MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT AUTOMOTIVE ENGINEERNG RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES LECTURER: PhD. NGUYEN MANH CUONG STUDENT: NGUYEN THANH LUAN PHAN PHU HIEU SKL012548 Ho Chi Minh City, 2024 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FALCUTY OF INTERNATIONAL EDUCATION GRADUATION PROJECT RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES NGUYEN THANH LUAN Student ID: 19145152 PHAN PHU HIEU Student ID: 19145146 Major: AUTOMOTIVE ENGINEERING Supervisor: NGUYEN MANH CUONG, PhD. Ho Chi Minh City, January 2024 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, January 08, 2024 GRADUATION PROJECT ASSIGNMENT Student name: NGUYEN THANH LUAN Student ID: 19145152 Student name: PHAN PHU HIEU Student ID: 19145146 Major: Automotive Engineering Technology Class: 19145CLA Supervisor: NGUYEN MANH CUONG, Ph.D Phone number: 0366288115 Date of assignment: _______________ Date of submission: _____________ 1. Project title: RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES 2.
Initial materials provided by supervisor: ___________________________________ 3. Content of the project: _________________________________________________ 4. Final product: ________________________________________________________ CHAIR OF THE PROGRAM SUPERVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- ---- SUPERVISOR’S EVALUATION SHEET Student name: Nguyen Thanh Luan Student ID: 19145152 Student name: Phan Phu Hieu Student ID: 19145146 Major: Automotive Engineering Technology Project title: RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES Supervisor: Nguyen Manh Cuong, Ph. Content of the project:.
Approval for oral defense? (Approved or denied). Ho Chi Minh City, January 08, 2024 SUPERVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- PRE-DEFENSE EVALUATION SHEET Student name: Nguyen Thanh Luan Student ID: 19145152 Student name: Phan Phu Hieu Student ID: 19145146 Major: Automotive Engineering Technology Project title: RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES Name of Examiner: Tran Dinh Quy, M. Content and workload of the project. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, January 08, 2024 EXAMINER (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name: Nguyen Thanh Luan Student ID: 19145152 Student name: Phan Phu Hieu Student ID: 19145146 Major: Automotive Engineering Technology Project title: RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES Name of Defense Committee Member:.
Content and workload of the project .) Ho Chi Minh City, January ., 2024 COMMITTEE MEMBER (Sign with full name) ACKNOWLEGEMENT Currently, across all car models worldwide, the main component that cannot be overlooked is the lead-acid battery. It serves as the foundation for more advanced energy storage sources like Li-Thium or Li-Ion batteries, gradually replacing traditional sources of electrical energy storage like lead-acid batteries. With the knowledge we have acquired over the past four years at university, we have decided to choose Lead-Acid batteries as the subject of our graduation thesis, titled "RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES." We are truly delighted and proud to have the opportunity to delve into more research and complete our project on time. During the research and development of our graduation thesis, due to limitations in knowledge and time constraints, we couldn't avoid making mistakes.
We sincerely hope to receive understanding and suggestions from our professors and peers to improve our work. We would like to express our heartfelt gratitude to Ph.D Nguyen Manh Cuong, our mentor, for his wholehearted assistance during the project. He provided us with valuable feedback that contributed to the completeness of our thesis. He also offered precious words of encouragement, enabling us to gain knowledge and motivation to complete this graduation project.
We also want to sincerely thank M.Sc Van Anh Duong, a lecturer from the Department of Mechanical Engineering, for finding a valuable and practical research topic that enriched our knowledge and learning from real-life experiences. His valuable encouragement helped us complete our project successfully. Through this, we want to extend our sincere gratitude to all the professors at the Faculty of International Training of Ho Chi Minh City University of Technology and Education, especially Mr. Duong Tuan Tung - Head of the Faculty of International Education and Mr.
Vu Dinh Huan - Head of Automotive Engineering Technology for providing us with valuable specialized knowledge, creating favorable conditions for us to complete this graduation project. Once again, we thank all our esteemed professors and wish them continued success in their endeavors to nurture future talents. 1 DISCLAIMER The authors, Nguyen Thanh Luan, and Phan Phu Hieu confirm that the work presented in this thesis is my own. All the data and statistics in the thesis are reliable and are not published in any previous studies or research.
