lithium ferro phosphate (lfp) batteries › wp-content › uploads › 2015 › 12 › lithiu… ·...
TRANSCRIPT
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Lithium Ferro Phosphate (LFP) Batteries The “Safe Lithium”
Simon Chan
Radlink Communications
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Workshop agenda
• Rechargeable batteries
– Why use rechargeable batteries?
– Different battery chemistries
– ‘Horses for courses’
• Lithium rechargeable batteries
– Are they safe?
– Different types of Lithium cells
• Different chemistries
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Workshop agenda
• Quiz time!
• Short break
• Lithium rechargeable batteries (continued)
– Shapes and sizes
– What cell types are best?
• What we do at Radlink
– Case studies
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Workshop agenda
• Lithium rechargeable batteries (continued)
– LFP characteristics – Facts & figures
– Selecting a suitable cell for your project
– Connecting cells together
– Charging and discharging
– Battery management systems
• Virtual factory tour
• Wrap-up!
• Share your questions
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WARNING
• This is a Workshop and not a lecture.
• We will be doing interactive activities together.
• Strap your brain on and let’s go
• Note: stop me at any time if you have questions or comments.
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Your presenter…
• Simon Chan
– Born in Hong Kong
– Lived in Australia since ’74
– Raised & educated in Perth
– I love R&D and creating new products
– Have worked 31 years in many awesome companies
– Now working for Australia’s largest 2-way radio integration company
– Started using Lithium batteries for our own energy storage needs
– Now creating unique Lithium battery solutions for industry
For more info about me, see: https://www.linkedin.com/in/simonskchan
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Rechargeable batteries – Why?
• Why use rechargeable batteries?
– Portable equipment
– People want batteries which are:
• Low cost
• Lightweight
• Have long battery life
– High expectations set by smartphones & smart devices
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Rechargeable batteries – Why?
• Charging rechargeable batteries
– 10+ years ago, it was very challenging
• Poor charger design often saw products fail early
• Eg Cordless telephones, shavers, torches, UPS
– Must include charger on-board
– Design is so much easier now!
• Batteries have also improved a great deal over the last 20 years!
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Rechargeable batteries – Why?
Audience participation
• Where have you seen rechargeable batteries in use?
– Hint: think of all the portable equipment in your life…
• What battery chemistry was used?
• How large were the batteries?
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Rechargeable batteries – Lead Acid
• Different battery chemistries
– Lead Acid
Readily available
Low cost
Tolerant to overcharge
1900’s
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Rechargeable batteries – Lead Acid
• Different battery chemistries
– Lead Acid
Lead is toxic
Heavy (30-50Wh/kg)
Easy to degrade & damage
– Heat
– Excessive discharge
– Electrodes become brittle with age
– Sulphation (not reaching full charge often enough)
Takes a long time to charge – cannot sustain ‘fast charge’
Limited cycle life
Bulge / crack / leak
1900’s
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Rechargeable batteries – NiCd
• Different battery chemistries
– Nickel Cadmium
Readily available
Low cost
Can be rapidly charged (1 to 2 hours to full charge)
High peak discharge current
1950’s
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Rechargeable batteries – NiCd
• Different battery chemistries
– Nickel Cadmium
Cadmium is toxic
Terrible self-discharge characteristics
Charge – discharge memory effect
Difficult to charge – multi-stage charging cycle
1950’s
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Rechargeable batteries – NiMH
• Different battery chemistries
– Nickel Metal Hydride
Readily available
Low cost
Good energy to weight ratio
Moderate peak discharge current
No charge – discharge memory effect
Low toxicity
1990’s
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Rechargeable batteries – NiMH
• Different battery chemistries
– Nickel Metal Hydride
Terrible self-discharge characteristics
Limited cycle life
Double charge time of NiCd
1990’s
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Useful
Summary
Slide
With thanks to Battery University http://batteryuniversity.com/learn/article/secondary_batteries
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Rechargeable batteries in general
• Different battery chemistries
– A case of ‘Horses for courses’
– For a long time, not a lot of choice
• Lead acid for heavy duty products
• NiMH for portable equipment
– Has been the status quo for a long time
– Early generation ‘Brick’ mobiles & laptops
• Not strictly ‘portable’ – more like ‘luggable’
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Rechargeable batteries in general
• Biggest challenge: not enough stored energy when you need it most
– Eg UPS fails to deliver power when needed!
