ioxus titan technologycii-resource.com/cet/aabe-03-17/presentations/ecap/rudisuela_ken.pdf• large...
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AABC 2017 Mainz Germany Ken Rudisuela CTO
Ioxus Titan Technology
1
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Ioxus Company Overview
Credible and Industry Leading Investor Base
2
Industry Awards
2
Founded:
• 2007
Products:
• Large cylindrical and pouch ultracapacitors
(EDLC)
• Light-weight and heavy-duty modules
Technology:
• ACN and PC
• High temperature and high voltage
Markets:
• Transportation, Wind, Industrial and Medical
• Worldwide sales and marketing
Manufacturing:
• Engineered and manufactured in America and
Japan
• ISO-9001:2008 certified working on TS-16949
Location:
• Oneonta NY
• Kusatsu Japan
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Ioxus Ultracapacitor Modules
3
• Ioxus designs and manufactures a number of different ultracapacitor modules using both the THiNCAP (pouch) and iCAP (cylindrical) cells.
• Ioxus standard designs are the most rugged and longest lasting in the industry.
• Building block designs, such as the X-Series allows for a cost effective “right sizing”
• Standard 48V modules have the highest rate capability and lowest temperature rise of any commercial product
• Inventive designs such as the new uSTART and liquid cooled modules are in a class all of their own.
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Ioxus THiNMOD Applications
Dynamic Voltage Recovery 4MW MRI Machines Automated Guided Vehicles
4
4
Stacker Crane
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Ioxus iMOD Products Are Field Proven
Grid Connected 40MW Generator Connected 1 MW Harbor Crane
5
5
City Bus Engine Start 32V
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Ioxus Titan HT ™ Cell Technology
6
Ioxus iCAP® with Titan HT TM technology is a
breakthrough in high temperature technology • Unprecedented electrochemical stability • Highest temperature durability • Highest rate capability • Highest round trip efficiency • Lowest leakage current • Lowest gas generation • Longest life, doubled durability spec • Patented
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Titan Objective
7
Increase the operating temperature range of EDLC’s for under-hood automotive applications and for longer life at any temperature: • In theory no faradaic reactions but in practice there are
Temperature: 𝐿 𝑇𝐼𝑛𝑡 = 𝐿0 𝑒𝐸𝑎
𝑘
1
𝑇𝐼𝑛𝑡−
1
𝑇0 ; 𝑇𝐼𝑛𝑡 = 𝑅𝑡ℎ𝑒𝑟𝑚 [𝐼2𝑅𝐷𝐶] 𝐹𝑑𝑢𝑡𝑦
Voltage: 𝐿 𝑉 = 𝐿0 𝑒−α 𝑉
𝑉0−1
Overall: L V, T 𝐹𝑙𝑜𝑎𝑡 = 𝐿0 𝑒−α
𝑉
𝑉0−1
𝑒 𝐸𝑎
𝑘
1
𝑇𝐼𝑛𝑡−
1
𝑇0
Goal: Increase the activation energy
• More thermal dynamically stable product • Higher temperature capability • Higher voltage capability • Longer life
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Approach
8
Keep specific capacitance constant
Increase electrolyte stability
Look at a number of:
- New salts
- New solvents
- Ionic liquids
- Additives
- Coated electrodes
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Additives
9
Stabilizing additives: Reduces capacitance loss, reduces ESR gain and reduces gas generation • High electrochemical stability • Affinity to the carbon surface • Polar characteristic • High dielectric constant • Water scavenger • Tertiary amine scavenging • Low cost Result: Absorbed mono-layer on the carbon, producing a protective surface coating, reducing contact between carbon and electrolyte slowing down electrolyte breakdown
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Cyclic Voltammetry at 65ºC
10
-40.0
-20.0
0.0
20.0
40.0
60.0
80.0
0.0 1.0 2.0 3.0 4.0Ewe (V)
-40.0
-20.0
0.0
20.0
40.0
60.0
80.0
0.0 1.0 2.0 3.0 4.0Ewe (V)
I(A
)
I(A
)
3.5V
3.7V
Titan HT
Gen 2
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0
200
400
600
800
1000
1200
1400
0.01 0.10 1.00 10.00
C" (
F)
Log F (Hz)
