Details
Lead-Acid Battery , while widely used in various applications, including Electric Vehicles (EVs), pose several risks due to their design, chemical composition, and operational limitations. Here’s an overview of the risks associated with lead-acid batteries:
1. Safety Risks
- Overheating and Thermal Runaway:
Cause: Overcharging, internal short circuits, or improper handling.
Impact: Overheating can lead to battery explosions or fires, causing serious injuries or property damage.
- Acid Spillage:
Cause: Cracked or damaged battery casing.
Impact: Sulfuric acid leakage can cause chemical burns, corrode surrounding materials, and harm the environment.
- Hydrogen Gas Emission:
Cause: During charging, lead-acid batteries emit hydrogen gas as a by-product.
Impact: Hydrogen is highly flammable; accumulation in enclosed spaces can lead to explosions.
- Heavy Weight:
Cause: The design and composition of lead-acid batteries.
Impact: Increased weight can affect vehicle performance and stability, especially in EVs.
2. Performance Risks
- Low Energy Density:
Cause: Inherent design limitations.
Impact: Shorter driving range compared to modern battery technologies like Lithium-ion, leading to frequent charging requirements. - Reduced Lifespan:
Cause: Deep discharging, overcharging, or poor maintenance.
Impact: Frequent replacements result in higher long-term costs. - Voltage Drops:
Cause: High internal resistance under load.
Impact: Reduced performance during peak power demands, affecting vehicle speed and acceleration.
3. Environmental Risks
- Toxic Materials:
Cause: Lead and sulfuric acid content.
Impact: Improper disposal leads to soil and water contamination, harming ecosystems and human health. - Recycling Challenges:
Cause: Limited infrastructure for proper recycling in some regions.
Impact: Inadequate recycling practices exacerbate environmental pollution.
We overcome the Lead Acid Battery challenges through developed customized, engineering configured Lithium NMC Batteries.
Title:
The development of an advanced, specially configured, customized, and enhanced/ highly sophisticated circuitry for a Battery Management System (BMS) and cost-efficient charging system specifically designed for 48V108Ah & 60V160Ah Lithium NMC, (Nickel, Manganese, Cobalt Oxide) batteries used in electric vehicles three-wheelers, scooters, easy bikes and Microbus.
The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:
The development of an advanced, specially configured, customized and enhanced/sophisticated circuitry for Battery Management System (BMS) and cost-efficient charging system specifically designed for 48V108Ah & 60V160Ah Lithium NMC, Nickel Manganese Cobalt Oxide (LiNiMnCoO2) batteries used in electric three-wheelers, such as scooters, easy bikes other Electric Vehicles.
Specifications of Battery Management System (BMS) enhanced/ highly sophisticated circuitry for 60V160Ah Lithium NMC Battery:
| Battery Voltage | Nominal 60V |
| Maximum Charge Voltage | ~67.2V |
| Cut-off Discharge Voltage | ~48V |
| Battery Capacity | 160Ah |
Current Ratings:
| Continuous Discharge Current | Typically ranges between 80A to 100A, depending on the motor’s power rating and operational requirements |
| Peak Discharge Current: | 200A to 250A (for short bursts, like acceleration) |
| Charge Current | 20A (depending on the charging infrastructure) |
The BMS should support balancing across the cells to ensure uniform charge and discharge cycles.
Balancing Current:
Passive or active balancing with a current rating of around 50mA to 100mA per cell. Ensures that all cells within the battery pack are at the same voltage level during charging to prolong the lifespan and improve efficiency.
Protection Features:
| Overcharge Protection | Prevents the battery cells from being charged above a specified voltage (typically 4.2V per cell). |
| Over-discharge Protection | Protects the cells from being discharged below a safe voltage (Typically around 3.0V per cell). |
| Over-current Protection | Limits the discharge current to prevent damage to the battery pack. |
| Short Circuit Protection | Detects and cuts off the circuit if a short circuit occurs. |
Temperature Protection:
Monitors the temperature of the battery pack and ensures that the cells operate within a safe temperature range (typically 0°C to 60°C). Includes thermal cut-off protection if the temperature exceeds a critical threshold.
| Under-voltage Protection | Ensures the battery does not drop below a certain voltage level during discharge to protect the cells. |
| SOH (State of Health) Monitoring | Tracks the battery’s health over time, indicating degradation |
Cooling:
| Auto-cooling System Control | The BMS may control cooling mechanisms, such as liquid cooling systems, to ensure the battery operates within safe temperature limits, especially during high-power operations. |
Voltage Detection Accuracy:
Voltage measurement accuracy within ±5mV per cell to ensure precise control during charge and discharge cycles.
