HYBRID VEHICLES AND BATTERY SYSTEMS.

PETER

BRUCE

G4WPB

WHY CHANGE

HYBRID VEHICLE – 2050.

The original consumer battery the Leclanché cell was invented and patented in 1866 by Georges Leclanché.

It consisted of a glass jar containing a porous pot with a central carbon element surrounded by powdered manganese dioxide. This formed the positive electrode. The negative electrode being a zinc rod standing in the jar which was half-filled with ammonium chloride solution, thickened by the addition of sand or sawdust. By 1868 20,000 such cells were in use and this original design, with little alteration, continued in use for nearly a hundred years.

1866

In 1888 the first 'dry' cells were developed by Carl Gassner.In 1888 the first 'dry' cells were developed by Carl Gassner.

These are where an outer zinc can serves both as container and as the negative electrode. The positive electrode, a carbon rod, is immersed in a manganese dioxide/carbon black mixture. This is separated from the zinc container by a folded paper sack, soaked in a solution of ammonium chloride which acts as the electrolyte. During use the zinc casing of the battery is gradually consumed by the chemical reaction. A bitumen seal prevents evaporation of water from the electrolyte and the ingression of oxygen. This development of the Leclanché cell still is the basis of the common zinc/carbon battery and its higher powered brother the zinc chloride battery, which remain the largest selling battery type world wide.

Dry Cell

1888

Alkaline BatteryDuring the Second World War this basic technology was further developed to produce a more reliable and robust battery. Allied Forces fighting in the Far East, in particular, found that the environment of high temperature combined with high humidity was extremely detrimental to existing battery types. The new development, the alkaline cell, became the second most widely used consumer battery. The alkaline cell has the zinc anode at the centre of the cell in powder form and the manganese dioxide/graphite cathode as hard-compressed cylindrical pellets surrounding the anode. Synthetic paper acts as the separator. A chemically aggressive and strongly alkaline gelled solution of potassium hydroxide acts as the electrolyte and gives its name to the system.

1943

Rechargeable BatteryThe reusable alternatives to zinc manganese primary batteries are secondary or rechargeable batteries. Initially these were a scaled down version of the lead acid car battery.This technology actually predates the Leclanché battery by several years being developed by Planté' in 1859. Lead acid is a 2 volt system and therefore not interchangeable with the popular zinc manganese systems. The popular rechargeable alternative to zinc manganese systems was the nickel cadmium system (NiCad) developed in 1909 and refined in the 1950s to conform to the standard consumer battery sizes. In overall capacity the NiCad battery can be considered equivalent in capacity to a zinc chloride battery or have about the third the capacity of a manganese alkaline battery. However, although it has a voltage of 1.2 volts, it has a flat discharge curve. Therefore, in applications where there is a high cut-off i.e. the equipment will not work below say 1.1 volts the NiCad battery can appear on par with the alkaline cell. Its great benefit is, however, that it can be recharged many hundreds of times. So although it is about three times the price, the disciplined owner can see a substantially saving over both alkaline and zinc batteries. Shortcoming are that it does not achieve its full potential if recharged too soon after only a shallow discharge. This is called the 'memory effect' and the battery acquires the habit of needing charging after only little use. To maximise the benefits of these batteries they should ideally be completely discharged before recharging. Another negative of this battery system is that it contains cadmium, which is a toxic metal and, therefore, should be recycled or discharged in a safe location. Environmental legislation may at some time in the future ban the sale of this product, especially as a new safer high performer is now available - the nickel metal hydride battery. This battery has twice the performance of the NiCad, it is lighter, has no memory effect and contains no toxic metals. They are of course more expensive but offer the disciplined consumer the best value for money.

1950s

Silver oxide coin cells which, although expensive due to its ingredients, has a very flat discharge profile at a voltage of about 1.55 volts. This type of battery was often used in cameras which gave automatic settings but did not drive auto focus or auto wind motors.

Silver Oxide Battery

1960s

Lithium manganese dioxide coin cells have a high energy density and can be made very thin. They are a 3-volt system with a flat discharge curve. Lithium cells are also found in cylindrical format often with two cells joined to form a 6-volt battery. Because of their high energy density they have found use in fully automatic cameras, especially those which require high power to drive auto focus and film winding motors. They are, of course, quite expensive.