Gen2 - Initials
Gen2 - 15,000 Cycles
0
200
400
600
800
1,000
1,200
1,400
0.01 0.10 1.00 10.00
C" (
F)
Log F (Hz)
HT - Initials
HT - 15,000 Cycles
EIS Cycling at 25 °C
0.0000
0.0002
0.0004
0.0006
0.0008
0.0010
0.0000 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006
-Im
(Z
)
Re (z)
Gen2 - Initials
Gen2 - 15,000 Cycles
HT - Initials
HT - 15,000 Cycles
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EIS of HT Cycled at RT/65
0
0.005
0.01
0.015
0.02
0 0.01 0.02 0.03 0.04
-Im
(Z
)
Initials
10000 Cycles
20000 Cycles
30000 Cycles
40000 Cycles
RT °C 65 °C
Re (Z) Re (Z)
0.000
0.005
0.010
0.015
0.020
0.00 0.01 0.02 0.03 0.04
-Im
(Z
)
Initials
10000 Cycles
20000 Cycles
Almost no change under high rate high temperature cycling
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Endurance EIS 3000F after 2000hr
13
0.000000
0.000100
0.000200
0.000300
0.000400
0.000500
0.000600
0.000700
0.000800
0.000000 0.000200 0.000400 0.000600 0.000800 0.001000
=-I
m(Z
)/O
hm
Re(Z)/Ohm
HT Endurance
HT @ 0hrs
HT @ 65C 2000hr
HT @ 85C 2000hr
Gen2 @ 65C 2000hr
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Endurance Capacitance and ESR
14
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High Rate Cycling at RT
15
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High Rate Cycling at 65ºC
16
0
500
1000
1500
2000
2500
3000
3500
0 100000 200000 300000 400000
Ca
pa
cita
nce
(F)
Cycles
Capacitance
Titan HT
0
0.1
0.2
0.3
0.4
0.5
0.6
0 100000 200000 300000 400000
ES
R (
mO
hm
s)
Cycles
ESR
Titan HT
3000F cells cycled at 120A continuous IEC measurement
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Gas Generation
17
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Leakage Current at Temperature
18
1
10
100
1 10 100
Leakag
e C
urr
en
t (m
A)
Time (h)
3000 F Titan HT Leakage Current vs. Temperature at 2.7 V
2.7 V 25°C AVERAGE
2.7 V 45°C AVERAGE
2.7 V 60°C AVERAGE
2.7 V 75°C AVERAGE
2.7 V 85°C AVERAGE
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Leakage Current after Cycling
19
y = -0.0043x + 2.7146 R² = 0.9963
2.4
2.45
2.5
2.55
2.6
2.65
2.7
2.75
0 20 40 60 80 100
Vo
ltag
e (
V)
sqrt(t)
200,000 Cycles
Fresh Cell
Leakage current is pure diffusion controlled after cycling; charge re-distribution between electrode and
electrolyte and inter-electrode
Governing Equation
V ∝ sqrt(t)
Fresh cells show mostly Faradaic reaction controlled
Cycled cells exhibit excellent agreement with pure
diffusion controlled self-discharge
𝑉𝑡 = 𝑉𝑖 − 2𝑧𝐹𝐴𝐷1/2π1/2𝑐0
𝐶𝑡1/2
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Influence of Charge-discharge Rate
iCAP HT 3000F – Discharge Energy vs. Discharge Current iCAP HT 3000F - Temperature Increase in Continuous Cycle
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Ioxus uSTART™: Benefits for Vehicle
• Improved Performance: uSTART™ provides greater starting power than battery only solutions and cranks engines faster
• Improved Reliability: uSTART™ reduces breakdowns by eliminating conditions where the battery is too discharged to start a vehicle
• Improved Efficiency: uSTART™ reduces battery discharge, so alternator load and emissions are lower
• Lower Costs: uSTART™ reduces battery cycling, so battery life is extended
uSTART™ Stabilizes the Vehicle Bus Voltage
21
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Ioxus uSTART™
• Lead-acid batteries have a limited charge/discharge cycle life and will have the least amount of degradation if they are kept at a high state of charge.
• By managing the vehicles bus voltage, uSTART handles the high current loads and reduces the amount of discharge on the batteries.
• uSTART maintains a higher system voltage reducing stress on the battery and increasing its life.
• The engine starts faster with uSTART reducing stress on the starter therefore increasing its life.
