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India is a fast-growing marketplace for electrical automobiles (EVs), with one examine predicting that greater than 30 p.c of automobiles bought in India shall be electrical by 2030 (Ref. 1). The battery packs that energy electrical automobiles are one of many foremost drivers of the electrical mobility revolution in India. To observe and handle the efficiency and security of battery packs, the packs are usually outfitted with a Battery Administration System (BMS). A BMS is an digital system that displays the voltage, temperature, coolant stream, and situation of a battery and predicts a lot of different efficiency parameters, equivalent to present variation and warmth technology, serving to to extract optimum efficiency from a battery pack.

The function of simulation in growing correct BMS

Exicom Tele-Programs Pvt. Ltd. designs, develops and implements energy options, together with the newest lithium-ion battery applied sciences. Thus far, it has deployed lithium-ion battery options totaling greater than 1.8 GWh, among the many highest on this planet by a single firm. Exicom additionally gives BMS and charging options for electrical two-wheelers and light-weight electrical automobiles, that are driving the expansion of electrical mobility in India. Exicom’s revolutionary BMS options are prized for his or her efficiency and lifelong.

At Exicom’s R&D heart in Gurugram, India, the expertise workforce led by Dr. Parmender Singh has developed a BMS that can be utilized to precisely monitor and handle lithium-ion batteries in purposes throughout a variety of purposes. voltage vary (as much as 1000 V). This BMS can also be chemistry unbiased; Can be utilized with lithium-ion batteries of a wide range of chemical compounds, together with lithium ferrophosphate or lithium iron phosphate (LFP), lithium nickel manganese cobalt oxide (NMC), and aluminum nickel cobalt oxide lithium (NCA).

For India’s transport sector to fulfill its formidable electrification targets, producers should speed up growth of important elements equivalent to battery administration techniques (BMS)

The accuracy of the BMS is determined by the standard and accuracy of the inputs used to program or calibrate the system. For instance, the BMS contains a number of thermal sensors distributed all through the battery pack. As a way to precisely monitor the temperature distribution of a battery pack and predict the corresponding efficiency, it’s crucial that the sensors be positioned within the appropriate places. This requires an in depth understanding of the warmth profile of every battery cell, in addition to how warmth varies all through the pack. That is the place COMSOL Multiphysics performs an integral function, enabling the exact calculation and assortment of inputs, equivalent to warmth profile info, required to develop a BMS with surgical precision.

Prediction and prevention of attainable thermal runaways

Dr. Singh’s workforce at Exicom used COMSOL Multiphysics to carry out a sequence of analyzes on the thermal conduct of battery cells. In addition they used simulation to research potential exterior brief circuits, which might trigger thermal runaway, an uncontrolled self-heating course of that may injury gear and even begin fires. The Exicom workforce began by analyzing the warmth generated in cylindrical cells with completely different type elements after which prolonged this mannequin to the package deal degree utilizing the profile of warmth generated by the cells. “We have been particularly occupied with enhancing the temperature gradient throughout the pack for air-cooled battery packs,” Dr. Singh stated.

The outcomes of cell-level thermal modeling for cylindrical cells throughout a 1C discharge are proven in Determine 1. The left visualization in Determine 1 reveals the temperature distribution, the place the utmost temperature is noticed in the midst of the cell. cell. The visualization to the best reveals the temperature boundary distribution, the place the utmost temperature is discovered within the lively cell materials.

The simulation outcomes, when validated with experimental findings, have been discovered to be inside the error limits of ±5 p.c on the usual charge-discharge profile. The mannequin was then additional prolonged for 2C discharge at one hundred pc state of cost (SOC) in accordance with the UL1642 commonplace, which is outlined for exterior brief circuit testing.

The optimistic and damaging terminals of the cell have been short-circuited by a resistance of 80 ± 20 mΩ. The thermal mannequin based mostly on the pooled method of the COMSOL software program was validated with experimental knowledge for the cost and discharge profiles of the cell. In addition they developed:

  • Cyclic and calendrical capability fading fashions for cylindrical cells based mostly on the optimization features out there in COMSOL
  • A high-fidelity pseudo-two-dimensional (P2D) mannequin for cylindrical cells utilizing extracted electrochemical parameters

They discovered that the pooled method allowed them to construct fashions utilizing a minimal variety of parameters, equivalent to cell geometry, electrode thickness, thermal conductivity, warmth capability, conduction cycle, and the open-circuit voltage SOC desk ( OCV), that are straightforward to research. out there from battery pack producers.