Late 1960s

LITHIUM

Zinc air is one system that offers great promise for the future, although it is uncommon in cylindrical sizes. It is a variation of the Leclanche cell having a zinc anode but taking air from the atmosphere via a catalyst to act as the cathode. This system has a potential energy 50% greater than the alkaline battery at 1.4 volts with a flat discharge curve. The difficulties with this system are three fold: how to get sufficient oxygen from air into the cell at high rates of discharge, how to stop the liquid electrolyte seeping out through the air holes and how to stop an adverse reaction between the electrolyte and the carbon dioxide in the air.A derivation of this is a hybrid cell half-alkaline half zinc air. A smaller proportion of manganese dioxide supports the discharge reaction in the short term and the recovery period between discharges allows the manganese dioxide to reoxidise with oxygen from the air.Zinc air is however most commonly found in button or coin cells and, in particular, batteries used in hearing aids. Early 1970s

ZINC AIR

ELECTRICELECTRIC

VEHICLES.VEHICLES.EVERYONE IS NOW AT ITEVERYONE IS NOW AT IT……

ELECTRIC VEHICLES

CRYSLER FORD

GM

HONDA HYUNDI

VW

TOYOTA PRIUS – HYBRID, VERSION 2.

THE WORLDS BIGGEST SELLING THE WORLDS BIGGEST SELLING HYBRID HYBRID PRODUCTIONPRODUCTION VEHICLE.VEHICLE.

THE NAME PRIUS IS LATIN FOR…

Ahead of it’s time

THE GEAR LEVER HAS NO “FEEL” TO IT.

IT’S JUST A SWITCH

IN A GROOVE…

PLENTY OF ROOM

BATTERY COMPARTMENT.

STANDBY BATTERY IS ¼ SIZE OF NORMAL CAR BATTERY.

SOME FEATURES OF THE VEHICLE MAY SURPRISE YOU…..

VOICE RECOGNITION - FOR NAVIGATION SYSTEM, TEMPERATURE CONTROL, PHONE, AUDIO VOLUME, CD, FM RADIO CONTROL, AIR CONDITIONING.

THE AIR CON IS ELECTRIC. FIRST IN THE WORLD.

POWER ASSIST STEARING IS ELECTRIC.

500 STORED TELEPHONE NUMBERS IN PHONE BOOK.

THE BATTERY PACK / ELECTRIC DRIVE TRAIN IS GUARANTEED FOR 8 YEARS.

USES NICKEL METAL HYDRIDE BATTERIES.

0 to 60 in 10.7 0 to 60 in 10.7 -------- SECONDS.SECONDS.

The Hybrid Synergy Drive has a 50 percent more powerful 50-kilowattdrive-motor operating at up to 500 volts, with a newly adopted high-voltage power converter.

Combined mpg is now in the mid-50s, higher than the first generation or any other mid-sized car (twice the combined mileage rating of its closest competitor). Hybrid Synergy Drive significantly improves acceleration, going from the mid- 12-second range to the mid- 10-second range. This acceleration level is comparable to the Toyota Camry LE four-cylinder.

New Prius.

WHAT YOU SEE WHAT YOU SEE –– BUT DONBUT DON’’T HEART HEAR

MYTHSMYTHS

ANDAND

MAGIC.MAGIC.

Restarting the Engine frequently is harmful.Not True! That assumption is based on traditional concepts.Prius starts the engine in a very different manner than methods of the past.Rather than just using a small motor to spin the gas engine to only 100 RPM, like traditional vehicles do, the hybrid system uses a much larger motor which spins the gas engine to a minimum of 800 RPM. Then it waits until oil-pressure is established before injecting fuel and producing a spark. This process enables a very smooth start up, reducing burden on bearings, pistons, and cylinders.Another important fact to be aware of is the design of engine components. They were modified from traditional design (weight reduced, size reduced, etc.) to help make the start up process easier.

Short trips will result in low MPG.What does "short" actually mean?To reduce emissions, the catalytic-converter must be hot for the cleansing of exhaust to occur. The source of that heat was exclusively from the engine. It required gas to be consumed just for the sake of getting the engine hot, so MPG would suffer during the first few minutes of driving. The design is different with the new Prius. Toyota added a 3-litre thermal storage container. When you power-off the hybrid system, hot coolant (anti-freeze) is pumped into that thermos. (It will remain hot overnight and warm for up to 3 days.) Then later when you power-on the hybrid system, that hot coolant is pumped into the head of the engine. Heat for the emissions system is available significantly faster than in the past. That allows the engine to shut off much sooner, which saves fuel.

