In recent years, my country’s electric vehicle industry has developed rapidly, and the number of electric vehicles has continued to grow, and the penetration rate has gradually increased. The latest data released by the Ministry of Industry and Information Technology shows that China’s electric smart vehicles have formed a certain first-mover advantage in the world, and the production and sales of new energy vehicles have ranked first in the world for six consecutive years. The release of the dual carbon goals of “carbon peak” and “carbon neutrality” has opened a new round of “golden age” for China’s electric vehicle industry.
As the core component of electric vehicles, the power battery is also the key to the increasingly fierce cooperation and competition between global automakers and battery manufacturers. Whether it is possible to master the security of the power battery supply chain and achieve stronger Competitive advantages in cost and performance are very important in the increasingly fierce market competition in the electric vehicle industry where more and more new forces enter the market.
Consistency is still a key constraint on battery manufacturing, and chemical composition technology leads innovation
Over the past few decades, lithium-ion batteries for power and energy storage have made unprecedented progress in large-scale commercialization, and battery manufacturers and supply chain players realize that if they want to get a share of this emerging industry, Scale-up of battery production and improved production efficiency are the keys, while the performance quality of the battery must be given top priority. “Chemical composition during battery manufacturing is a time-consuming process involving multiple charges and discharges to activate the battery chemistry, which is critical to ensuring high quality power pack consistency, safety and long cycle life. It is especially critical.” ADI marketing manager Zhu Zhen mentioned in a recent public interview.
ADI Marketing Manager Zhu Zhen was interviewed
Chemical formation refers to the electrochemical process in which the positive and negative active materials of the lithium battery are excited by supplying a certain current to the battery after the lithium battery is assembled, and finally the battery has the ability to discharge. Factors affecting the formation include formation current, SOC, aging time and temperature, etc. The battery material system and production capacity requirements also need to be considered. Therefore, formation is not only a simple charging and discharging process, but a comprehensive measure of the impact of different parameters on battery performance, which requires a large amount of accurate data testing and research and verification using instruments and equipment.
The capacity distribution is to charge and discharge the completed battery. The charge and discharge currents of different types of batteries are slightly different, so as to distinguish the battery capacity, charge constant current ratio, discharge platform voltage, internal resistance, etc., and filter out the same indicators. The monomers can be divided into groups, and only those with very similar performance can form a battery pack. On the other hand, poor consistency of single cells may also lead to reduced safety of the battery pack. For example, in order to meet the energy requirements of electric vehicles, power battery packs often need to be composed of dozens to thousands of batteries. Affected by the complexity of the system, the behavior of battery packs has its own uniqueness. It is not a simple addition or subtraction of single cells. method to obtain the performance of the battery pack.
The process of lithium-ion battery manufacturing
Therefore, in order to improve the electrochemical performance of the battery such as cycle life, stability, self-discharge, and safety, the consistency of the battery must be strictly controlled and the battery grade must be accurately assessed. It will also help battery manufacturers and test equipment providers to expand the scale of battery production and improve efficiency, and seize the key opportunities for the explosion of production and sales in the electric vehicle market.
How to balance cost and flexibility?Traditional solutions face new challenges
Limited to sensor acquisition accuracy, and at the same time to reduce battery costs, manufacturers need to take a holistic approach and use the supplier’s system-level expertise to reduce the overall battery test circuit area while increasing the number of channels, and must maintain the accuracy and reliability of test measurements. performance and speed, achieving an accuracy of over ±0.05% even under harsh factory conditions.
According to Zhu Zhen, the bidirectional DC-DC converter module solutions used in traditional battery-based components can be divided into two categories, namely discrete device-based solutions and digital solutions. Discrete device solutions are generally used in small and medium power scenarios, while digital solutions are It can adapt to different power scenarios of large, medium and small at the same time.
