Gateway to a New Thinking in Energy Management - Ultracapacitors By: Maxwell Technologies - San Diego January 18th, 2005 Ultracapacitors z Microelectronics z High-Voltage Capacitors About Maxwell Capacitor Manufacturer since 1965 www.maxwell.com Maxwell is a leading developer and manufacturer of innovative, cost-effective energy storage and power delivery solutions. Certifications: ISO 9001:2000 ISO/TS 16949 ISO 9002 Ultracapacitors z Microelectronics z High-Voltage Capacitors Manufacturing facilities: US, Europe, Asia Table of Content 1. 2. 3. 4. 5. 6. 7. 8. When can I use an Ultracapacitor? What is an Ultracapacitor? Ultracapacitor Market Ultracapacitor Applications Sizing your System Sizing Examples Guidelines to Designing an Ultracapacitor System Summary Ultracapacitors z Microelectronics z High-Voltage Capacitors When can I use an Ultracapacitor? • Applications that require high reliability back-up power solutions • Short term bridge power 1 - 60 seconds for transfer to secondary source or orderly shut down • Power quality ride-through to compensate for momentary severe voltage sags • Power buffer for large momentary in-rush or power surges Ultracapacitors z Microelectronics z High-Voltage Capacitors Power vs Energy What is the difference between Power and Energy? Ultracapacitors z Microelectronics z High-Voltage Capacitors Application Model Ultracapacitors z Microelectronics z High-Voltage Capacitors Peak Power Shaving Peak Power Shaving • Ultracapacitors provide peak power ... Available Power Required Power Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Peak Power Back-up Power Back-Up Power Support • Ultracapacitors provide peak power… ...and back-up power. Available Power Required Power Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Backup Power What is an Ultracapacitor? Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Performance Characteristics • Ultracapacitors perform mid-way between conventional capacitors and electrochemical cells (batteries). • Fast Charge and Fast Discharge Capability • Highly reversible process, 100,000’s of cycles • Lower energy than a battery ~10% of battery energy • Greater energy than electrolytic capacitors • Excellent low temperature performance Ultracapacitors z Microelectronics z High-Voltage Capacitors What is an Ultracapacitor? Ultracapacitors are: A 100-year-old technology, enhanced by modern materials Based on polarization of an electrolyte, high surface area electrodes and extremely small charge separation Known as Electrochemical Double Layer Capacitors and Supercapacitors Dielectric C = εr A/d Minimize (d) Maximize (A) Electrolyte E = 1/2 CV2 Film foil Ultracapacitors z Microelectronics z High-Voltage Capacitors Electrode ECDL Separator Technology Comparison Available Performance Charge Time Discharge Time Energy (Wh/kg) Cycle Life Specific Power (W/kg) Charge/discharge efficiency Lead Acid Conventional Ultracapacitor Battery Capacitor 1 to 5 hrs 0.3 to 30 s 10 -3 0.3 to 3 hrs 10 to 100 1,000 <1000 0.7 to 0.85 0.3 to 30 s 1 to 10 >500,000 <10,000 0.85 to 0.98 10 -3 Ultracapacitors z Microelectronics z High-Voltage Capacitors to 10 -6 -6 s to 10 s < 0.1 >500,000 <100,000 >0.95 Technology Comparison (page 2) 1000 Fuel Cells 10h 100 Energy Density/[Wh/kg] 0,1h 1h 36sec LiBattery Lead Acid Battery 10 Ni/Cd 3,6sec U/C Double-Layer Capacitors 1 36msec 0,1 Al-Elco 0,36sec 0,01 10 100 1000 Power Density/[W/kg] Ultracapacitors z Microelectronics z High-Voltage Capacitors 10000 Ultracap vs Battery Technologies Efficiency 4 Charge Acceptance Self Discharge Pb-AGM 3 Temperature Range Availability 2 NiMH Li Ion 1 Environment