The cold engine is strained in the winter.Just the opposite!In the winter, not only does the engine have a chance to properly warm up, it actually gets a longer opportunity than in the summer. The electric propulsion is favoured even greater in cold conditions. This is possible because there is much less of a concern about being able to keep the battery-pack cool.The hot coolant stored in thermos is pumped into the engine head the moment you push the "Power" button. So warming actually begins before the engine is even started. That helps to reduce strain. Then later when stressful thrust is needed, the motor works hard to prevent the engine from needing to provide much of it. The engine just continues to run at a constant slow RPM to create heat. As a result, energy is available for generating electricity. And that's exactly what the system uses it for. That, along with the battery-pack, feeds the electric-motor enough to protect the engine until it's warm enough to run like it normally does.As a result of the special control for cold conditions, the engine isn't strained and warm up actually occurs surprisingly fast.In other words, the hybrid system offers an advantage that traditional vehicles cannot compete with.

The fuel gauge isn't working correctly.It's different from traditional vehicles, like other aspects of the hybrid.There is a bladder inside the fuel tank. It is there to significantly reduce evaporative emissions from the gas by eliminating space for air inside, contracting & expanding as the tank is emptied & refilled. Unfortunately, the bladder also contracts & expands due to temperature changes. To prevent these effects from interfering with normal operation, it was setup to display in a non-linear format. In other words, each of the ten squares does not represent an equal amount of gas. Instead, it is relative, with greater emphasis on accuracy as the toward the low end.

The brakes are more complicated.No! They are the same as traditional brakes.The brakes are just plain, old, ordinary disc (front) and drum (back). Any auto shop can repair & replace them.Primary deceleration is provided by the electric motors, which are part of the transmission. They are always engaged, a standard part of the propulsion system. So no additional parts are needed for the braking ability. Energy capture (regenerated electricity) begins when you lift your foot from the accelerator-pedal; slowing occurs by the 10kW motor spinning. When you step on the brake-pedal, the 50kW motor takes over; this provides greater deceleration aswell as more electricity. Thrust beyond the standard tolerance for the large motor is handled by the traditional brake pads & shoes. As a result of this setup, the brakes are used less than in traditional vehicles. So they should last longer.

WHAT KEEPS ALL THE WHAT KEEPS ALL THE SYSTEMS IN LINESYSTEMS IN LINE……

LOTS TO GO WRONGLOTS TO GO WRONG……

NOTHING WRONG YET.NOTHING WRONG YET.

CPU CPU -- BRAINS.BRAINS.

THIS MEANS THIS MEANS –– IN SIMPLE TERMSIN SIMPLE TERMS……

IN THIS COLD WEATHERIN THIS COLD WEATHER……

MY CAR HEATERMY CAR HEATER

WARMS ME UP QUICK.WARMS ME UP QUICK.

TRANSAXLE COMPONENTS

PLANET GEARS – THE ASTRONOMICAL TOUCH

THE KEY OF THE DRIVE TRAIN SYSTEM

FOR SUCH AN IMPORTANT ITEM IT’S NOT VERY BIG.

WHAT’S IN THE POWER CONVERTER

POWER CONVERTER.

INSIDE THE POWER CONVERTER.

THE LATEST – FUEL CELL FITTED TO PRIUS.

FUEL CELL

Alkaline fuel cells - AFCAlkaline fuel cells were first used in the Gemini-Apollo space program to produce drinking water and electrical energy.Operate on compressed hydrogen.

Direct methanol fuel cells - DMFCDirect methanol fuel cells use methanol instead of hydrogen.

Molten carbonate fuel cells - MCFCMolten carbonate fuel cells use a liquid solution of lithium, sodium, and/or potassium carbonates soaked in a matrix.

Phosphoric acid fuel cells - PAFCPhosphoric acid fuel cells use phosphoric acid as the electrolyte to make electricity.

Proton exchange membrane fuel cells - PEMPEM fuel cells are the most common type of fuel cell being developed for transportation use.

FUTURE FUEL CELL PROBLEMS

OIL COMPANIES.

DISTRIBUTION.

MANUFACTURE.

STORAGE.

THERE ARE MANY MORE “PROBLEMS” BUT ABOVE ARE ENOUGH.

ELECTRIC BIKE’S

ANY FUTURE…..THE EUROPEAN GOVERNMENTS HAVETHE EUROPEAN GOVERNMENTS HAVE

KILLED THIS OFF WITH LIMITED POWERKILLED THIS OFF WITH LIMITED POWER

AND DAFT AND DAFT P.A.S.P.A.S. CONTROL SYSTEM. CONTROL SYSTEM.

