SENSOR*:

Embedded Fiber-Optic (FO)

Sensing for Battery Packs

Dr. Ajay Raghavan

raghavan@parc.com | 1-650-812-4724
*SENSOR: Smart Embedded Network of Sensors with an Optical Readout

www.parc.com/sensor

ARPA-E AMPED Program

AMPED:

Advanced Management and Protection of Energy Storage Devices

2

SENSOR Overview

Online at www.parc.com/sensor
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FO Sensor Example: Fiber Bragg Gratings

Fiber Bragg grating sensor
mirror
(FBGs)
white

gain medium

light
1

reflection

La

1+

1
stimulus

wavelength

Strain, temperature, gas,

chemical, current, voltage, ...

Multiplexable: multiple
sensors on single FO
reflection

Photonic crystal sensor

1

1+
1

wavelength

white
light

Silicon micro-sphe
5

Initial Study for External Strain, Temperature

Readout

1 (fixed) 2 (loose)

Picks up
total strain

Picks up only
thermal strain

Setup mimics
module pressure,
cooling

FBG signal (pm)

FBG signal (pm)

FBG signal (pm)

Mechanical Strain Across C Rates

Curves similar across C rates, including dynamic cycles

7

FBG signal derivative (pm/s)

Intercalation Stages from FBG Strain Signal

FBG derivative peaks
intercalation stage transitions
Graphite

Stage 4

Stage 3

Stage 2

Stage 1

From Sethuraman et al. 2010

Peaks aligned
across C-rates

SOC (%)
Stage transitions shift
w/ life: aging metric

From Liu, P. et al. 2010

8

Cold Test at 15.5oC

~50% SoC at end of charge

accurately sensed by FBG

C/2 to cell V limit

C/10 to cell
V limit

Strong, accurate FBG signal even at cold temperatures

9

NTC signal (oC)

FO signal (pm)

Strain gauge signal ()

FBG signal (pm)

FO signal (pm)

Electrical v/s FBG: Cell External Sensing

No load

CC Charge CV

No load

Time (hours)
Time (hours)
FBG strain v/s electrical strain gauge

Loose FBG v/s NTC thermistor

Electrical strain gauge signals seem not as repeatable

NTC signal shows tendency to pick up EMI
10

Pouch Cells with Internally Embedded FO

15 Ah large-format

1.5 Ah small-format

Stable embedded config w/ FBGs bonded to electrode

Approach extended to large-format cells
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Internal Small-Format Cell FBG Signals

FBG signal (pm)

Internal FBG signal

FBG T signal

Time (h)

Internal signals 2-5x stronger than external

Cell internal temperature, other SOX features detectable
12

Internal FBG Robustness: Dynamic Cycles

Internal more robust than external; both better than cell V

13

4-Cell Module Assembly w/ Large FO-Cells

Individual
15 Ah cell

Optical
fibers

Connectors for cooling fins

No major module assembly line changes for FO-cells

14

HPPC Response at 50% SOC, 20oC

Strain changes linearly over pulse, settles

60s rest

7C for 10s
60s rest

5C for 10s

The ideal HPPC response

- Major OEM battery engineers
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FBG Strain Signals: Rapid Dynamic Cycles

Red: UDDS cycles
Blue: Static cycles

US06
Red: US06 cycles
Blue: Static cycles

Cell #3

Cell #1

UDDS

Error of <2.5% over 5-100% SOC achieved: >2x SOTA

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Initial Aggressive Cycle SOH Results

Observed
Model

200
180
160
140
120
100

50
100
Number of cycles

150

0.22
Compensated strain

Compensated strain (pm)

220

0.2
0.18
0.16
0.14
0.12
0.1
14.8

14.9
15
15.1
Charge capacity (Ah)

Prediction horizon

Mean error Max error

1 cycle ahead

0.14%

0.38%

5 cycles ahead

0.24%

1.1%

10 cycles ahead

0.4%

2.2%

15.2

10-cycle horizon capacity prediction error of <2.2%

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16

Wavelength shi (pm)

Discharge Capacity (Ah)

FO-Embedded Cells: xEV-Grade Life, Seal

15.5
25C
Disharge: 30A
Charge: 15A 1C

15
14.5

25C
Disharge: 30A
Charge: 30A 2C

14
13.5

Fiber-op c cell

12.5
50

Cycle #

100

150

Projected FO-cell life: 1100+ cycles

FO
Only electrolyte
(Without Cell)

+ 3 deg C

- 3 deg C

20
0
10

20

30

40

50

-40

12
0

FBG signal

40

-20 0

Base Cell

13

60

-60

Time (weeks)
Electrolyte-robust FO coatings

FO-pouch seal
integrity as good as
pouches w/o FO in
60oC, 95% RH test

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And One More Thing PARCs FO Readout

Prototype size:
8 x 4.5 x 4

Anticipated
production size:
3.5 x 3 x 0.7

50 fm (0.05 ) res.: 20x SOTA

Up to 480 channels at 40 Hz

From Thylen and Wosinski 2011

~$300 for high-vol. system

Drop to $150 feasible

SENSOR can replace BMS electrical sensing

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Ext. v/s Int. FO Value: Chevy Volt Example

Electronics Lightweight Coolant Fewer cells V harness
$29
$90
sensor
$100
recycling
$15
i sensor
$7
$28

BMS boards
$354

High V
sensor
$10
Isola on
$204
T sensor
$19

Internal FO 2011 Volt

All cells w/ embedded FO
Savings: $1134+ 19.2 lbs.
Cost: $333 + 0.2 lbs.
Net: $801 + 18.9 lbs.