• In the end, designers created over-engineered solutions to overcome inherent weaknesses
– Think about lead acid systems that only reach 20% DoD (Depth of Discharge)
– Think about how your older portable electronics used to leave you in the lurch?
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Rechargeable batteries in general
But… science and technology have been improving by leaps and bounds!
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Lithium batteries – Safe?
• Are Lithium batteries safe?
– First question everyone asks!
– Yes and no
Apple & Sony – 2008 Mac laptop fire lawsuit
Morphing Li-Po battery
Flaming Hoverboards
Exploding Tesla Model S
1990’s
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Lithium batteries – Safe?
• Under what conditions are Lithium batteries considered unsafe?
– Early generations of Lithium ion batteries were really difficult to charge
• Lots of heat being generated leading to fires
– When lots of discharge current is flowing…
• Heat leads to fires
– Shock / impact / compression / piercing
• Short circuits lead to high currents which lead to fires
1990’s
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Lithium batteries – Safe?
• High energy and power density means one small fault leads to a big mess
– Lead acid: 30-50Wh/kg
– Lithium Cobalt Oxide: 150-250Wh/kg
• Earlier lithium chemistries had thermal runaway problems…
1990’s
5x - 8x More energy per kg
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Lithium batteries – Safe? 1990’s
https://www.youtube.com/watch?v=UaCMevegaiA
T = 0:00 T = 0:12 T = 0:18 T = 0:27
T = 0:36 T = 0:44 T = 1:06 T = 2:16
One Lithium cell experiences thermal runaway, which then ruptures… This then set off other cells into thermal runaway state. Kiss goodbye to laptop…
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Lithium batteries – Safe?
Bottom line
Stick to design guidelines = Safe!
1990’s
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Lithium chemistries – LiCoO2
• Lithium Cobalt Oxide – LiCoO2
– Nominal voltage: 3.6V
– Capacity: Wh/kg
– CC/CV charging
– Eg 18650 cell: 3.6V 2400mAh • Charge up to (2.4A) up to 4.2V
• Discharge up to (2.4A) – no lower than 2.5V
– 500-1000 cycles
– Good for smartphones, tablets, laptops, cameras
– Beware of thermal runaway at 150°C due to overcurrent
– Toxicity issues with Cobalt
1C
150-250
– Beware of thermal runaway at 150°C due to overcurrent – Toxicity issues with Cobalt
1C
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Lithium chemistries – LiMn2O
4
• Lithium Manganese Oxide – LiMn2O4
– Nominal voltage: 3.7V
– Capacity: 100-150 Wh/kg
– CC/CV charging
• Charge up to 3C up to 4.2V
• Discharge up to 10C – no lower than 2.5V
– 300-700 cycles
– Inside power tools, medical devices, electric cars
– Beware of thermal runaway at 250°C
100-150
3C
10C
– Beware of thermal runway at 250°C
– 300-700 cycles
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Lithium chemistries – LiNiMnCoO2
• Lithium Nickel Manganese Cobalt Oxide – LiNiMnCoO2 (NMC)
– Nominal voltage: 3.7V
– Capacity: 150-250 Wh/kg
– CC/CV charging
• Charge up to 1C up to 4.2V
• Discharge up to 2C – no lower than 2.5V
– 1000-2000 cycles
– Inside E-bikes, electric cars
– Beware of thermal runaway at 210°C
150-250
– Beware of thermal runway at 210°C
– 1000-2000 cycles
1C
2C
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Lithium chemistries – LiFePO4
• Lithium Iron Phosphate – LiFePO4 (aka Lithium Ferro Phosphate or LFP)
– Nominal voltage: 3.2V • 4 x 3.2V = 12.8V – simple retrofitting of 12V lead acid systems
• 8 x 3.2V = 25.6V (think 24V) and 16 x 3.2V = 51.2V (think 48V)
– Capacity: 90-120 Wh/kg (1/3rd weight of lead acid)
– CC/CV charging • Charge up to 1C up to 3.65V (specially designed cells for rapid charging)
• Discharge up to 5C – no lower than 2.5V
90-120
2C
5C
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Lithium chemistries – LiFePO4
• Lithium Iron Phosphate – LiFePO4 (continued)
– 1000-2000 cycles (dependent on DoD = Depth of discharge)
– Good for high load currents and endurance
– Low risk of thermal runaway (trigger at >270°C)
– Can tolerate over-charging without damage
– The ‘Safe Lithium battery’
– Good for Australian conditions & my favourite battery chemistry!