Ultracaps Cycle Stability 0 Recycling Energy Density Safety Power Density System Cost Energy Cost Power Cost Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Market Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Market Ultracapacitor World Market Consumer Products Industrial Transportation Digital Camera UPS Hybrid Bus/Truck PDA Windmill Engine starting Toys Stationary Fuel Cell Light Hybrid Memory back-up Automation/Robotics Local Power Rail Ultracapacitors z Microelectronics z High-Voltage Capacitors Available Products • Aqueous Electrolyte: ESMA, Elit, Evan, Skeleton Technologies and Tavrima • Advantages: • High electrolytic conductivity • No need for tight closure to isolate • Low environmental impact • Disadvantages: • Low decomposition voltage (1.23V) • Narrow operational range (freezing point of water) • Organic Electrolyte: Maxwell Technologies, Panasonic, EPCOS, Ness Capacitors, ASAHI GLASS • Advantages: • High decomposition voltage • Wide operating voltage • Disadvantages: • Low electrolytic conductivity • Need for tight closure to isolate from atmospheric moisture Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Applications Ultracapacitors z Microelectronics z High-Voltage Capacitors Applications Automotive Traction 14/42 V systems HEV Electrical Subsystems Regen braking Voltage stabilization Diesel engine starting Large Cells Consumer Electronics Industry Power quality Pitch systems Actuators AMR PDAs Digital cameras 2-Way pagers Scanners Toys Ultracapacitors z Microelectronics z High-Voltage Capacitors Small Cells Today’s Markets Electric Rail Pack Braking Energy Recapture Diesel engine starting Wind power plant pitch systems Burst power TRACTION Ultracapacitors z Microelectronics z High-Voltage Capacitors INDUSTRY Small cell applications Digital cameras, AMR, Actuators, Memory boards CONSUMER Ultracapacitors z Microelectronics z High-Voltage Capacitors SITRAS® SES - Solution Energy storage system: Stationnary or on the vehicle Time t1 Vehicle 1 is braking Energy storage system stores the braking energy Time t2 Vehicle 2 is acccelerating Energy storage system delivers the energy Application: Time shifted delivery of the stored braking energy for vehicle reacceleration Solutions: Possible with either stationary or on-vehicle energy storage system Advantage: Cost savings through reduced primary energy consumption Ultracapacitors z Microelectronics z High-Voltage Capacitors SITRAS® SES - Benefits Saved energy kWh/h 50 ⇒ Reduction of the power need by 50 kW ⇒ Energy saving of 340.000 kWh per year and per installation ⇒ thermal limit 68 kWh/h 40 30 20 10 0 04.08.01 07.08.01 Ultracapacitors z Microelectronics z High-Voltage Capacitors 10.08.01 13.08.01 MITRAC of Bombardier Transport MITRAC energy saver Ultracapacitors z Microelectronics z High-Voltage Capacitors Diesel Engine Cranking by Stadler Ultracap module for diesel engine vehicles Robust construction with voltage balancing Easy to scale up for additional cranking power Easy to integrate in existing housing Easy to use, maintenance free Ultracapacitors z Microelectronics z High-Voltage Capacitors Wind Turbine Pitch Systems Modern wind turbines consist of threebladed variable speed turbines Independent electro-mechanical propulsion units control and adjust the rotor-blades Latest technology uses the wind not only to produce wind energy but also for its own safety Ultracapacitors z Microelectronics z High-Voltage Capacitors Pitch System Storage Systems Each pitch systems is equipped with an ultracapacitor emergency power supply Ultracapacitors represent an optimum emergency power supply system due to their • Enhanced level of safety • High reliability • Efficiency • Scalability Ultracapacitors z Microelectronics z High-Voltage Capacitors Switch box including 2600F ultracapacitors 75 V, 81 F ultracapacitor module 4 modules are put in series to power 300 V pitch systems of 3-5 MW wind power plants Fuel Cell Powered Fork Lift • • Fork lift equipped with a fuel cell Cell system and an ultracapacitor module • Ultracapacitors z Microelectronics z High-Voltage Capacitors BOOSTCAP module: 48 BCAP0010 112 V, 55 F 40 kW peak power Vehicle Applications of Ultra-capacitors • Distributed energy modules are located at the actuator level in the vehicle control hierarchy in close proximity to the actuator power driver (should be within 18”). Vehicle System Controller Power & Communications (PDA) Steering electric assist Brakes Regen Brake Sys Steering actuator Belt or Crankshaft Rack ECU Mtr UC UC UC ECU Steering Wheel HCU Mtr ISG Torque Continuous, Scheduled, Selectable Transmission ECU ETC, Fan, Water Pump ECU Brake Pedal Other 42V Loads SOC, SOH,Vsys Brake actuators Engine Distributed Energy Storage Modules Energy Storage System Mgm't ISG Subsystem Accel Throttle Pedal Body Ultracapacitors z Microelectronics z High-Voltage Capacitors Gear Sel, L/U Clutch Oil Pump UC High Voltage Battery Primary Storage HVAC UC Electric air cond. comp. Fuel Cells with Ultracapacitors Ultracapacitors are accepted as the normal energy storage option for fuel cells • • • Every major automotive company in the world is testing fuel cells as an alternative drive train power system. All significant fuel cell companies are either using or experimenting with ultracapacitors as an integral part of the system. Several major automotive companies have declared fuel cells with ultracapacitors as their baseline system architecture. Honda and Hyundai have gone public, others we are working with have not. “Utilizing ultracapacitors we have gained an edge in energy efficiency and throttle responsiveness over competitors that are pursuing the hybrid battery–fuel cell model” Honda Motor Company Ultracapacitors z Microelectronics z High-Voltage Capacitors Sizing Your System Ultracapacitors z Microelectronics z High-Voltage Capacitors Data sheet Ultracapacitors z Microelectronics z High-Voltage Capacitors Data sheet Ultracapacitors z Microelectronics z High-Voltage Capacitors How to measure Ultracapacitors • To measure UC you need: • bi-directional power supply (supply/load) OR • separate power supply and programmable load (constant current capable) • voltage vs. time measurement and recording device (digital scope or other data acquisition) • Capacitance and Resistance: Capacitance = (Id * td)/(Vw - Vf) = (Id * td)/Vd ESR = (Vf - Vmin)/Id Vw = initial working voltage Vmin = minimum voltage under load Id = discharge current Vf = voltage 5 seconds after removal of load. td = time to discharge from initial voltage to minimum voltage Ultracapacitors z Microelectronics z High-Voltage Capacitors Basic Equations Definition of Capacitance: Charge = current * time: Q = I*t Solving for voltage: Dynamic Voltage: Stored Energy At initial voltage Vo, At final voltage Vf, C = Q/V C = I*t/V V = I*t/C dV/dt = I/C E = ½ C*V2 (1) (1a) (2) (3) (4) Eo = ½ C*Vo2 Ef = ½ C*Vf2 Delivered energy = Eo – Ef Ultracapacitors z Microelectronics z High-Voltage Capacitors ∆E =½ C*(Vo2 – Vf2) (5) Voltage & Current vs. Time C = 15 farad; Resr = 100 milliohm Vo = 48V; I = 30A 50 50 2– dV/dt ==V I/C dV I*dt/C dV ∆E =½ dV I*dt/C C*(V ==; Q/C I*R I*R Vf2esr ) total esr o =+esr Voltage 45 40 Resr i 40 Voltage (V) 45 - 35 + 30 + C - 35 25 Current (A) Vo 20 30 15 Vmin 25 10 5 