External FO 2011 Volt

1 of || strings monitored
Savings: $856+ 8.3 lbs.
Cost: $294+ 0.2 lbs.
Net: $562 + 8.1 lbs.
Coolant
Electronics Lightweight
sensor
$67
recycling
$28
$7
Fewer cells
$328
BMS boards
$354
Isola on
$204

V harness
$90

i sensor
$28
High V
T sensor sensor
$19
$10

Costs comparable; internal more SOX accuracy, value

Low added $ for more sensors; more value w/ larger packs
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Summary
Laser cavity sensor

mirror

reflection

gain medium
1

1+

n1
n2
fluidic
channel

wavelength

stimulus
wavelength

FO: a new BMS enabler

tonic crystal sensor

Surface plasmon resonance sensor

Practical for xEV field deployment

Coolant
Electronics Lightweight
sensor
$67
recycling
$28
$7
Fewer cells
$328
BMS boards
white
$354

Red: US06 cycles

Blue: Static cycles

1+

length

light

Silicon micro-sphere sensor

transmission

white
light

<2.5% accurate SOX: >2x SOTA

stimulus

white
light

reflection

white
light
1

output intensity

Exciting results for BMS sensing, cell state challenges:

Fiber Bragg grating sensor

Isola on
$204

V harness
$90

wavelength

i sensor
$28
High V
T sensor sensor
$19
$10

$-cost competitive

In OEM discussions for further validation,

tech transfer
wavelength
raghavan@parc.com; Booth #1954
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May contain trade secrets or commercial or financial information that is privileged or confidential and exempt from public disclosure.

SENSOR Cost Est.: 11 Volt Ext. v. Internal

Readout
$250

Module
FO sensors
connect
$13
$8
Recycling
Light source
Controls
Power
fee
$10
$5
$1
$3

External Config 1 of
||Cost Estimate:
$303 (1M xEVs/year)
$366 (200k xEVs/year)
Readout
$250
Module
connect
$8

Recycling
Internal Strain + Temp. all FO sensors
fee
$34
cells Configuration Cost
$3
FO cell
Light source
Tech.
Estimate:
Power
embedding
$10
premium
$1 Controls
$6
$26
$352 (1M xEVs/year)
$14
$572 (200k
Cost estimates
incl.xEVs/year)
assembly, on solid footing w/ new data
Readout key cost: low cost to embed/sense more cells
May contain trade secrets or commercial or financial information that is privileged or confidential and exempt from public disclosure.

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May contain trade secrets or commercial or financial information that is privileged or confidential and exempt from public disclosure.

New BMS Scenarios w/ SENSOR: Summary

1. xEV dynamic cycle utilization not limited by cell V
2. BMS control to maximize life w/ better cell state info:
Detect, manage early incipient issues, excessive strain

Track intercalation stage shifts for cell aging estimate

Minimize temp. differential between internal/external

3. More informed charging, regen, balancing

4. Better cell utilization for cold temp. use: avoid

polarization issues in cell V

5. Enhanced safety from awareness of incipient failure

Broad range of new use cases anticipated to enable

better BMS for longer life and pack utilization to true limits
May contain trade secrets or commercial or financial information that is privileged or confidential and exempt from public disclosure.

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FBG signal (pm)

Voltage (V)

Current (A)

Applicable to Other Chemistries: LiFePO4

Time (h)

Considerable external FBG strain signal, features

also seen in flat-voltage chemistry like LFP
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After 1st overV

V limit (4.2 V)

Voltage (V)

Current (mA)

FBG signal (nm)

Ext. FBG Strain for Over-V (AA PP Pouch Cell)

Sample point
Clear FO strain signal change right after 1st mild overcharge
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Residual Strain Effect on Cell Performance

Cell performance and strain curves (from Wang et al., JECS 04, 07)

Residual cell strain after cycles affects performance

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Cell Internal Temperature: Higher C Rates

(a)

(b)
(a) Internal 4.4 Ah LiFePO4 cell temp: 5oC, 16 C pulses, cooled;
(b) Persistent SOC difference (from Fleckenstein et al. JPS 11)

Worse (20oC) at higher C rates and large-format cells

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Use Case #2: Control to Maximize Cell Life

(b) 4.4 Ah LiFePO4 cell temp.: 5oC, 16 C,

cooled (Fleckenstein et al. JPS 11)
4.35

100
4.348

Voltage (V) (V)

Voltage

(a) FBG sensors useful for detecting

excess cell strain (can lead to
electrode cracking)

FBG strain at end

(pm)
charge
of Strain
at end of charge (pm)

110

90

4.346

80

4.344

70

60

4.342

50

4.34

40
4.338

30

20
0.97

0.98

0.99

1.01

1.02

1.03

Discharge cell capacity (Ah)

Discharge cell capacity (Ah)

1.04

4.336
0.97

0.98

0.99

1.01

1.02

1.03

1.04

Discharge cell capacity (Ah)

Discharge cell capacity (Ah)

(c) Better SOH, capacity fade

prediction to manage cell life

SENSOR-enabled better real-time cell state awareness for

BMS to manage for longer pack life
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Use Case #5: Enhanced Safety

LCO cells fatigued under
rapid dynamic cycles
Cell failure seen much
later in cell V (plating)
Electrical signals

FBG signals and SOC

Drop in SENSOR
signal despite
expected flat SOC
from i-counting

SENSOR can detect subtle failures not seen in cell V/i signals
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