P. A. S. SYSTEM.

The PAS system was developed by governments but it’s useless – twist grip type handlebar throttle is far better.

MY FIRST ELECTRIC BIKE. WEIGHS A TON

Heavy SLA

MY NEW BIKE – BUT LOTS OF MODS.

NEW DESIGN SHIMANO 7 GEAR FREEWHEEL. CAN BE TAKEN APART AND ALSO HAS AN 11 T HIGH GEAR.

INSIDE THE BRUSHLESS MOTOR.

NEW CRANK FITTED 61 T

LOWEST ROLLING RESISTANCE TYRES.

NEW GEAR SHIFTER WITH MOD THROTTLE.

THE FUTURE.

IT’S HERE…

X PRIZE CONTENDER…

FAILED.

ELECTRIC MOTORS & BATTERIES IN MODELS.

REVOLUTION

ELECTRIC HELICOPTER.

BRUSHED MOTOR WAS USED FIRST – DESPITE ALTERING TIMING IT NEEDED EXTENSIVE SERVICES AND GOT VERY HOT IN USE….

OUTRUNNER BRUSHLESS.

TOP OUTER CASE IS IN MOTION

SPECIFICATIONSPart # PHX-80

Price $159.95

Cells w/BEC 5-12

Cells w/o BEC 5-20

Continuous 80 amps

Surge 120 amps

Switching Rate Programmable(11, 22, or 41KHz)

Resistance 0.001 Ohms

Brake Programmable

Reversible Yes - change any two wires

Low Voltage Cut-off Programmable

Size 1.05 x 2.65 x .45 in.

Weight (with wires) 2.1 oz. (60g)

Universal Connector

MY BRUSHLESS CONTROLLER – MICRO TECHNOLOGY.

BRUSHLESS OUTRUNNER MOTOR INSTALLED – LOADS OF POWER, ONLY GETS WARM AND NOT A SERVICE FOR OVER A YEAR.

MY OTHER SCALE MODELS

KOK2000-15C-3S2P-Deans

£94.00 (excl.vat)

11.1 Volt... 4 Ampere Hours capacity !! All cells in this complete pack are specially selected for close matching charge and discharge characteristics. The continuous current rating of this pack is an outstanding 60Amps. size: 245mm x 44mm x 18mmWeight: 382gmsRating: 60 Amps continuous Average Power delivery: 500 Watts!! Yes the average power delivery of these packs is as stated, the pull down on the voltage under load is so good that the pack is averaging 500 watts delivery. These 4 th generation cells are astounding.

LITHIUM POLYMER BATTERY.

1/6TH THE WEIGHT OF NICADS.

Safety Notes on Lithium Polymer BatteriesSafety in using Polymer cells or assemblies is your first priority.

If you do not understand the characteristics of Polymer cells or assemblies ask before buying. Please be sure to read and follow these instructions carefully.

Warranty will not be considered if requirements are not followed.Safe ChargingLithium Polymer cells have very strict charging requirements. Always charge Lithium Polymer cells or packs with recommended PCM or great damage may occur. Always use chargers specifically approved for Lithium Polymer cells or packs. Always test your charger to assure it is functioning properly. Always charge your Lithium Polymer cells or packs outdoors and in a fire proof container. Always store Lithium Polymer cells or packs in a fire proof container. Always have sand or dry fire extinguisher handy in the event of fire. Always keep any battery out of the reach of children. Always handle Lithium Polymer cells and packs with great care. Always purchase a factory authorized built pack instead of building your own. Always observe the correct polarity when connecting cells or packs to charger or application. Always seek medical attention if electrolyte gets in your eyes (flush with cold water immediately). Always scrub with soap and water if electrolyte comes in contact with your skin.

Never charge Lithium Polymer cells or packs unattended. Never charge Lithium Polymer beyond factory specifications and is strictly prohibited. Never charge Lithium Polymer in your car, home or garage or where other physical damage can occur. Never charge Lithium Polymer while in the application as the hot pack may ignite certain materials. Never charge Lithium Polymer on flammable materials such as wood, foam or plastic. Never extinguish a Lithium Polymer fire with water. Never disassemble a Lithium Polymer cell or pack (see Damaged notes below).Never short circuit Lithium Polymer cells or packs. Never use a Lithium Polymer cell or pack that has been damaged (see Damaged notes below).Never put loose cells with uncovered terminals in your pocket, purse, bag, desk drawer, etc. Never keep cells or packs in temperatures that exceed 60C/140F. Never exceed the factories maximum allowed discharge rates. Never combine different cell sizes or capacities together in the same pack Never unplug Battery from PCM while charging (Unplug charger before disconnecting Battery).