Where information has been derived from other sources, I confirm that this has been indicated in the thesis. 2 ABSTRACT Electric vehicles are rapidly becoming a significant trend in the automotive industry, driving a surge in research on electric vehicle battery technology. Despite these advancements, internal combustion engine vehicles predominantly rely on Lead-Acid batteries for their starting mechanism, a component whose importance remains unrivaled by any alternative. Thus, developing diagnostic and management systems for Lead-Acid batteries is crucial.
Understanding the characteristics, operational principles, and structure of Lead-Acid batteries is vital for the progress of internal combustion engine vehicles. Yet, the focus on management systems for these batteries is relatively scarce, often overshadowed by systems designed for Lithium-based batteries. Our objective is to initiate and encourage research into diagnostic and management systems specifically for Lead-Acid batteries. Our team is embarking on a project titled "RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES." This project aims to create a module capable of assessing battery life and monitoring its condition.
As the automobile industry evolves and the need to optimize fossil fuel usage intensifies, our research seeks to innovate in the realm of "RESEARCH AND DESIGN MODULE FOR DIAGNOSIS AND MANAGEMENT OF LEAD-ACID BATTERIES” contributing to the sustainability and efficiency of automotive technologies. 3 TABLE OF CONTENTS ACKNOWLEDGEMENT i DISCLAIMER ii ABSTRACT iii TABLE OF CONTENTS iv LIST OF FIGURES vii LIST OF TABLES ix CHAPTER 1: INTRODUCTION 1 1. Reason for choosing topic 1 1. Subject and scope of research 1 1.
Subject of research 1 1. Scope of research 2 1. Purposes of research 2 1. Domestic and international research on the topic 3 CHAPTER 2: THEORETICAL BASIS 4 2.
Lead-Acid Batteries 4 2. History of Lead-Acid Battery 4 2. Structure of Lead-Acid batteries 4 2. Classification of Lead-Acid Batteries 9 2.
The Operating Principle of Lead-Acid Batteries 11 2. The Discharge Principle of the Lead-Acid Battery 11 2. The Charging Principle of the Lead-Acid Battery 12 2. Characteristics of Lead-Acid Batteries 13 2.
The electromotive force of Lead-Acid batteries 13 2. Capacity of Lead-Acid batteries 14 2. Discharge Characteristics of Lead-Acid batteries 14 2. Charge Characteristics of Lead-Acid batteries 16 2.
Simulate the charging and discharging process of lead-acid batteries using Matlab-Simulink software 17 4 2. Build a simulation program 17 2. Select battery parameters 17 2. Build a diagram of simulation blocks 17 2.
Annotate the meaning of used blocks 17 2. Programs used for simulation 18 2. Simulation results of the battery Discharging process 20 2. Lead-acid battery diagnostic and management module 22 2.
Concepts and composition 22 2. Digital ports and Analog ports 28 CHAPTER 3: MODULE BUILDING AND BATTERY MANAGEMENT AND DIAGNOSIS SOFTWARE DESIGN 29 3. Build modular hardware 29 3. Components included in the module 29 3.
System diagram of the module 47 3.2 Design battery diagnostic and management module software 48 3. Collect input data 48 3. Calculate State of Charge of battery 51 3. Calculate and predict battery life 53 3.
Transmit and receive data from the HMI display screen 54 3. Design interface of battery diagnostic and management module 55 3. Programming and interface design software for display screens 55 3. Design the cooling box for battery 58 CHAPTER 4: EXPERIMENTAL RESULTS 59 4.
Evaluation of the module's design 59 4. Evaluate the data collection ability of sensors 63 5 4. Evaluate all the systems 64 CHAPTER 5: CONCLUSION AND FUTURE DEVELOPMENT 69 5. Limitations of the Study 69 5.