• The more times an engine is stopped and started, the greater the benefit uSTART provides, e.g. engine auto-stop or delivery vehicle applications
uSTART™ Stabilizes the Vehicle Bus Voltage
22
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Ioxus uSTART™: Assembly
23
uSTART controls;
1. Cell balancing board
2. Power board; DC/DC converter, transfer MOFETS
3. Control board; micro processor
4. Function board
1
2 3
4
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Easy Installation
24
Wiring before uSTART installed Wiring after uSTART installed
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Engine Cranking Current 12V System
25
0
200
400
600
800
1000
1200
1400
1600
1800
2000
-40 -30 -20 -10 0 10 20 30 40
CA R
equi
red
Temperature (°C)
Engine Cranking Amps vs. Oil Temperature*
Long Haul 16L
Heavy Duty 12L
Medium Duty 9L
Delivery 5.9L
*Assumes Enginesusing SAE-10 grade
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Power Output vs Ultracapacitor Voltage
26
Output terminal voltage and delivered power is a function of the ultracapacitor voltage
Multiple engine starts with 1100 CCA uSTART ultracapacitors at different starting voltages
7
8
9
10
11
12
13
14
Current (A)
Ou
tpu
t V
olt
ag
e (
V)
Ultracapacitor (V)
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uSTART Field Operation Class 6 Delivery Truck
27
-2000
-1500
-1000
-500
0
500
uSTART™ Amp Batt Amp Vehicle Amp
1) The current that the systems sees is strictly determined by the internal combustion drive system but the uSTART absorbs the majority of the demand reducing stress on the battery significantly
uSTART handles the majority of the starting current reducing drastically the current on the battery, maximizing its’ life
Cu
rre
nt
(Am
p)
1
Typical Engine Cranking Load Sharing between Battery and uSTART
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uSTART Field Operation Class 6 Delivery Truck
28
7
8
9
10
11
12
13
14
15
0 0.5 1 1.5 2
Vo
ltag
e (
V)
Time (s)
2 Batteries uSTART_V5
2
1
3
1) Minimum voltage during cranking is increased by approximately 3V
2) Average cranking voltage is increased by 1.8V
3) Cranking time is reduced by 540 mille-sec
• uSTART maintains a higher system voltage reducing stress on the battery and increasing its life • The engine starts faster with uSTART reducing stress on the starter therefore increasing its life
Typical Engine Cranking Voltage on a 6L diesel with and without uSTART
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uSTART Field Operation Class 6 Delivery Truck
29
0
2
4
6
8
10
12
14
16
18
20
7
7.2
7.4
7.6
7.8 8
8.2
8.4
8.6
8.8 9
9.2
9.4
9.6
9.8 10
10.2
10.4
10.6
10.8 11
Sta
rts
Minimum Voltage (V)
2 Batteries uSTART_V5
1 1) During each day of operation the
delivery vehicle stops over 125 times, the average minimum voltage is nearly 2V higher with uSTART compared to without dramatically increasing the battery life
2) Telematics monitoring of nearly 200 delivery trucks, over the last 16 months, shows an average minimum +2V and start time reduction of > 700 m-sec
Typical Daily Minimum Bus Voltage per Start
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Operation
30
Maintenance Mode (Safe Mode)
• No energy at uSTART terminals
• Safe to install or remove from vehicle
• Press and hold button for 10 seconds to enter Run Mode
Run Mode
• uSTART is on and supporting the vehicle battery
• Press and hold button for 10 seconds to switch to Maintenance Mode, or 3 seconds to initiate Jump Start
Jump Start Mode
• uSTART will charge up from the battery for a jump start and the green and yellow lights will flash while charging
• The yellow light will stay solid when the uSTART is fully charged
• Start the vehicle
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uSTART™ Safety Features
• Maintenance Mode
• No power available at terminals
• Protection against reverse bias to -30 V
• Protection against input voltage surge up to +80 V
• Run Mode
• Under and over voltage lockouts
• Protection against input voltage surge up to +80 V
• Short circuit protection
• Thermal protection
uSTART™ Electronics Safety Features
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Ioxus uSTART™ Next Products
• 1100 CCA 12V uSTART; intended for trucks Class 3 to Class 6
• 2000 CCA 12V uSTART; intended for trucks Class 7 to Class 8
• 1000 CCA 24V uSTART; intended for Europe and Japan
• Remote start capability will be available on all uSTART products in Feb 2017
• Certified to standards: UL810A, SAE J1455 and J930
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Ioxus Japan Co. LTD 1381-1 Okamotocho
Kusatsu-city, Shiga Pref 525-0044, Japan [email protected]
TEL : +81-77-569-5106 FAX: +81-77-569-5168
Corporate Headquarters 18 Stadium Circle
Oneonta, NY 13820, USA Toll Free: +1-877-751-4222
[email protected] TEL: 607-441-3500 FAX: 607-433-9014
33
THANK YOU !