4.1. Test Description
The proposed electro-thermal model was developed in the MATLAB environment and considered in three main validation tests, whose characteristics are shown in
Table 5. The tests 1 and 2 are based on typical battery current profiles gained from a numerical simulation model [
23] adapted to a BEV (pure battery electric vehicle) running on the Class 3 category of world-wide harmonized light duty driving test cycle (WLTC), indicative of vehicles driven in Europe and Japan [
24]. In particular about test 1, after a 1C discharging for a duration of 360 s, the WLTC current profile was imposed and scaled in order to match a maximum discharge current of 3C, as in the upper plot of
Figure 8. About test 2, after a 1C discharging for the same duration, the current profile was remodelled to reach a maximum charge current of about 4C, while during discharge, current values exceeding that limit were cut to 250 A (see always
Figure 8). Test 2 was meant to be an intensive test for both electric and thermal solicitation in order to validate the model even in case of higher cell temperatures, with respect to test 1. Finally, test 3 instead validated the model against a 1C constant current discharge.
For every simulated test, the initial conditions of the model were SOC = 100% (fully charged cell) and model temperatures were set equal to the average value recorded by the respective thermocouples before starting. The other input to the model was the current profile, as imposed in the experimental test.
According to the symbols used in
Figure 2,
Appendix A shows the plot related to the currents flowing in the
R1C1 block—e.g.,
I1 and
I2 for the reader’s convenience, always under test 1 solicitation.
4.2. Simulation Results
The model outputs that were chosen as validation indicators were the cell voltage and surface temperature, as both are the main safety control variables to be monitored. Both cell voltage and surface temperature simulated curves were compared with the respective experimental data as follows:
is cell voltage percentage error, while is the surface temperature deviation. In each formula, the subscript exp refers to the experimental measure, acting as the reference value, while the subscript mod indicates the model simulation result.
Table 6 reports for all validation tests a series of aggregating factors such as root mean square error (RMSE), mean value, and standard deviation for absolute values of voltage percentage error
, and the maximum, mean, and standard deviation for the absolute surface temperature deviation
.
Starting from the contents shown in
Table 6, the following main considerations can be remarked. First of all, the model correctly reproduced the experimental voltage profile in all cases and provided reliable results also for the cell surface temperature: in fact, with respect to the actual experimental data, maximum absolute error was lower than 1 K for test 1.
The model also offered a calculation of the core temperature, as it is the temperature at which each set of electric parameters is estimated at every timestep. Despite that, a direct comparison with experimental core temperature was not available, as the approximation of internal cell temperature as the electrode temperature was not proven to be reliable for the performed validation tests reported in
Table 6, which largely differ from the ones related to parameter calibration, such as tests reported in
Figure 6.
An example of simulation plots regarding experimental and modelled voltage (
), experimental and modelled surface temperatures (
), and modelled core temperature (
) during test 2, are depicted in
Figure 9.
An important result relates to the surface temperature estimation: despite an increase of more than 10 K from start to end of the test, the model constantly provided accurate values, with a mean absolute deviation less than 1 K.
In the following, different conditions are analysed in order to assess whether the thermal model calibration assumption, i.e., the core temperature equal to the electrode temperature, can be or cannot be taken as reference also with more significant thermal solicitations.
To accomplish that, the simulation was then repeated for different and much more realistic case studies (e.g., test 1, 2, and 3), forcing the model internal temperature to be equal to the registered temperature at the electrodes. In
Table 7, results of voltage errors of this scenario are reported.
If compared with
Table 6, which refers to the estimation of the voltage error as originally evaluated by the model, the results show slightly increasing errors between modelled and experimental voltage, especially for test 2. More interesting results are related to temperature estimation. The illustration in
Figure 10 reports both the previously obtained results given by the model with electrical parameters referring to the estimated internal cell temperature (
,
), as well as the results achieved by the model with electrical parameters calculated referring to electrode temperature (
,
). In particular, as assumed,
represents experimental data from ring thermocouples placed on the electrodes, while
is the model surface temperature obtained when electrode temperature is chosen as the indicator of internal temperature, and it is shown by the purple curve.
In particular, for test 2, an overestimation of surface temperature with respect to the experimental data from thermocouples
can be observed, as shown by the purple curve of the upper plot of
Figure 10. This means that, when model considers temperature at the electrodes as the internal reference, and significant current solicitations are modelled (as the ones adopted in test 2), the model does not work properly, especially in representing the core and surface cell temperatures.
Instead, test 3, which involves a current rate limited to 1C, as in the thermal characterization test, shows that electrode experimental temperature
and model internal temperature
are well aligned, as reported in the second plot of
Figure 10. In addition, the same accuracy is also observed for the surface temperatures
and
.
These last results confirm that the assumption of considering internal cell temperature equal to the one measured on the cell electrodes appears to be acceptable only for currents in the same range of the one used for the thermal characterisation test (1C). This supports the legitimacy of referring to experimental electrode temperatures for parameter calibration purposes.