The Design and Fabrication of Energy Storage System for Solar Racing Vehicle

二次電池為電動車輛最重要的能量儲存元件。能量儲存系統扮演著緩衝、調節動力的角色，是所有電動車輛都不可或缺的關鍵裝置。本研究目的在發展一套二次電池能量儲存系統的設計與製作流程，除電池系統規格的設定與電池模組製作外，亦包括電池管理系統的設計與電池測試。對於電池管理系統最重要的SOC預測及電池保護系統方面，採用了兩種SOC 計算法的搭配運用並以IC 晶片達成自動化；電池保護系統也針對鋰電池之特性提出專屬設計。電池測試則是為了得出電池之極限而進行充放電循環測試、高溫測試與破壞測試。藉由台灣大學機械系─Formosun 太陽能車研發計畫之執行，將本研究提出之設計方法應用於蓄電池系統的設計與製作上，檢驗其可行性。研究證明，此設計流程可確實製造出提供優異動力性能的能量儲存系統。Rechargeable batteries are the most important energy storage device in electric vehicles. The energy storage system plays the role of buffer battery and is the key device in electric vehicles. The study brings out the design and manufacture procedure of energy storage system using rechargeable batteries, including the specifications of battery system, the making of battery module, the design of battery management system and the test of battery system. We adopt two SOC calculation methods to predict SOC and automate it by IC. We also bring out the unique design of battery protection system for lithium ion batteries. The tests of battery system, including cycle test, high temperature test and nail penetration test, are to find the limit of batteries. The design and manufacture procedure is applied to the fabrication of battery system for Formosun solar racing car of mechanical engineering department of National Taiwan University to verify its feasibility. The result shows the design method is indeed able to achieve the design goal of the energy storage system for sporty performance for solar racing cars.目錄 致謝.................................................................................................................................. i 摘要................................................................................................................................ iii ABSTRACT ................................................................................................................... iv 目錄................................................................................................................................. v 圖目錄............................................................................................................................. ix 表目錄........................................................................................................................... xiv 第一章 緒論................................................................................................................... 1 1-1 研究動機............................................................................................................ 1 1-2 研究目的............................................................................................................ 3 1-3 研究內容與方法................................................................................................ 3 1-4 使用軟體............................................................................................................ 6 1-4-1 CATIA─3D 繪圖軟體............................................................................. 6 1-4-2 Protel DXP ................................................................................................ 7 1-4-3 MasterCAM.............................................................................................. 7 第二章 研究背景與文獻回顧....................................................................................... 8 2-1 現有電動車輛介紹............................................................................................ 8 2-1-1 純電池動力車（Traditional battery electric vehicle）........................ 8 vi 2-1-2 油電混合車（IC engine/electric hybrid vehicle） ............................. 10 2-1-3 燃料電池車（Fuelled electric vehicle）...............................................11 2-1-4 電聯車（Electric vehicles using supply lines）.................................. 14 2-1-5 太陽能動力車（Solar powered vehicles）.......................................... 15 2-2 現有二次充電電池介紹.................................................................................. 16 2-2-1 鉛酸電池（Lead-acid batteries）........................................................ 16 2-2-2 鎳鎘電池（Nickel-cadmium batteries）............................................. 17 2-2-3 鎳氫電池（Nickel-Metal Hydride batteries） ................................... 18 2-2-4 銀鋅電池（Sliver-zinc batteries）....................................................... 19 2-2-5 鋰離子電池（Lithium-ion batteries） ................................................ 21 2-2-6 超電容（Supercapacitors / Ultracapacitors） ................................... 24 2-2-7 歷屆WSC 冠軍隊伍採用之二次充電電池演進史.............................. 26 2-3 能量儲存系統相關文獻回顧.......................................................................... 27 2-4 二次充電電池專有名詞介紹.......................................................................... 28 2-4-1 電池儲存的能量..................................................................................... 28 2-4-2 能量密度與功率密度............................................................................. 29 2-4-3 殘電量（State of Charge） .................................................................. 31 第三章 太陽能車能量儲存系統設計......................................................................... 35 vii 3-1 設計目標與方法.............................................................................................. 35 3-1-1 系統規格方面......................................................................................... 35 3-1-2 電池管理系統方面................................................................................. 36 3-2 儲能媒介的選擇.............................................................................................. 37 3-3 決定系統規格.................................................................................................. 38 3-3-1 太陽能板規格限制................................................................................. 38 3-3-2 馬達規格限制......................................................................................... 39 3-3-3 電池規格................................................................................................. 41 3-3-4 電池串並聯............................................................................................. 42 3-4 電池管理系統.................................................................................................. 44 3-4-1 電池單元均衡......................................................................................... 45 3-4-2 充放電監控與SOC 計算....................................................................... 47 3-4-3 電池保護系統......................................................................................... 48 第四章 太陽能車能量儲存系統實作......................................................................... 52 4-1 電池模組並聯.................................................................................................. 52 4-2 BPS 電路板....................................................................................................... 54 4-3 電池箱製作...................................................................................................... 55 4-3-1 電池箱複合材料結構............................................................................. 56 viii 4-3-2 電池箱尺寸與鎖固方式......................................................................... 59 4-3-3 電池箱製作過程..................................................................................... 61 4-4 電池系統測試.................................................................................................. 65 4-4-1 充放電循環測試..................................................................................... 66 4-4-2 高溫測試................................................................................................. 70 4-4-3 破壞測試................................................................................................. 74 第五章 世界太陽能車挑戰賽..................................................................................... 77 5-1 WSC 比賽簡介................................................................................................. 77 5-2 各車隊設計特色.............................................................................................. 79 5-2-1 Aurora Team........................................................................................... 80 5-2-2 Arizona Solar Racing Team................................................................... 81 5-2-3 Osaka Sangyo University Solar Car Project........................................ 82 5-2-4 Nuon Solar Team.................................................................................... 83 5-3 Formosun 團隊於挑戰賽中遭遇問題與解決辦法......................................... 85 第六章 結論與未來研究方向..................................................................................... 87 6-1 成果總結.......................................................................................................... 87 6-2 未來研究方向.................................................................................................. 88 參考文獻.......................................................................................................................