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How can you design hybrid vehicle batteries to last longer?

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Hybrid vehicles are becoming more popular as they offer lower emissions, better fuel economy, and reduced dependence on fossil fuels. However, one of the main challenges of hybrid vehicles is the battery life, which affects the performance, reliability, and cost of the vehicle. How can you design hybrid vehicle batteries to last longer? In this article, we will explore some of the factors that influence battery life and some of the strategies that can help you optimize your hybrid battery design.

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Jesús I.

Senior Engineer - Battery Energy Storage | Master in Energy Management and Renewable Sources

1 Battery chemistry

One of the first aspects to consider when designing hybrid vehicle batteries is the battery chemistry, which determines the capacity, power, efficiency, and durability of the battery. Different types of battery chemistry have different advantages and disadvantages, such as lead-acid, nickel-metal hydride, lithium-ion, and lithium-polymer. For hybrid vehicles, lithium-ion batteries are the most common choice, as they offer high energy density, fast charging, and long cycle life. However, lithium-ion batteries also have some drawbacks, such as high cost, safety risks, and degradation over time. Therefore, choosing the right battery chemistry for your hybrid vehicle depends on your specific design goals and trade-offs.

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Jesús I.

Senior Engineer - Battery Energy Storage | Master in Energy Management and Renewable Sources
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One of the problems that has been observed in lithium batteries is the formation of dendrites and "whiskers" in the anode. These conditions cause heating, internal short circuits and sometimes explosions. These conditions could be improved by taking care of the vacuum in manufacturing, among others. aspects. The problem with any "sealed" type battery is internal heating. In the case of lead-acid batteries, having a limited power and energy density, they are no longer a good option to use in the automotive industry. Lithium batteries lead the highest energy density today, the task is to adapt to the needs of the market while taking care of safety.

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2 Battery management system

Another key factor that affects hybrid vehicle battery life is the battery management system, which is the software and hardware that controls and monitors the battery operation. The battery management system is responsible for maintaining the optimal temperature, voltage, current, and state of charge of the battery, as well as protecting the battery from overcharging, overdischarging, short-circuiting, and thermal runaway. The battery management system can also optimize the energy flow between the battery and the engine, as well as provide diagnostic and prognostic information. A well-designed battery management system can significantly improve the performance, safety, and longevity of your hybrid battery.

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Jesús I.

Senior Engineer - Battery Energy Storage | Master in Energy Management and Renewable Sources
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The float voltage must be normalized, since if the value is higher there is an overstress and this leads to degradation due to heating; otherwise, a low voltage will generate sulfates more quickly, resulting in a loss of capacity. The charging voltage must be considered appropriate for each type of technology; failure to take care of the appropriate equalization value at the appropriate times that the battery needs it will shorten its life. The BMS system must know the ideal settings for each moment, that is, when the battery requires charging and observing the temperature. Having a battery with adequate BMS control leads us to be careful with impedance, capacitance, cell degradation, and loss of capacity among other failures.

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3 Battery size and configuration

The size and configuration of your hybrid battery also influence its life span, as they affect the weight, space, and cost of your vehicle. The size of your battery depends on the power and energy requirements of your hybrid vehicle, which are determined by factors such as the driving range, speed, acceleration, and regenerative braking. The configuration of your battery refers to how you arrange the individual cells and modules into a pack, which affects the electrical, thermal, and mechanical characteristics of the battery. The size and configuration of your hybrid battery should be optimized to balance the power and energy density, thermal management, and modularity of your battery.

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4 Battery usage and maintenance

The last factor that impacts hybrid vehicle battery life is the usage and maintenance of the battery, which depends on the driver's behavior and the environmental conditions. The usage of the battery refers to how often, how long, and how fast you drive your hybrid vehicle, as well as how you charge and discharge your battery. The maintenance of the battery refers to how you store, clean, and service your battery. The usage and maintenance of your battery can affect the aging and degradation of the battery, as well as the performance and efficiency of the battery. To extend your hybrid battery life, you should follow some best practices, such as avoiding extreme temperatures, charging and discharging your battery regularly and moderately, and checking and replacing your battery when needed.

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Jesús I.

Senior Engineer - Battery Energy Storage | Master in Energy Management and Renewable Sources
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In my experience I have observed that the factor that most affects batteries is temperature, it is difficult for a user to control the temperature of the environment. Having better control of the temperatures of the cells with cooling, can improve their useful life. The maintenance required by a sealed battery is minimal, what it needs is better control and design before requiring extensive maintenance.The user will have the responsibility of charging at the recommended times and making good use of it without abusing it.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you design hybrid vehicle batteries to last longer?

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1 Battery chemistry

2 Battery management system

3 Battery size and configuration

4 Battery usage and maintenance

5 Here’s what else to consider

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How can you design hybrid vehicle batteries to last longer?

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1 Battery chemistry

2 Battery management system

3 Battery size and configuration

4 Battery usage and maintenance

5 Here’s what else to consider

Automotive Engineering

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