– 1000-6000
high load currents endurance
– Low risk of thermal runaway (trigger at >270°C)
over-charging without damage
‘Safe Lithium battery’
– Good for Australian conditions
With thanks to Battery University
http://batteryuniversity.com/learn/article/types_of_lithium_ion
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Useful
Summary
Slide
With thanks to Battery University http://batteryuniversity.com/learn/article/types_of_lithium_ion
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Useful summary slide
12V 22Ah = 260Wh
Lithium Cobalt Oxide Weight: 1.65kg Volume: 0.86L
Lithium Ferro Phosphate Weight: 2.63kg Volume: 1.48L
Lead Acid Weight: 7.01kg Volume: 2.32L
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Useful
Summary
Slide
With thanks to Battery University http://batteryuniversity.com/learn/article/secondary_batteries
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Quiz time!
Let’s review what we have
learnt so far today
5 minutes
Tick… Tock…
Tick… Tock...
5 questions – 5 minutes
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Quiz time!
Question 1
Before Lithium batteries came along, what rechargeable battery chemistries were available to a design engineer or product developer?
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Quiz time!
Question 2
List 2 things why Lead Acid batteries are still a viable option for some energy storage systems
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Quiz time!
Question 3
Name at least one reason NiMH batteries have fallen out of favour for use in portable equipment?
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Quiz time!
Question 4
Of the Lithium battery chemistries discussed so far, which one has the highest energy density?
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Quiz time!
Question 5
What are some of the key benefits of using LFP batteries?
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Quiz time!
Please feel free to discuss
among yourselves then share
your answers with everyone
5 minutes
Tick… Tock…
Tick… Tock...
5 questions – 5 minutes
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Quiz time!
Question 1
Before Lithium batteries came along, what rechargeable battery chemistries were available to a design engineer or product developer?
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Quiz time!
Answer
•Lead Acid
•Nickel Cadmium
•Nickel Metal Hydride
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Quiz time!
Question 2
List 2 things why Lead Acid batteries are still a viable option for some energy storage systems
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Quiz time!
Answer
Lead acid batteries are:
Readily available
Low cost
Tolerant to overcharge
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Quiz time!
Question 3
Name at least one reason NiMH batteries have fallen out of favour for use in portable equipment?
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Quiz time!
Answer
NiMH batteries have:
Terrible self-discharge characteristics
Limited cycle life
Slow charge time
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Quiz time!
Question 4
Of the Lithium battery chemistries discussed so far, which one has the highest energy density?
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Quiz time!
Answer
Both LiCoO2 (LCO)and LiNiMnCoO2
(NMC) are able to achieve an Energy Density of 150-250Wh/kg
12V 22Ah = 260Wh
Lithium Cobalt Oxide Weight: 1.65kg Volume: 0.86L (This could be even smaller and lighter)
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Quiz time!
Question 5
What are some of the key benefits of using LFP batteries?
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Quiz time!
Answer – LFPs charge at up to 2C and discharge at up to 5C
– 1000-6000 cycles (dependent on DoD = Depth of discharge)
– Good for high load currents and endurance
– Low risk of thermal runaway (trigger at >270°C)
– Can tolerate some over-charging without damage
– Good for Australian conditions
– 1000-6000
high load currents endurance
– Low risk of thermal runaway (trigger at >270°C)
over-charging without damage
– Good for Australian conditions – zero maintenance and high ambient temperatures
2C 5C
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Lithium battery shapes and sizes
• 18650
– 18mm diameter
– 65mm long
• 26650
– 26mm diameter
– 65mm long
• 32650
– 32mm diameter
– 65mm long
Lithium Cobalt Oxide 3.6V 2.2Ah
LFP 3.2V 3.3Ah
LiNMC 3.7V 6.0Ah
Note: Photos not to scale!
