GFR 2023 Battery Cell Testing/Simulation

By

Casey Hennessey

The goal of this project is to parameterize a model of the battery cell and battery pack in Matlab/Simulink. This will be accomplished using actual Pulse Discharge data collected during Senior Capstone with the OSU Global Formula Racing (GFR) Team. The testing was accomplished using the Tesla sponsored COSMX brand Lithium-ion battery cells that are to be used to build a large (600V) battery pack for the 2023 competition vehicle. The cell model will be a Resistance-Capacitance based model and run through various simulated charges and discharges. The simulated voltage and current responses will be compared both visually and numerically for curve matching of the emulated versus actual response. Additional testing and simulation will be completed as necessary. UPDATED 10 September 2023: A new more accurate battery model has been uploaded.

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Artifacts

Name Description
3a. Python Script (main) 3a. 1`An automated test end when the temperature nears maximum (55 C*). Keyboard "listener" for keyboard press for an "Emergency Shutoff" button that will disable the equipment and stop the test in progress. Option on all of the tests to start from nominal voltage instead of charging to maximum first. A new "Test" (menu) option: "Charge or Discharge to Nominal Voltage" which will prepare the cell for storage. Fix issue in Charge/Discharge test where there is no logic to exit the outer loop when the inner loop reaches minimum voltage. Reduce the recovery time between pulses for the Charge/Discharge test.   Download
3a. Python Script (Source Library) 3a. 1`An automated test end when the temperature nears maximum (55 C*). Keyboard "listener" for keyboard press for an "Emergency Shutoff" button that will disable the equipment and stop the test in progress. Option on all of the tests to start from nominal voltage instead of charging to maximum first. A new "Test" (menu) option: "Charge or Discharge to Nominal Voltage" which will prepare the cell for storage. Fix issue in Charge/Discharge test where there is no logic to exit the outer loop when the inner loop reaches minimum voltage. Reduce the recovery time between pulses for the Charge/Discharge test.   Download
3a. Python Script (Load Library) 3a. 1`An automated test end when the temperature nears maximum (55 C*). Keyboard "listener" for keyboard press for an "Emergency Shutoff" button that will disable the equipment and stop the test in progress. Option on all of the tests to start from nominal voltage instead of charging to maximum first. A new "Test" (menu) option: "Charge or Discharge to Nominal Voltage" which will prepare the cell for storage. Fix issue in Charge/Discharge test where there is no logic to exit the outer loop when the inner loop reaches minimum voltage. Reduce the recovery time between pulses for the Charge/Discharge test.   Download
3a. Python Script (Optional) Rigol device identification script.   Download
4. A Charge/Discharge (CD) Test that emulates regenerative braking of an electric vehicle will be completed for temperature and response data for future GFR simulations. 4. The CD Test(s) will produce a CSV file which will include a metadata header as well as data for duration, voltage, current, ambient (inside the Capstone Oven testing chamber) temperature, and temperature data from 7 set points on the battery cell.   Download
3b. Arduino Script (main) 3b.An automated test end when the temperature nears maximum (55 C*).   Download
3b. Arduino Script (Dimmer Library) 3b.An automated test end when the temperature nears maximum (55 C*).   Download
1. The parameters of the most accurate cell model(s) in the form of Resistance-Capacitance (RC) pairs (Resistance and Tau is the actual output where Tau is the RC time constant) using the Mathworks Matlab/Simulink module. 1. The cell model responds within ~0.05 volts of expected values.   Download
Project Video 2 Demonstration of simulation using parameterized values   Link
Project Video 1 Demonstration of quality of life improvements for Python scripts controlling Rigol testing equipment   Link
MATLAB Model A zipped file containing parameters, a cell model, a stack (140-cell) model, and an .ini file that will parameterize and run the simulations.   Download
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