Power Consumption:
Low standby current to prevent excessive power drain when the system is idle, typically <50μA in sleep mode.
Waterproof Rating (IP Rating):
IP65 or higher, ensuring the BMS is protected from dust and water, especially for outdoor or rough terrain applications common in EVs.
Circuit Design for BMS:
| Voltage Monitoring Unit | Each cell in the 16S configuration has a voltage sensor that continuously monitors individual cell voltages. |
| Current Sensing Unit | High-precision shunt resistors or Hall-effect current sensors measure the total current entering or leaving the battery. |
Cell Balancing Circuit:
Passive balancing using resistors to dissipate excess charge from higher-voltage cells. Active balancing (optional) to redistribute charge between cells, improving efficiency.
Protection Circuit:
MOSFET switches to disconnect the battery in case of over-voltage, under-voltage, or over-current situations. Thermal sensors integrated near high-power components or cell modules.
| Microcontroller Unit | A central processing unit that processes data from all sensors and manages charging, discharging, balancing, and protection. It also handles communication with external devices. |
| Cooling Control | Relay-controlled fans or liquid cooling systems activated based on temperature sensor feedback |
This BMS would offer comprehensive protection, monitoring, and balancing for a 60V160Ah Lithium NMC battery, ensuring optimal performance and safety in electric vehicles, particularly for high-capacity applications like the ones used in your EV Three-Wheeler, Three Wheelers, and Micro Buses.
Key Features of the Invention:
- Enhanced Battery Management System (BMS): Optimized for Lithium NMC batteries (48V108Ah & 60V160Ah). Intelligent monitoring of voltage, current, and temperature ensures maximum battery life and enhances safety. Provides advanced protection against overcharging, deep discharging, and overheating, ensuring optimal battery health. Enhances mileage, providing 170-200 km on a single charge.
- Cost-Efficient Charging System: Charges the battery from household electricity (180V-220V). Requires only two units of electricity for a full charge. The charging cost is approximately 20 BDT (for a 4KW Motor EV Three-Wheeler), making it highly affordable for low-income users.
- High Compatibility and Usage: Compatible with electric three-wheelers, such as scooters and easy bikes.
Advantages of the Invention:
- Affordability: The system is highly cost-effective, providing substantial savings on charging costs.
- Energy Efficiency: By utilizing just two units of electricity, the invention contributes to lower energy consumption and sustainability.
- Extended Battery Life: The sophisticated BMS enhances battery health, leading to longer operational life and reducing replacement costs.
- Environmental Impact: Promotes green energy solutions by reducing carbon emissions.
Claims:
- We claim an advanced Battery Management System (BMS) designed for 48V108Ah & 60V160Ah Lithium NMC batteries that optimizes the charging process, manages the battery’s health, and provides enhanced safety and longevity.
- We claim a cost-effective charging system that uses household electricity (180V-220V) to fully charge a 48V108Ah & 60V160Ah Lithium NMC battery, requiring only two-three units of electricity per charge.
- We claim the ability of this system to provide a mileage range of 170-200 kilometers for electric Three-wheelers, making it highly suitable for scooters, easy bikes, and other Electric Vehicles.
- We claim that the system significantly reduces the cost of operation for electric vehicle drivers, especially benefiting low-income individuals.