The solution based on discrete devices is more flexible in device selection and procurement. It is necessary to consider the accuracy requirements of each device to select the corresponding device, which corresponds to a certain range of output voltage, current, and number of channels. However, its shortcomings include too many devices, and it takes a lot of man-hours for research and development, debugging, testing, and system calibration. It requires additional circuits to realize the functions of channel interleaving and paralleling, and current sharing between channels, and it has significant shortcomings such as being relatively complex, making it a single unit. Under the trend of increasing cell capacity, the comprehensive cost disadvantage becomes more and more significant.
In contrast, traditional digital core components use DSP or a processor with DSP functions as the main controller of the power conversion loop, and the PID loop adopts software or hardware mode, using digital PWM to control switch tubes, peripheral voltage and current sampling, and buffer amplifiers. There is not much difference between the op amp and hardware scheme used. The advantage is that the control is more flexible, the debugging of the digital scheme is also more convenient, and it can realize more complex functions, such as interleaved parallel operation, multi-channel parallel current sharing, voltage feedforward and so on. However, its software development is difficult, high cost, long cycle, and high maintenance cost in the later period.
It can be seen that the traditional solutions have their own advantages in their respective application fields, but also have corresponding inherent disadvantages that cannot be overcome. “That’s why ADI integrates the analog front end, power control, and monitoring circuitry into a single IC, combining the test components into a complete solution that combines the cost advantages of a discrete approach with the versatile flexibility of a digital approach .” Zhu Zhen said.
Control from analog to digital, ADI’s new generation of chemical composition test solution interpretation
ADI’s latest generation digital four-channel bidirectional DC-DC controller ADBT1000/1/2 series integrates the bidirectional DC-DC solution used in the battery industry into a single-chip system-level integration, and integrates the analog front-end for voltage and current sampling. And auxiliary ADC, using digital core, can realize multi-channel interleaved parallel operation, digital current sharing between channels and other operations.
It is worth mentioning that the previous generation product AD8452 of ADI’s chemical composition is based on the architecture of the analog control loop, and its design concept is also very advanced, which has been widely used and widely recognized by customers. However, for different battery test parameters, the traditional analog loop can only improve the value by modifying or adjusting the capacitor or resistor network on the circuit board, which not only puts forward high requirements on circuit design, but also in the debugging of different products. will be very inconvenient. The needs of the battery formation industry are relatively uniform. If various functions can be realized through register configuration, the test efficiency will be greatly improved, which is one of the reasons why the battery formation capacity test equipment has gradually shifted from analog control to digital control.
“ADBT1000/1/2 series chips are based on digital loop control design, including four-channel analog front-end, four-channel digital PWM generator, digital GPIO port, interrupt interface, 8-channel 12-bit auxiliary ADC, of which four ADCs have current sources The output function is convenient for temperature monitoring.” Zhu Zhen pointed out, “Compared with the single-channel solution of AD8452, the ADBT1000 series chip has up to 4 data acquisition channels, which can be freely combined by customers, and can output more data through two channels in parallel. The current of 4 channels can also be connected in parallel at the same time, and the single chip can achieve a high current charge and discharge of up to 240A or even higher, which is in line with the general trend of continuous improvement of battery capacity at this stage. The built-in state machine to achieve PID adjustment mode will bring Faster loop response capability while eliminating the risk of program runaways associated with software control.”
The many features and functions of ADBT1000 series chips are integrated together, which simplifies the hardware design of battery charge and discharge channel devices. The digital core is equipped with a dedicated GUI software that can directly set registers, which directly avoids complex DSP code and algorithm development and development. The cost of post-maintenance, for high-power applications, greatly optimizes the design threshold and development difficulty. The integrated high-precision analog front end can ensure system accuracy and temperature drift, and greatly reduce the time for customers to develop battery-based capacity test systems.
With the explosive growth of the power battery market, the demand for high-capacity batteries has also increased. “ADI has continued to develop many new products, reference designs and integrated solutions. The new generation ADBT1000 series test chip provides high precision, and uses a state machine to realize digital loop control instead of analog control. It expands the test scale and increases the stability of battery formation equipment, enabling manufacturers to more efficiently produce safe and powerful power battery packs.” Zhu Zhen emphasized.
