tool for intelligent power management systems
5
BFG Implementation
Mobile Application
Customer
Navistar Defense
UK MOD/NATO
Vehicle
Husky Tactical Support Vehicle
Application
Monitors Battery SOC and SOH
Over 1500 HDM BFGs have
been installed in Husky
TSVs in Afghanistan
supporting the NATO troops
6
BFG Implementation
Stationary Application
Customer
Raytheon Company
System
R-Series Regenerator Hybrid
Power System
Application
USMC Experimental
Forward Operating Base
Phase IV Demonstration in
2010 at 29 Palms, CA
HDM BFG is critical component
of intelligent Hybrid Power
System
7
Configuration 1
System Level Monitoring Only
Inline Fuse
Battery Positive Sense Wire
12VDC
Battery
#1
12VDC
Battery
#3
12VDC
Battery
#5
DC Load
(Alte
ernator)
Cha
arger
Interface Connection
(Display, RS232, CAN-Bus)
12VDC
Battery
#4
12VDC
Battery
#6
Load
Neg
Batt
Neg
Advantage: SIMPLICITY
9
Configuration 2
Cell Level Monitoring Only
12VDC
Battery
#1
Load
Neg
Batt
Neg
12VDC
Battery
#3
Load
Neg
Batt
Neg
12VDC
Battery
#5
Load
Neg
DATA
R E A D IN G S
SOH
C e ll
SOC
C e ll
Batt
Neg
Inline Fuse
DC Load
(Alte
ernator)
Cha
arger
12VDC
Battery
#2
Load
Neg
Batt
Neg
12VDC
Battery
#4
Load
Neg
Batt
Neg
12VDC
Battery
#6
Load
Neg
Batt
Neg
olta ge)
Interface(V
Connection
(Display, RS232, CAN-Bus)
C e ll
HFuel
R Gauge
(H r R em ain )
Sensor Module
C e ll
I (C u rre nt)
C e ll
Tem p
C e ll
Advantage: PRECISION
10
Configuration 3
System/String/Cell Level Monitoring
12VDC
Battery
#1
12VDC
Battery
#3
12VDC
Battery
#5
DATA
READINGS
SOH
Cell/String/System
SOC
Cell/String/System
Inline Fuse
DC
C Load
(Altternator)
Ch
harger
Cell/System
Interface(Voltage)
Connection
(Display, RS232, CAN-Bus)
HR
(Hr Remain)
Fuel Gauge
Sensor Module
12VDC
Battery
#2
12VDC
Battery
#4
12VDC
Battery
#6
Load
Neg
Batt
Neg
System
I (Current)
Cell/String/System
Temp
System
12
SOC Measurement
Using Dual Tracking Method
100
Fuel Gauge SOC
Theoretical SOC
Fuel Gauge SOH:82%
(at discharging time = 0 min.)
80
SOC (%)
60
40
20
0
0
10
20
30
40
50
60
70
80
90
100
14
Voc
AH
SOC (%)
> 12.8
100-98
12.80-12.74
98-96
12.74-12.69
96-94
12.69-12.66
94-92
.
.
.
.
.
.
.
.
.
.
.
.
48
11.14-11.08
6-4
49
11.08-10.88
4-2
50
10.88-10.64
2-0
SOC: 100%-0%
15
Voc
AH
SOC (%)
> 12.8
1.8
100-98
12.80-12.74
1.8
98-96
12.74-12.69
2.1
96-93
12.69-12.66
2.1
93-90
.
.
.
.
.
.
.
.
.
.
.
.
48
11.14-11.08
1.6
6-4
49
11.08-10.88
1.6
4-2
50
10.88-10.64
1.8
2-0
Total Segments:
1-50
Voc:
>12.8 10.64
Self-Calibrated
Total AH: 90
SOC:
100%-0%
16
100
Accurate
Underestimated
SOC (%)
80
60
40
20
0
0
50
100
150
200
250
300
350
400
450
500
B (78%SOC)
26
V
o
c(V
o
lta
g
e
)
Voc (Volts)
25
A (100%SOC)
24
23
Voc 12Hrs Rest after Full Charge
Voc No Rest after Full Charge
22
21
0
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
time(mins)
Time (min)
100
Combined SOC
Voltage-based SOC
SOC
(%)
SOC
(%)
80
60
40
20
0
0
50
100
150
200
250
Configuration 3
System/String/Cell Level Monitoring
12VDC
Battery
#1
12VDC
Battery
#3
12VDC
Battery
#5
DATA
READINGS
SOH
Cell/String/System
SOC
Cell/String/System
Inline Fuse
DC Load
L
(Altern
nator)
Charrger
Cell/System
Interface(Voltage)
Connection
(Display, RS232, CAN-Bus)
HR
(Hr Remain)
Fuel Gauge
Sensor Module
12VDC
Battery
#2
12VDC
Battery
#4
12VDC
Battery
#6
Load
