Deformation Analysis of Different Lithium Battery Designs Using the DIC Technique

Abstract

The growing number of electric vehicles and devices drives the demand for lithium-ion batteries. The purpose of the batteries used in electric vehicles and applications is primarily to preserve the cells and extend their lifetime, but they will wear out over time, even under ideal conditions. Most battery system failures are caused by a few cells, but the entire system may have to be scrapped in such cases. To address this issue, the goal is to create a concept that will extend the life of batteries while reducing the industrial and chemical waste generated by batteries. Secondary use can increase battery utilization and extend battery life. However, processing a large number of used battery cells at an industrial level is a significant challenge for both manufacturers and users. The different battery sizes and compositions used by various manufacturers of electric vehicles and electronic devices make it extremely difficult to solve the processing problem at the system level. The purpose of this study is to look into non-destructive battery diagnostic options. During the tests, the condition of the cells is assessed using a new diagnostic technique, 3D surface digitalization, and the fusion of electrical parameters. In the case of surface digitalization, the digital image correlation (DIC) technique was used to estimate the cell state. The tests were conducted on various cells with widely used geometries and encapsulations. These included a lithium polymer (soft casing), 18650 standard sizes (hard casing), and prismatic cells (semi-hard). The study also included testing each battery at various charge states during charging and discharging. The findings help to clarify the changes in battery cell geometry and their localization. The findings can be applied to cell diagnostic applications such as recycling, quality assurance, and vehicle diagnostics.