In recent years, my country’s electric vehicle industry has developed rapidly, and the number of electric vehicles has continued to grow, and the penetration rate has gradually increased. The latest data released by the Ministry of Industry and Information Technology shows that China’s electric smart vehicles have formed a certain first-mover advantage in the world, and the production and sales of new energy vehicles have ranked first in the world for six consecutive years. The release of the dual carbon goals of “carbon peak” and “carbon neutrality” has opened a new round of “golden age” for China’s electric vehicle industry.
As the core component of electric vehicles, the power battery is also the key to the increasingly fierce cooperation and competition between global automakers and battery manufacturers. Whether it is possible to master the security of the power battery supply chain and achieve stronger Competitive advantages in cost and performance are very important in the increasingly fierce market competition in the electric vehicle industry where more and more new forces enter the market.
Consistency is still a key constraint on battery manufacturing, and chemical composition technology leads innovation
Over the past few decades, lithium-ion batteries for power and energy storage have made unprecedented progress in large-scale commercialization, and battery manufacturers and supply chain players realize that if they want to get a share of this emerging industry, Scale-up of battery production and improved production efficiency are the keys, while the performance quality of the battery must be given top priority. “Chemical composition during battery manufacturing is a time-consuming process involving multiple charges and discharges to activate the battery chemistry, which is critical to ensuring high quality power pack consistency, safety and long cycle life. It is especially critical.” ADI marketing manager Zhu Zhen mentioned in a recent public interview.
ADI Marketing Manager Zhu Zhen was interviewed
Chemical formation refers to the electrochemical process in which the positive and negative active materials of the lithium battery are excited by supplying a certain current to the battery after the lithium battery is assembled, and finally the battery has the ability to discharge. Factors affecting the formation include formation current, SOC, aging time and temperature, etc. The battery material system and production capacity requirements also need to be considered. Therefore, formation is not only a simple charging and discharging process, but a comprehensive measure of the impact of different parameters on battery performance, which requires a large amount of accurate data testing and research and verification using instruments and equipment.
The capacity distribution is to charge and discharge the completed battery. The charge and discharge currents of different types of batteries are slightly different, so as to distinguish the battery capacity, charge constant current ratio, discharge platform voltage, internal resistance, etc., and filter out the same indicators. The monomers can be divided into groups, and only those with very similar performance can form a battery pack. On the other hand, poor consistency of single cells may also lead to reduced safety of the battery pack. For example, in order to meet the energy requirements of electric vehicles, power battery packs often need to be composed of dozens to thousands of batteries. Affected by the complexity of the system, the behavior of battery packs has its own uniqueness. It is not a simple addition or subtraction of single cells. method to obtain the performance of the battery pack.
The process of lithium-ion battery manufacturing
Therefore, in order to improve the electrochemical performance of the battery such as cycle life, stability, self-discharge, and safety, the consistency of the battery must be strictly controlled and the battery grade must be accurately assessed. It will also help battery manufacturers and test equipment providers to expand the scale of battery production and improve efficiency, and seize the key opportunities for the explosion of production and sales in the electric vehicle market.
How to balance cost and flexibility?Traditional solutions face new challenges
Limited to sensor acquisition accuracy, and at the same time to reduce battery costs, manufacturers need to take a holistic approach and use the supplier’s system-level expertise to reduce the overall battery test circuit area while increasing the number of channels, and must maintain the accuracy and reliability of test measurements. performance and speed, achieving an accuracy of over ±0.05% even under harsh factory conditions.
According to Zhu Zhen, the bidirectional DC-DC converter module solutions used in traditional battery-based components can be divided into two categories, namely discrete device-based solutions and digital solutions. Discrete device solutions are generally used in small and medium power scenarios, while digital solutions are It can adapt to different power scenarios of large, medium and small at the same time.