Technical Comparison between Traditional Lead Acid & Lithium-NMC Battery:
| SL No. | Description of Parameter | Performance | Remarks | ||
|---|---|---|---|---|---|
| Traditional Lead Acid Battery | Traditional Lithium NMC Battery | ||||
| 01 | Energy Density | Low, around 30-50 Wh/kg | High, typically around 180-240 Wh/kg | Lithium NMC is high high-efficiency | |
| 02 | Weight | 200 kg of 5 sets | 52 kg 1 pc | Lithium NMC Lite weight | |
| 03 | Charging Cost | Higher, with about Tk. 200 per cycle charge | Less than Tk. 20 per cycle charge | Lithium NMC Less cost | |
| 04 | Emissions | Toxicity, Sulfuric Acid (H2SO4), sulfur dioxide (SO2) gas, Hydrogen Gas (H2) Arsenic (As), | Zero CO2, No toxicity emissions | Lithium NMC Environment Friendly | |
| 05 | Efficiency | Performance typically deteriorates after 4-6 months. Lower around 60-70%. | 36 Months guarantee 8 years lifespan. Higher efficiency 90-95% | Lithium NMC Long lifespan | |
| 06 | Cycle Life | 200-300 cycles max. | 3000-3500 Cycle | Lithium NMC Long life | |
| 07 | Degradation | Degrades faster, especially with deep discharges, reducing overall lifespan. | Handles deep discharges better, resulting in a significantly extended lifespan | Lithium NMC Long life | |
| 08 | Charging Time | Takes about 10-12 hours for a full charge. 3 Phase. | Max. 5-6 Hours in normal 2-phase electric line. | Lithium NMC Lowest Charging Cost. | |
| 09 | Energy Loss | More energy is lost as heat during charging and discharging. | More efficient in converting and retaining energy, making it suitable for frequent use. | Lithium NMC saves energy. | |
| 10 | Maintenance | Requires regular checks, such as monitoring electrolyte levels and cleaning terminals. | Low maintenance, with no need for regular checks or topping up. | Lithium NMC has almost no maintenance. | |
| 11 | Environmental Impact | Toxicity: Contains lead, which is highly toxic and poses significant recyclingchallenges. Health Risks: Lead emissions can cause cancer, and in Bangladesh, it’s estimated that one in five people may be exposed to toxins from Lead Acid batteries. Environmental Hazard: If not disposed of properly, these batteries are extremely hazardous to the environment. | Environmental Concerns: While mining for lithium and cobalt has environmental challenges, the overall impact is lower than that of lead. Recyclability: Lithium NMC batteries are more recyclable and environmentally friendly. Carbon Emissions: Produce no carbon emissions over their lifecycle, especially beneficial when used in EVs. | Lithium NMC is more environmentally friendly. | |
Our Newly configured, formulated, and customized Lithium NMC Battery with an integrated Battery Management System (BMS), enhanced with advanced circuitry for compatibility with all types of Electric Vehicles (EVs) development for Bangladesh.
Referring to the comparison above, we have addressed the challenges and have customized and upgraded the Lithium NMC Battery (48V108Ah & 60V160Ah) with a Battery Management System (BMS) dedicated to Electric Vehicles (EV). This battery features high-quality prismatic cells and a robotic battery pack system with BMS, providing optimal performance in various environments, including extreme temperatures and challenging road conditions. Especially designed for EV’s Three Wheelers, Easy Bikes, Lithium NMC batteries with a customized Battery Management System (BMS) are tailored to the specific road conditions in Bangladesh. These batteries are compatible with motors ranging from 1,000 watts to 7,500 watts at 48v & 60v. We developed the Lithium NMC Battery as a customized solution to protect our environment from carbon emissions, enhance the earning potential of a specific group of people, and improve technology in the EV sector, contributing to the overall economic growth of low-income communities. Our customized Lithium NMC batteries offer a maximum charges cost of just Tk. 20, (Approx. 2-3 units Electricity consumption) allowing Electric Vehicles (EVs) Three-Wheeler to achieve a mileage of 180-200 km per cycle charge. This results in an exceptionally low cost of only Tk. 0.12 per kilometer.
This advanced environmentally friendly, long-lifespan Lithium NMC Battery technology for EVs developed by:
- Engr. Md. Fazle Rabbe, -Research Fellow, The LINQ (A Platform for New Ideas & Research).
- Abdul Jabbar Masud, – Research Fellow, The LINQ (A Platform for New Ideas & Research).