Current 20 0 -5 -4 -3 -2 -1 0 1 2 3 Ultracapacitors z Microelectronics z High-Voltage Capacitors 4 5 6 Time (sec) 7 8 9 10 11 12 13 14 15 Vf Basic Model • Series/Parallel configurations • Changes capacitor size; profiles are the same • Series configurations • Capacitance decreases, Series Resistance increases Rs=Rcell*(# of cells in series) • Cs=Ccell/(#of cells in series) • Parallel configurations • Capacitance increases, Series Resistance decreases RP=Rcell/(# cells in parallel) • CP=Ccell*(# of cells in parallel) • Current controlled • Use output current profile to determine dV/dt dV = I * (dt/C + ESR) • Power controlled • Several ways to look at this: Pterm = I*Vcap –I2*ESR (solve quadratic for I) I = [Vcap - sqrt(Vcap2-4*ESR*Pterm)]/(2*ESR) • Solve for dV/dt as in current-controlled • J=W*s=1/2CV2 Solve for C. Ultracapacitors z Microelectronics z High-Voltage Capacitors Applications with a single energy storage component • Applications in which little total energy is required (i.e. memory backup) • Possibly used with other energy sources • Short duration, high power (i.e. pulse transmit) • Long duration, low power (i.e UPS backup) • Opportunities for high charge rates (i.e toys) Ultracapacitors z Microelectronics z High-Voltage Capacitors Applications with two energy storage components • Power vs. Energy design trade when using two components • Single component vs. two components • Engines/Fuel cells/Batteries/Solar Arrays are energy rich/power poor (or poor response) • Size these components for enough energy, system may be limited in power • Size these components for power, system may have surplus of energy • Ultracapacitors are power rich/energy poor • Size an ultracapacitor for enough energy, system may have a surplus of power • Size an ultracapacitor for power, system may be limited in energy • Two components • A primary source for energy; Ultracapacitor for power • Requires appropriate definition of peak power vs. continuous power Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Aging • Unlike batteries, Ultracapacitors do not have a hard end of life criteria. • Ultracapacitors degradation is apparent by a gradual loss of capacitance and a gradual increase in resistance. • End of life is when the capacitance and resistance is out of the application range and will differ depending on the application. • Therefore life prediction is easily done. Ultracapacitors z Microelectronics z High-Voltage Capacitors Capacitance and ESR vs Frequency ESR vs . Frequency 3,50E+03 7,00E-04 3,00E+03 6,00E-04 2,50E+03 5,00E-04 ESR [mOhm] Capacitance [F] Capacitance vs. Frequency 2,00E+03 1,50E+03 4,00E-04 3,00E-04 1,00E+03 2,00E-04 5,00E+02 1,00E-04 0,00E+00 1,00E-02 1,00E-01 0,00E+00 1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+00 1,00E+01 1,00E+02 1,00E+03 Frequency [Hz] Ultracapacitors z Microelectronics z High-Voltage Capacitors Frequency [Hz] C and ESR Temperature Dependency 1,2 2000 1,1 ESR [m O hm ] 0,9 1600 0,8 1400 0,7 0,6 1200 ESR BCAP0 0 0 8 (DC) 0,5 Cap acitance BCAP0 0 0 8 0,4 1000 -60 -40 -20 0 20 40 Temperature [°C] Ultracapacitors z Microelectronics z High-Voltage Capacitors 60 80 100 Capacitance [F] 1800 1 BCAP Self Discharge Self Discharge vs Temperature 100,0 90,0 % U (t = 0) 80,0 70,0 60,0 - 35 °C 50,0 + 5 °C + 25 °C 40,0 + 65 °C 30,0 0 2 4 6 8 10 12 14 16 Time [days] Ultracapacitors z Microelectronics z High-Voltage Capacitors 18 20 22 24 26 28 30 BCAP Cycling Capacity Change in Capacitance [%] 110.0 2.0E-03 1.8E-03 1.6E-03 1.4E-03 100.0 90.0 Capacitance 80.0 70.0 ESR 60.0 50.0 0 20000 40000 60000 Cycle Number Ultracapacitors z Microelectronics z High-Voltage