Second Life Hybrid Vehicle Batteries Used In Solar Backup
Chad Davis, Ph.D., P.E.
School of Electrical and Computer Engineering
University of Oklahoma
Norman, OK, USA
Abstract For solar power to provide 24/7 capabilities an energy
storage is needed. In this project, an energy storage system was
constructed from second life batteries taken out of hybrid
vehicles. The batteries were removed from five vehicles, graded
and reassembled into a high voltage storage system that was then
integrated with a solar power system. The storage system also
allows a larger solar array to be used with a smaller inverter.
This poster session will show initial results of this system. The
ultimate goal is determining the suitability and longevity of
second life hybrid vehicle batteries for energy storage.
Keywords- hybrid, vehicle, batteries, solar, backup, storage.
I. INTRODUCTION
For solar power to provide continuous capabilities a method
of energy storage is required. This is usually provided by large
lead acid batteries that are charged by the panels during sunny
times and then discharged at night or bad weather. The most
common setup is a lower pack voltage with at most 48V and
high capacity batteries in the thousands of amp hours. There
are many advantages of having a higher backup battery
voltage. While this can be accomplished with traditional lead
acid batteries, the number of batteries required can be cost
prohibitive. An alternative solution is inexpensive second life
NiMH batteries from end of life hybrid vehicles. While these
batteries have come out of vehicles that are no longer rated for
traction applications, they still have enough useful life for
stationary storage operation. In addition they are sealed and
maintenance free making them attractive for backup storage.
II. SYSTEM OVERVIEW
This poster session will present a 330 volt battery that was
constructed from second life hybrid vehicle batteries that
directly backups a set of solar panels with their inverter. The
first step to create this system was testing the batteries to
determine if they were suitable for energy storage and their
expected life. In a hybrid vehicle the battery is built for power
transfer. In vehicle operation, the battery might be charged and
discharged many times at relatively high power rates. In a
storage application the battery might be charge once during
the day at a slow rate and then discharged at a slow rate at
night. The hybrid vehicle packs were disassembled and the
individual batteries tested for capacity, temperature
abnormalities, and maximum power transfer. Data from good
and bad Saturn Vue hybrid batteries will be presented.
Batteries that passed testing were grouped together to form
240 cell strings. In the current storage system, a 240 cell string
978-1-4673-0967-7/12/$31.00 2012 IEEE
Bryan Schultz
ATC Drivetrain
Oklahoma City, OK, USA
of Honda Civic batteries and a 240 cell string of Toyota Prius
batteries are used to store the energy generated from 12 Sanyo
solar modules. The batteries are cycled from about 80% soc to
20% soc, while charging in the morning and discharging
through the night. The two different strings are individually
controlled and are joined in the controller. Voltage, current,
power, and state of charge are live streamed over a wireless
link to a dashboard in the lab for continuous monitoring.
A controller was also built to integrate the battery to the
solar panels and inverter and cycle tests were performed. The
last and ongoing part of the project is running the high voltage
battery in combination with the solar cells and inverter over
time. The procedure is to charge the cells in the morning,
while still placing power on the grid. Once the battery is full
the entire amount of incoming solar power is placed on the
grid. In the evening the battery takes over and fully supplies
the inverter with power over the night. There are a few
benefits observed from using the high voltage battery with the
solar system. The batteries voltage is very close to the solar
panels output so the batteries can be directly wired to the
inverter with no additional voltage conversion. During the day
after the batteries are charged, the inverter is switched to
maximum power tracking to get the most energy out of the
panels. Once the sun drops lower in the sky the batteries assist
with the remaining solar power to provide a constant output on
the inverter. By the time of sunset the batteries are providing
all of the power to the inverter. This continues through the
evening until next morning.
For the 3 kW inverter the current is 9.1 amps when running
with a 330V battery and 62.5 amps with a 48 V battery. The
much lower current from the high voltage battery reduces
losses and decreases the size of wire required. The other
important benefit is the reduced cost associated with the
second life batteries. In addition the batteries behave as sealed
maintenance free batteries not needing water top off, venting
and as much infrastructure such as acid trays. Another
application this system can be helpful in is load shifting. The
solar panels normally displace grid electricity moment by
moment. For users on a fixed rate plan electricity produces in
the morning is just as valuable as in the afternoon. For variable
rate pricing however electricity produced in the afternoon can
be as much as 10 times the price and morning electricity. The
batteries would allow energy to be stored from the solar panels
right up until the high priced electricity started. The batteries
could then be discharged along with the incoming solar energy
to maximize the value of the produced energy.