Neg
Batt
Neg
System
I (Current)
Cell/String/System
Temp
System
Battery 1
10
15
20
25
30
35
Theoretical SOC
Theoretical - 5%
Battery 4
10
15
20
25
30
Theoretical + 5%
Theoretical - 5%
Battery 2
100 0
90
80
70
60
50
40
30
20
10
0
SOC (%)
Theoretical + 5%
SOC (%)
100
90
80
70
60
50
40
30
20
10
0
Theoretical SOC
SOC (%)
SOC (%)
Theoretical + 5%
35
100
90
80
70
60
50
40
30
20
10
0
10
15
20
25
30
100
90
80
70
60
50
40
30
20
10
0
35
Battery 5
Battery5
5
AH Discharged
10
15
20
25
30
SOC (%)
Theoretical SOC
100
90
80
70
60
50
40
30
20
10
0
Theoretical - 5%
Battery 3
10
15
20
25
30
35
Theoretical + 5%
Theoretical - 5%
Battery 6
35
Theoretical SOC
SOC (%)
10
AH Discharged
15
20
25
30
35
AH Discharged
100
90
80
70
60
50
40
30
20
10
0
SOC (%)
100
90
80
70
60
50
40
30
20
10
0
Theoretical - 5%
Battery System
6 Batteries Combined
0
20
40
60
AH Discharged
80
100
21
SOC (%)
SOC (%)
Theoretical + 5%
Theoretical - 5%
Battery 1
90
80
Theoretical SOC
70
Theoretical + 5%
60
Theoretical - 5%
50
40
Battery 2
30
20
10
0
100
90
80
70
60
50
40
30
20
10
0
10
15
20
25
30
35
10
15
20
25
30
Theoretical SOC
80
Theoretical SOC
70
Theoretical + 5%
SOC (%)
Battery 4
60
Theoretical - 5%
50
40
30
20
Battery 5
10
0
10
15
20
25
30
35
10
AH Discharged
15
20
AH Discharged
25
30
Theoretical + 5%
Theoretical - 5%
Battery 3
100
90
80
70
60
50
40
30
20
10
0
35
10
15
20
25
30
35
40
Battery 6
10
15
20
25
30
35
40
AH Discharged
100
90
80
70
60
50
40
30
20
10
0
SOC (%)
Theoretical SOC
SOC (%)
90
SOC (%)
Battery Monitor
Theoretical - 5%
35
100
Theoretical + 5%
100
90
80
70
60
50
40
30
20
10
0
SOC (%)
100
90
80
70
60
50
40
30
20
10
0
Theoretical + 5%
Theoretical - 5%
Battery System
6 Batteries Combined
0
20
40
60
80
100
AH Discharged
22
Battery #
11.3V
11.5V
11.4V
11.4V
10.8V
12.0V
Sum
1-3
Sum
1-6
1
2
Discharge Current
From
To
12A
10A
18A
19A
18A
4A
SOC
%
SOH
%
10
73
16
78
12
71
12
73
50
36
78
0%
68%
Battery #
11.3V
11.4V
10.6V
12.1V
11.2V
11.5V
Sum
1-3
Sum
1-6
1
2
49A
6A
45A
SOC
%
SOH
%
14
77
19
80
55
51
93
12
75
22
87
0%
62%
Battery Voltage
@ End Point 1
(Bat 3 SOC=0%)
11.3V
9.9V
11.4V
11.1V
10.6V
9.6V
12.1V
11.5V
11.2V
9.7V
11.5V
Sum
1-3
Sum
1-6
22.7V
1
2
Discharge Current
Charge Current
@ 100%
SOC
@ End
Point 1
@ End
Point 2
@ Low SOC
36A
51A
20A
20A
30A
6A
65A
3A
11.3V
36A
45A
17A
19A
21.0V
102A
102A
102A
Set @ 42A
100
Theoretical - 5%
90
80
SOC (%)
70
60
50
40
30
20
10
0
0
200
400
600
800
1000
1200
1400
1600
1800
2000
AH Discharged/Charged
SOC accuracy reaches 90-95% during the charge portion of the cycle
within 3 cycles
26
Maintenance Level
Enables precision pinpoint of unhealthy batteries for CBM
Thank You!
Contact Information:
Dr. David Liu, VP of R&D: davidliu@hdm-sys.com
HDM Systems, Inc.
226 Lincoln Street
Allston, MA 02134
Tel: 617.562.4054
Fax: 617.562.4013
Web: www.HDM-Sys.com
28
Appendix
29
100
100
80
80
60
Fuel Gauge SOH: 89%
at Discharge Time = 0 min.
40
SOC (%)
SOC (%)
40
20
20
0
0
20
40
60
80
100
20
40
60
Discharging Time (min)
100
100
100
80
Theoretical SOC
80
SOC (%)
SOC (%)
80
40
60
40
20
20
0
0
20
40
60
80
100
20
40
60
80
100
100
90
80
70
60
50
40
30
20
10
0
SOC (%)
SOC (%)
Battery H2
50
100
AH Discharged/Charged
150
200
100
90
80
70
60
50
40
30
20
10
0
0
100
200
300
400
500
600
AH Discharged/Charged