The solution based on discrete devices is more flexible in device selection and procurement. It is necessary to consider the accuracy requirements of each device to select the corresponding device, which corresponds to a certain range of output voltage, current, and number of channels. However, its shortcomings include too many devices, and it takes a lot of man-hours for research and development, debugging, testing, and system calibration. It requires additional circuits to realize the functions of channel interleaving and paralleling, and current sharing between channels, and it has significant shortcomings such as being relatively complex, making it a single unit. Under the trend of increasing cell capacity, the comprehensive cost disadvantage becomes more and more significant.
In contrast, traditional digital core components use DSP or a processor with DSP functions as the main controller of the power conversion loop, and the PID loop adopts software or hardware mode, using digital PWM to control switch tubes, peripheral voltage and current sampling, and buffer amplifiers. There is not much difference between the op amp and hardware scheme used. The advantage is that the control is more flexible, the debugging of the digital scheme is also more convenient, and it can realize more complex functions, such as interleaved parallel operation, multi-channel parallel current sharing, voltage feedforward and so on. However, its software development is difficult, high cost, long cycle, and high maintenance cost in the later period.
It can be seen that the traditional solutions have their own advantages in their respective application fields, but also have corresponding inherent disadvantages that cannot be overcome. “That’s why ADI integrates the analog front end, power control, and monitoring circuitry into a single IC, combining the test components into a complete solution that combines the cost advantages of a discrete approach with the versatile flexibility of a digital approach .” Zhu Zhen said.
Control from analog to digital, ADI’s new generation of chemical composition test solution interpretation
ADI’s latest generation digital four-channel bidirectional DC-DC controller ADBT1000/1/2 series integrates the bidirectional DC-DC solution used in the battery industry into a single-chip system-level integration, and integrates the analog front-end for voltage and current sampling. And auxiliary ADC, using digital core, can realize multi-channel interleaved parallel operation, digital current sharing between channels and other operations.
It is worth mentioning that the previous generation product AD8452 of ADI’s chemical composition is based on the architecture of the analog control loop, and its design concept is also very advanced, which has been widely used and widely recognized by customers. However, for different battery test parameters, the traditional analog loop can only improve the value by modifying or adjusting the capacitor or resistor network on the circuit board, which not only puts forward high requirements on circuit design, but also in the debugging of different products. will be very inconvenient. The needs of the battery formation industry are relatively uniform. If various functions can be realized through register configuration, the test efficiency will be greatly improved, which is one of the reasons why the battery formation capacity test equipment has gradually shifted from analog control to digital control.
“ADBT1000/1/2 series chips are based on digital loop control design, including four-channel analog front-end, four-channel digital PWM generator, digital GPIO port, interrupt interface, 8-channel 12-bit auxiliary ADC, of which four ADCs have current sources The output function is convenient for temperature monitoring.” Zhu Zhen pointed out, “Compared with the single-channel solution of AD8452, the ADBT1000 series chip has up to 4 data acquisition channels, which can be freely combined by customers, and can output more data through two channels in parallel. The current of 4 channels can also be connected in parallel at the same time, and the single chip can achieve a high current charge and discharge of up to 240A or even higher, which is in line with the general trend of continuous improvement of battery capacity at this stage. The built-in state machine to achieve PID adjustment mode will bring Faster loop response capability while eliminating the risk of program runaways associated with software control.”
The many features and functions of ADBT1000 series chips are integrated together, which simplifies the hardware design of battery charge and discharge channel devices. The digital core is equipped with a dedicated GUI software that can directly set registers, which directly avoids complex DSP code and algorithm development and development. The cost of post-maintenance, for high-power applications, greatly optimizes the design threshold and development difficulty. The integrated high-precision analog front end can ensure system accuracy and temperature drift, and greatly reduce the time for customers to develop battery-based capacity test systems.
With the explosive growth of the power battery market, the demand for high-capacity batteries has also increased. “ADI has continued to develop many new products, reference designs and integrated solutions. The new generation ADBT1000 series test chip provides high precision, and uses a state machine to realize digital loop control instead of analog control. It expands the test scale and increases the stability of battery formation equipment, enabling manufacturers to more efficiently produce safe and powerful power battery packs.” Zhu Zhen emphasized.
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