Damaged cells or packsIn the event your cells or packs were involved in a crash..... Totally inspect the cells, wire leads and connections for possible short circuit. If there is any doubt completely cut all wires from the cells and pack. If any cells are dented or deformed do not use the pack again ever. Follow disposal notes below.

This is for all of you guys out there just getting into Micro Helis,like myself, who have heard how dangerous Litho batteries are but never encountered or considered the fire hazards. I just got my first Micro,a Hornet2 about a month ago. I traded a good guy here,and it came with all the necessary equipment to get it flying including a Lithium-Ion charger. I have been working on this heli for about 3 weeks working out the kinks and getting familiar with the heli as a whole. I had a friend help me assemble the pack, 2 Etec 1200 litho cells. I also purchased a 3 cell pack from Deetee as a spare and had been primarily using the 3 cell pack to test fly and such.

THIS IS HOW BAD IT CAN BE – REPRODUCED FROM R.C. GROUP.

CONTINUED.

Today I used the 2 cell pack...hovered a while until the batterydischarged and promptly brought the heli done in the workshop for a recharge. Plugged it in and went and played some PS2 with my son.About 30 minutes later, the smoke detectors went off. As I yelled for my wife to bring all the kids in the basement upstairs, I ran to the workshop and found 3 large fires burning. One where the Hornet used to be, one on a center bench under a Q500 airplane and one directly under 2 helicopters on a plastic shelf. What confused me was I could understand the fire where the Hornet was, I was very worried and confused to see 2 other fires 2 and 6 feet away from the source fire.

CONTINUED

I ran back upstairs, told my wife to get the kids completely out of the house and got a fire extinguisher. On the way back down I told myself I was only going to give this one serious attempt toput out, I could barely breath and my ego isn't to large where being a dead hero would keep me down there. I hit the 3 fires hard,ran back outside and got some air.Convinced I had the fires out, I went back down, but the smoke was so intense I could get back far enough to the work shop to confirm the fire was out. Dialed 911. Turned out I was right...the fire was out indeed. But what the hell happened???? How did the fire jump from one bench to the other and then another 3 feet to start another fire??? The firefighters were at a loss...

CONTINUED

Finally the small burn marks in the carpet told the tale..The batteries had exploded. As I sat in the shower after the fire dept left, and just tried to mellow out, it hit me. The battery charger I use has jumpers on it to determine how many cells and what charge rate you want. Please make sure your cell jumper is set properly, mine wasn't and I almost burned down my house because of it. I had the jumper set for a three cell pack and was charging a 2 cell pack.This fire happened in 30 minutes tops and anything flamable within 6 feet started on fire.I'm lucky. The Hornet is completely melted, the airplane is repairable and the other 2 helis are just scorched not to mention all the powered for the extinguisher that covers everything. My house stinks. I'm a mental disaster. BUT,my family is safe, thats all that matters anyway.

PICTURES FOLLOW

HELICOPTER.

RESPECT…….

THE PICTURES SAY IT ALL.

BE CORRECT WITH ALL PROCEEDURES

THE LITHIUM BATTERY SYSTEMS GIVES THE BEST “ENERGY DENSITY”

Whatever Next…

Battery Technology is a race at this moment in time – being driven by the severe demands from mobile phones, cameras and portable computers = VOLUME SALES.

There’s lot’s of money to be made.

HOW CLOSE IS ALL THIS!

Laptops with fuel cells approach

Get ready for a laptop that can run for eight hours between recharges.IBM and Sanyo are working on a hybrid power system for portable computers that combines batteries with a methanol fuel cell. But the extra working life comes at a cost because early versions will resemble a bulky docking station that will add to the weight of the device. IBM and Sanyo said the first hybrid power packs should go on sale in 2006 or 2007.Battery betThe two firms said that, once finished, the power pack would work with future and existing IBM Thinkpad notebooks without them needing to be modified. The methanol fuel cell uses methanol and oxygen to generate power and is one of several technologies vying to replace lithium ion batteries that are commonplace today. It is widely accepted that all possible power has been squeezed out of lithium ion batteries and alternatives are needed if laptop life is to extend beyond eight hours between recharges.

Almost

NOW.

THATTHAT’’S ALL FOLKSS ALL FOLKS……..

The Future Looks Bright.

Have a good ChristmasPETER BRUCE. G4WPB.