Future Development Directions 69 REFERENCES 70 6 LIST OF FIGURES Figure 1.1: The Sealed Lead-Acid Battery (12V – 75Ah) 1 Figure 2.1: Structure of Lead-Acid Battery 5 Figure 2.2: Layers of plates inside the battery 6 Figure 2.3: Structure of vent caps 9 Figure 2.4: Sealed Lead-Acid batteries with H2SO4 acid in gel form 10 Figure 2.5: Flooded Lead-Acid batteries with a liquid solution 11 Figure 2.6: Discharge Principle of the Lead-Acid Battery 12 Figure 2.7: Charging Principle of the Lead-Acid Battery 13 Figure 2.8: Discharge Characteristics of Lead-Acid batteries 15 Figure 2.9: Charge Characteristics of Lead-Acid batteries 16 Figure 2.10: Select battery parameters for simulate 17 Figure 2.11: The program simulates the battery in a charging state 18 Figure 2.12: The program simulates the battery in a discharged state 19 Figure 2.13: The program controls the charging and discharging process of the battery 19 Figure 2.14: SOC value 20 Figure 2.15: Current value 21 Figure 2.16: Battery voltage value 22 Figure 2.17: Operation of CANBus 24 Figure 2.18: UART Communication 26 Figure 2.19: Frame Formats of UART communication 27 Figure 3.1: Arduino Mega 2650 29 Figure 3.2: Arduino Mega 2650 Pinout Diagram 30 Figure 3.3: HMI UART TJC display screen 31 Figure 3.4: WCS1700 Hall current sensor 33 Figure 3.5: Function block of WCS1700 34 Figure 3.6: 25VDC Voltage Sensor 35 Figure 3.7: Structure of Voltage Sensor 36 Figure 3.8: Two-channel 5V relay module 37 Figure 3.9: Structural diagram of relay 38 7 Figure 3.10: NTC Thermistor 39 Figure 3.11: Plot for the thermistor 41 Figure 3.12: Peltier chips TEC1-12710 43 Figure 3.13: Principle of Super-tech semiconductor panels 44 Figure 3.14: Radiator fan 45 Figure 3.15: Low voltage DC module DC-DC 46 Figure 3.16: Hardware structure diagram 47 Figure 3.17: Circuit diagram of the module 47 Figure 3.18: Diagram of voltage divider circuit 48 Figure 3.19: UART communication port on HMI screen 55 Figure 3.20: UART communication port on Arduino Mega 2560 56 Figure 3.21: USART HMI software logo 57 Figure 3.22: Working interface of USART HMI software 57 Figure 3.23: The 3D shape of the cooling box is designed using Solidworks software 58 Figure 4.1: Lead-Acid battery diagnostic and management module box 60 Figure 4.2: Cooling box for Lead-Acid batteries 60 Figure 4.3: Electrical system inside the module box 61 Figure 4.4: Electrical system of the cooling box 62 Figure 4.5: Actual image of the cooling box installed on the vehicle 63 Figure 4.6: Data is collected from sensors 64 Figure 4.7: First page of the module interface 65 Figure 4.8: Second page of the module interface 66 Figure 4.9: Danger warning about low battery voltage 67 Figure 4.10: Temperature and cooling warnings for batteries 68 8 LIST OF TABLES Table 2.1: The physical and chemical properties of the electrolyte 8 Table 3.1: The relation between the battery capacity and open circuit voltage 52 Table 4.1 Statistics of hardware and software of the module system 59 9 Chapter 1: INTRODUCTION 1. Reason for choosing the topic Globally, with a particular emphasis on Vietnam, electric vehicles (EVs) are witnessing substantial growth. While the future landscape of the automotive industry will likely be dominated by EVs, it's undeniable that the Lead-Acid Batteries used in internal combustion engines have not yet been fully optimized and can't be immediately replaced with an alternative type. Our market research and analysis have pinpointed several significant issues associated with these batteries, leading to startup failures or disruptions in the vehicle's primary electrical systems.
Surprisingly, no dedicated system exists to alert drivers to these battery-related challenges. This identified gap serves as the primary impetus for our research project.