Capacitors 80000 1.2E-03 1.0E-03 8.0E-04 6.0E-04 4.0E-04 2.0E-04 0.0E+00 100000 ESR [Ohm] 90 A CC, 1.15-2.3 V, 25 s, RT BCAP Cycling 500’000 cycles between 1.8 and 2.7 V, 100 A ESR (1 Hz) increase 140 % (0.49 to 0.79 mOhm Capacitance decrease 38 % (2760 to 1780 F), 30% compared to rated capacitance Ultracapacitors z Microelectronics z High-Voltage Capacitors BCAP DC Life Capacitance and ESR variation at U, T = 40 °C 105,0 200,0 100,0 180,0 95,0 160,0 90,0 140,0 120,0 % ESR (t = 0) 85,0 % C (t = 0) 2.5V 40°C 2.1V 40°C 2.3V 40°C 80,0 75,0 70,0 100,0 80,0 60,0 40,0 65,0 20,0 2.5V 40°C 60,0 0,0 2.1V 40°C 55,0 -20,0 2.3V 40°C 50,0 -40,0 0,0 100,0 200,0 300,0 duration [days] Ultracapacitors z Microelectronics z High-Voltage Capacitors 400,0 0,0 100,0 200,0 300,0 duration [days] 400,0 BCAP DC Life Capacitance and ESR variation at U, T = 65 °C 120,0 120,0 2.5V 65°C 2.1V 65°C 2.3V 65°C 100,0 100,0 80,0 % ESR (t = 0) % C (t = 0) 80,0 60,0 40,0 40,0 20,0 0,0 2.1V 65°C 2.3V 65°C 2.5V 65°C 20,0 60,0 -20,0 0,0 -40,0 0 100 200 duration [days] Ultracapacitors z Microelectronics z High-Voltage Capacitors 300 400 0 100 200 300 duration [days] 400 Sizing Examples Ultracapacitors z Microelectronics z High-Voltage Capacitors Example sizing 1) Define System Requirements 15 W delivered for 10 seconds 10V max; 5V min 2) Determine total energy needed: a) Determine Capacitance based on: b) Substitute the energy from above: c) Solve for C: J=WS=10W*10sec=150J J=1/2CV2 150J=1/2C(Vmax2-Vmin2) C=300/(102-52)=4F Csystem = 4.8F 3) Add 20-40% safety margin to cover I2R losses 4) Calculate number of cells in series (since maximum cell voltage = 2.5V) 10V/2.5V = 4 cells in series 5) Calculate cell-level capacitance C = Csys * # of series cells = 4.8F* 4 = 19.2F per 2.5V “cell” 6) Calculate number of cells in parallel (we will assume a 10F cell) # in parallel = 19.2/10F = 2 x 10F cells in parallel Ultracapacitors z Microelectronics z High-Voltage Capacitors Guidelines to Designing an Ultracapacitor System Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Cell Balancing Why Cell Balancing? • Achieve cell to cell voltage balance • Accounts for variations in capacitance and leakage current, initial charge and voltage dependent on capacitance, sustained voltage dependent on leakage current • Reduces voltage stress on an individual cell • Increase overall reliability of the individual cells Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Cell Balancing How to Cell Balance? • Resistor method, resistor placed in parallel, resistor value calculated at 10x leakage current for slow balance, 100x for faster balance, good for low cycle when efficiency or stand by loss not an issue Surface Mount Resistor for low duty cycle application Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Cell Balancing • Active method, use semiconductors to limit or balance voltage between cells, best for high duty cycle or when efficiency and stand by loss from leakage current are important, highest cell reliability option Active cell to cell balance circuit Ultracapacitors z Microelectronics z High-Voltage Capacitors Cell Balancing • Low Cost • Scalable balance current • 10mA, 300mA circuits • Very low quiescent current (<20µA) • No on/off required • Modular installation • N cells requires N-1 circuits • Voltage independent 2600F cells; 4 in Series Note high and low points; low capacitance cell Low capacitance, high leakage cell 1.5 hours of Vehicle cycling (~ 200A) 300mA balancer for 50 & 60mm Ø cells 10mA balancer for 5F & 10F cells Ultracapacitors z Microelectronics z High-Voltage Capacitors Cell Balancing C1 Positiv e R1 1M 1% VPP + - C1 R3 C1-C2 Midpoint 475 1% Ultracapacitors U1 VNN R2 1M 1% POS C2 R4 499k 1% C2 Negativ e NEG 10mA Balancer C1 Positive 100 R1 100K 1% Q1 TLV2211CDBV VPP + - R2 100K 1% POS MMBT2222AWT1 C1 R3 5.6 1% 1.5W C1-C2 Midpoint Ultracapacitors U1 VNN 100 R4 R6 C2 Q2 MMBT2907AWT1 C2 Negative R5 49.9k 1% 300mA Balancer Ultracapacitors z Microelectronics z High-Voltage Capacitors NEG Cell Balancing Three cells with one cell balancing resistor removed: OCTA Cycles Max. Voltage Profiles 5.00 4.50 4.00 Cell voltage (V) 3.50 3.00 C1-V 2.50 C2-V C3-V 2.00 1.50 1.00 0.50 0.00 0 1 2 3 4 5 Day # Ultracapacitors z Microelectronics z High-Voltage Capacitors 6 7 8 9 10 Ultracapacitor Packaging Why Packaging? • • • • • • • Ensure proper mechanical stress Ensure robust low resistance interconnect Ensure proper electrical isolation Ensure proper thermal considerations Ensure agency compliance Increase overall cell reliability Reduce or eliminate maintenance requirements Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Packaging How to Package Cells? • Care should be taken for the electrical interconnect, a few key guidelines to follow: • Do not over torque. Over torque at the terminals may cause internal failure of contact points. For example, the Maxwell BCAP specification is 100 in.-lbs • Use similar conductor metal interconnect bus bars to eliminate galvanic corrosion. • Good surface to surface contact will reduce inter-cell resistance, reducing voltage drop and temperature stress Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Packaging How to Package Cells? • Cell to cell spacing should take into consideration two key points and can be accomplished by the design of the interconnect or the cell balancer: • Depending on the cell some part of the outer case may be electrically the same as one of the terminals, ensure electrical isolation and watch for rubbing components that may wear through ultracapacitor insulation, do not remove the factory installed insulator sleeve • Some air space between the cells allows convection cooling via air flow improving reliability, depends on cycle time, short duration high cycle applications may require forced air or other cooling method Ultracapacitors z Microelectronics z High-Voltage Capacitors Ultracapacitor Packaging Electrical Isolation Aluminum Interconnect Proper Torque and Hardware Ultracapacitors z Microelectronics z High-Voltage Capacitors Summary Ultracapacitors z Microelectronics z High-Voltage Capacitors Benefits Summary Calendar Life • Function of average voltage and temperature Cycle Life • Function of average voltage and temperature Charge acceptance • Charge as fast as discharge, limited only by heating Temperature • High temp; no thermal runaway • Low temp; -40°C Ultracapacitors z Microelectronics z High-Voltage Capacitors Benefits Summary No fixed Voc • Control Flexibility; context-dependent voltage is permitted • Power Source voltage compatibility • Examples; Fuel cells, Photovoltaics No Vmin • Cell can be discharge to 0V. • Control Safety; No over-discharge • Service Safety Cell voltage management • Only required to prevent individual cell over-voltage State of Charge & State of Health • State of Charge equals Voc • Dynamic measurements for C and ESR = State of Health • No historical data required Ultracapacitors z Microelectronics z High-Voltage Capacitors Useful Links • Useful links on Maxwell Technologies Web-site: • • • • • White Papers Technology Overview Sizing worksheet Application Notes Data Sheets www.maxwell.com Ultracapacitors z Microelectronics z High-Voltage Capacitors
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