Extracting these parameters experimentally shouldn’t be solely a sluggish course of, but in addition error-prone attributable to variable experimental situations. For instance, ambient temperatures fluctuate, so extracting an correct warmth profile of a cell requires working an in depth sequence of exams at completely different ambient temperatures. Nevertheless, utilizing simulation, Dr. Singh and the workforce have been in a position to carry out these experiments with nice ease. They have been in a position to effectively examine cost and discharge profiles, thermal conduct at completely different cost and discharge charges, and thermal runaway attributable to exterior or inner brief circuits for various cell chemistries. They have been additionally in a position to establish hotspots on the battery pack and decide cell classification based mostly on capability fading evaluation with excessive precision. These outcomes had direct purposes in lowering the BMS growth cycle time, because the entry factors indicated the very best positions to deploy the thermal sensors inside the BMS to make them work extra effectively. In line with Dr. Singh, “COMSOL is an adaptable and easy-to-learn finite factor device for battery design and thermal modelling.”

Determine 4. The COMSOL Multiphysics consumer interface exhibiting a battery mannequin.

Future Scope: Extending Battery Simulations to Predict Getting old

Along with thermal simulations, Dr. Singh has expanded using simulations to research one other necessary phenomenon: battery ageing. Through the lifetime of a battery, its state of well being (SOH) progressively deteriorates attributable to irreversible bodily and chemical adjustments, equivalent to the expansion of a strong electrolyte interface (SEI) layer, which might result in lack of porosity within the battery. a battery cell, which in flip can result in a rise in polarization and inner resistance. Magnetic Subject Probing (MFP) is a non-invasive methodology of monitoring the SOH of a battery. As a way to display the potential of the MFP methodology, Dr. Singh developed a multiphysics mannequin in COMSOL to judge the magnetic subject response, battery polarization, and inner resistance of the lithium-ion battery (Ref. 2). . The workforce discovered that variation in electrode porosity has a big affect on the magnetic subject response. Though this analysis is at present in its preliminary levels, the potential purposes are far-reaching. “We hope that additional analysis on this phenomenon will permit monitoring features for battery growing old to be developed and carried out, in addition to higher safety mechanisms in opposition to it within the BMS itself,” stated Dr. Singh.

Diagram showing the magnetic field and current density inside a rectangular battery, and a graph showing the field and voltage over time.

Determine 5. Cell geometry designed in 3D (left). Variation of the magnetic subject response and polarization conduct throughout discharge at anode porosity values ​​of 0.12 and 0.36 (proper).

The Exicom workforce is at present engaged on electrochemical P2D modeling for thermal and capacitance fading evaluation on the cell degree. It’s meant to additional lengthen the mannequin with extra thermal exothermic equations on the electrodes and the SEI layer for increased accuracy throughout thermal runaway. In addition they plan to make use of the lumped capability fading mannequin for cyclical and calendrical predictive evaluation. Sooner or later, additionally they plan to implement a lowered order mannequin for SOC and SOH and export the mannequin to MATLAB for code technology all the way down to the ASIC degree.

With the accelerated transition to electrical mobility in India and world wide, analysis into battery expertise is anticipated to extend considerably within the coming years. Simulation software program like COMSOL gives an important benefit for firms within the electrical mobility house that need to present more practical options and enhance time to marketplace for their merchandise.


  1. S. Sen, “30% of automobiles in India shall be electrical by 2030: examine”, The Occasions of India, June 17, 2022;
  2. P. Singh et al., “Lithium-ion Battery Getting old Parameter: Evaluation of Porosity Conduct Utilizing Magnetic Subject Probing” ECS Assembly Summaries, vol. MA2021-02, 2021, no. 3, p. 294, 2021.

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Exicom Refines Battery Management Systems with Simulation

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