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Lithium battery shapes and sizes
• Prismatic cells
• Pouch cells
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Lithium battery shapes and sizes
• What cell type works best? Prismatic cells: – Encased in aluminium or steel for stability
– Jelly-rolled or stacked
– Cell is space-efficient
– Costlier to manufacture
– Modern prismatic cells are used in the electric powertrain and energy storage systems
With thanks to Battery University http://batteryuniversity.com/learn/article/types_of_battery_cells
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Lithium battery shapes and sizes
• What cell type works best? Pouch cells: – Latest technology
– Lightweight
– Cost-effective
– Exposure to humidity shortens life
– Exposure to high temperature shortens life
– Swelling of 8–10 percent over 500 cycles must be considered in mechanical design
– The pouch cell is growing in popularity and serves similar applications to the prismatic cell.
With thanks to Battery University http://batteryuniversity.com/learn/article/types_of_battery_cells
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Lithium battery shapes and sizes
• What cell type works best? Cylindrical cells: – High specific energy
– Good mechanical stability
– Easy to automate manufacturing.
– Cycles well
– Offers long calendar life
– Low cost
– Less than ideal packaging density
– The cylindrical cell is commonly used for portable applications
With thanks to Battery University http://batteryuniversity.com/learn/article/types_of_battery_cells
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Time for a stretch! Please be back in 10 mins
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It is a case of ‘Horses for courses’
• Depending on your specific requirements, you need to weigh up the Pros and Cons before selecting a particular Lithium battery form factor
OR
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For us at Radlink…
• While we offer ‘off-the-shelf’ LFP products, we are VERY selective about what we sell to customers: – Mining
– Telecommunications
– Utilities
– Agriculture
– Healthcare
– Transport
– Etc
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For us at Radlink…
• ‘Mission critical’ systems
• Must ask: “Is it fit for purpose?”
• We are not ‘white box shifters’…!
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For us at Radlink…
• So we design our own energy storage solutions using 26650 Cylindrical form factor: – Temperature tolerance (must work whether hot or cold)
– Mechanical stability (must work on mobile equipment)
– Lower cost (price sensitive market)
– Long life (lower $/kWh/cycle)
– Simpler design (time to market)
– Re-usable design (time to market)
– Low maintenance (no warranty claims due to poor design)
– Proprietary design optimises packaging density (maximise space usage of cabinets)
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Case study: AAA
• Replace Lead Acid – 23kg
– Lightweight – 7.5kg
• Improved longevity
– 2000+ cycles
• Rapid fitment
– IP67 connector
• High capacity
– 12.8V 50Ah = 640Wh
• Vermin proof
– Aluminium case with handle
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Case study: Water Corporation
• Aging Lead Acid batteries
– Due for replacement
• Trial installation
• 3 x 12.8V 50Ah in parallel
• Monitored system
• Rapid fitment
• Lightweight
• Zero maintenance
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Case study: 19-inch rack mounted
• High power output
• High density storage
• Modular
• Scalable
• Lightweight
• Hot swappable
• Smart BMS
• Standard form factor
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Lithium Ferro Phosphate
Facts and Figures
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LFP cell technical data
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LFP cell technical data
Single cell charge–discharge characteristics taken from manufacturer’s data sheet
CC = Constant Current charge @ 1.6A (0.5C)
CV = Constant Voltage charge
@ 3.65V (32mA = 0.01C)
©2016 Radlink Communications / genZ Energy
CC = Constant Current discharge
@ 1.6A (0.5C)
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The following information
is sourced from our supplier’s
latest QA/QC data and reports
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LFP discharge characteristics
Data sourced from supplier’s latest QA/QC reports
©2016 Radlink Communications / genZ Energy
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LFP discharge characteristics
Data sourced from supplier’s latest QA/QC reports
Vo
lts
/ A
mp
s
Discharge seconds
Watt-h
ou
rs 2RU 3kWh 51.2V battery discharged at 57.6A (1C)
©2016 Radlink Communications / genZ Energy
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LFP discharge characteristics
Data sourced from supplier’s latest QA/QC reports
©2016 Radlink Communications / genZ Energy
Note: Charge/discharge at 1C = 3.2A
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LFP discharge characteristics
Data sourced from supplier’s latest QA/QC reports
©2016 Radlink Communications / genZ Energy
Note: Charge/discharge at 0.5C = 1.6A
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LFP discharge characteristics
Data sourced from supplier’s latest QA/QC reports
©2016 Radlink Communications / genZ Energy
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LFP discharge characteristics
This is the question we get asked the most!
Data sourced from supplier’s latest QA/QC reports
26650-3200-3.2V Cycle life at different depths of discharge at 1C rate
Re
mai
nin
g ca
pac
ity
(%)
1 Year 5.5 Years
10 Years
Charge/discharge cycle number
13.5 Years
14 Years
19 Years
©2016 Radlink Communications / genZ Energy
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Selecting the right cell for the job
Moving from data sheets
to an actual design example
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Selecting the right cell for the job
• How will you connect the cells together?
– What is your nominal operating voltage?
• Divide that by 3.2V to get number of cells in SERIES
– What is your required Amp-hour capacity?
• Divide that by cell capacity to give cells in PARALLEL
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Selecting the right cell for the job
• Example: we need 36V 90Ah for a scooter
• Nominal operating voltage: 36V
– Divide 36V by 3.2V = 11.25 cells
– Can circuit operate at higher or lower voltage?
– Higher => 12 cells in series
– Lower => 11 cells in series
– Since it is a motor, go higher voltage = 12 cells
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Selecting the right cell for the job
• Example: we need 36V 90Ah for a scooter
• Require 90Ah
– 18650 cells come in 1400, 1500 and 1600mAh
– 26650 cells come in 3000, 3200 and 3300mAh
– 32650 cells come in 5000mAh only (at this time)
– Is there a size restriction?
• No, then select largest cell available = 32650
– Larger size = higher charging and discharging rate
– 90Ah divided by 5Ah = 18 cells in parallel
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Selecting the right cell for the job
• Example: we need 36V 90Ah for a scooter
• 12 cells in series = 38.4V nominal
– 12 x 2.5V = 30V minimum (100% DoD)
– 12 x 3.65V = 43.8V maximum (just charged)
• 18 cells in parallel = 90Ah
• “12S18P 32650 3.2V 5000mAh” battery pack
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Selecting the right cell for the job
• Example: we need 36V 90Ah for a scooter
Single cell charge–discharge characteristics
©2016 Radlink Communications / genZ Energy
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Selecting the right cell for the job
©2016 Radlink Communications / genZ Energy ©2016 Radlink Communications / genZ Energy
©2016 Radlink Communications / genZ Energy
©2016 Radlink Communications / genZ Energy
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Selecting the right cell for the job
• Example: we need 36V 90Ah for a scooter
• What charging current?
– 32650 cells can be charged at up to 2C
– Recommended charge rate C/3 for just over 3 hours
– 90Ah => CC Charge at 30A for 3.5 hours
• Or slower at 10A for 10 hours
– CC/CV => Maximum CV voltage = 43.8V
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Selecting the right cell for the job
• Example: we need 36V 90Ah for a scooter
• What working current?
– 32650 cells can be discharged at up to 5C peak
– 90Ah => 450A starting current
– Up to 1C operating current => up to 90A for one hour
• Make sure connectors are ‘fit for purpose’!!
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Selecting the right cell for the job
• Remember I2R losses generate a lot of heat!
– Interconnections between cells
– Cables to the load
– Connector pin sizes
• Make sure there is enough space for heat to escape…
©2016 Radlink Communications / genZ Energy
©2016 Radlink Communications / genZ Energy
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Battery Management System (BMS)
• Insurance policy… protects against misuse and abuse:
– Over-voltage (ie over-charging)
– Under-voltage (ie over-discharging)
– Over-current (ie excessive continuous current)
– Short-circuit (ie fault generated over-current)
– Over-temperature (eg incorrect usage)
• Monitors each parallel bank of cells continuously for fault conditions
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Virtual factory tour
Please come to the Radlink display table to go for a virtual tour
of an LFP factory
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Wrap-up…
• Although Lithium batteries have been around for nearly 20 years, the rate of adoption only took off after smartphones became a commodity
• Proliferation of EV and Solar PV systems are driving new requirements and opportunities
• The demand for lightweight, long life and low cost energy storage solutions is going ‘gangbusters’
• I personally believe smart, networked and managed LFP based battery solutions will have a bright future
• Coupled with correct energy harvesting, conversion and distribution systems, energy storage will change the world
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Q & A
It’s your turn again!