ultracapacitors microelectronics high-voltage capacitors tecate training by: maxwell technologies -...

Ultracapacitors Microelectronics High-Voltage Capacitors

Tecate Training

By:

Maxwell Technologies - San Diego


About Maxwell

Capacitor Manufacturer since 1965

www.maxwell.com

Manufacturing facilities:

US, Europe, AsiaMaxwell is a leading developer and manufacturer of innovative,

cost-effective energy storageand power delivery solutions.

Certifications:ISO 9001:2000ISO/TS 16949

ISO 9002


Table of Content

1. When can I use an Ultracapacitor?

2. What is an Ultracapacitor?

3. Ultracapacitor Market

4. Ultracapacitor Applications

5. Sizing your System

6. Sizing Examples

7. Guidelines to Designing an Ultracapacitor System

8. Summary


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


Power vs Energy

What is the difference between Power and Energy?


Application Model


Peak Power Shaving• Ultracapacitors provide peak power ...

AvailablePower

Required PowerUltracapacitor Peak Power

Peak Power Shaving


Back-Up Power Support

• Ultracapacitors provide peak power…

...and back-up power.

Required Power

Available Power Ultracapacitor Backup Power

Back-up Power


What is an Ultracapacitor?


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


What is an Ultracapacitor?

C = r A/dMinimize (d)Maximize (A)

E = 1/2 CV2

Dielectric

Film foil Electrode

Electrolyte

ECDL

Separator

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


Technology Comparison

AvailablePerformance

Lead AcidBattery

Ultracapacitor ConventionalCapacitor

Charge Time 1 to 5 hrs 0.3 to 30 s 10-3 to 10-6 s

Discharge Time 0.3 to 3 hrs 0.3 to 30 s 10-3 to 10-6 sEnergy (Wh/kg) 10 to 100 1 to 10 < 0.1Cycle Life 1,000 >500,000 >500,000Specific Power (W/kg) <1000 <10,000 <100,000Charge/discharge efficiency

0.7 to 0.85 0.85 to 0.98 >0.95


Technology Comparison (page 2)

0,01

0,1

1

10

100

1000

10 100 1000 10000

Power Density/[W/kg]

En

erg

y D

en

sit

y/[

Wh

/kg

]

Double-Layer Capacitors

10h 1h0,1h

36sec

3,6sec

0,36sec

36msec

Lead Acid Battery

Ni/Cd

Li-Battery

Al-Elco

U/C

Fuel Cells


0

1

2

3

4

Efficiency

Self Discharge

Availability

Cycle Stability

Energy Density

Power Density

Energy Cost

Power Cost

System Cost

Safety

Recycling

Environment

Temperature Range

Charge AcceptanceUltracaps

Pb-AGM

NiMH

Li Ion

Ultracap vs Battery Technologies


Ultracapacitor Market


Ultracapacitor Market

Ultracapacitor World Market

Consumer Products

Digital Camera

PDA

Toys

Memory back-up

UPS

Windmill

Industrial

Stationary Fuel Cell

Automation/Robotics

Transportation

Hybrid Bus/Truck

Engine starting

Light Hybrid

Local Power

Rail


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


Ultracapacitor Applications


Applications

Automotive 14/42 V systems HEV Electrical Subsystems

Traction Regen braking Voltage stabilization Diesel engine starting

Industry Power quality Pitch systems Actuators

Consumer Electronics AMR PDAs Digital cameras 2-Way pagers Scanners Toys

Small Cells

Large Cells


Electric Rail PackBraking Energy Recapture Diesel engine starting

Today’s Markets

Wind power plant pitch systemsBurst power

Small cell applicationsDigital cameras, AMR, Actuators, Memory boards

TRACTION INDUSTRY CONSUMER


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

SITRAS® SES - Solution

Advantage: Cost savings through reduced primary energy consumption

Application: Time shifted delivery of the stored braking energy for vehicle re-acceleration

Solutions: Possible with either stationary or on-vehicle energy storage system


SITRAS® SES - Benefits

Saved energy

Reduction of the power need by 50 kW

Energy saving of 340.000 kWh per year and per installation

thermal limit68 kWh/h

04.08.01 07.08.01 10.08.01 13.08.01

50

40

30

20

10

0

kWh/h Saved energy

Reduction of the power need by 50 kW

Energy saving of 340.000 kWh per year and per installation

thermal limit68 kWh/h

04.08.01 07.08.01 10.08.01 13.08.01

50

40

30

20

10

0

kWh/h

04.08.01 07.08.01 10.08.01 13.08.01

50

40

30

20

10

0

kWh/h


MITRAC of Bombardier Transport

MITRAC energy saver


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


Wind Turbine Pitch Systems

Modern wind turbines consist of three- bladed 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


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

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

Switch box including 2600F ultracapacitors


Fuel Cell Powered Fork Lift

• Fork lift equipped with a fuel cell

• Cell system and an ultracapacitor module

• BOOSTCAP module:

48 BCAP0010 112 V, 55 F 40 kW peak power


Sizing Your System


Data sheet


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 loadId = discharge current Vf = voltage 5 seconds after removal of load.td = time to discharge from initial voltage to minimum voltage


Basic Equations

Definition of Capacitance: C = Q/V (1)

Charge = current * time: Q = I*t C = I*t/V (1a)

Solving for voltage: V = I*t/C (2)

Dynamic Voltage: dV/dt = I/C (3)

Stored Energy E = ½ C*V2 (4)

At initial voltage Vo, Eo = ½ C*Vo2

At final voltage Vf, Ef = ½ C*Vf2

Delivered energy = Eo – Ef

ΔE = ½ C*(Vo2 – Vf

2) (5)


Voltage & Current vs. TimeC = 15 farad; Resr = 100 milliohm

Vo = 48V; I = 30A

-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Time (sec)

20

25

30

35

40

45

50

Vo

ltag

e (

V)

0

5

10

15

20

25

30

35

40

45

50

Cu

rre

nt

(A)

-

Resr

+

+C-

i

Voltage

Current

Vo

Vmin

Vf

V = Q/CdVesr = I*ResrdV/dt = I/C ; dV = I*dt/CdVtotal = I*dt/C + I*ResrΔE = ½ C*(Vo2 – Vf

2)


Basic Model

• Series/Parallel configurations• Changes capacitor size; profiles are the same• Series configurations

• Capacitance decreases, Series Resistance increases• Cs=Ccell/(#of cells in series) Rs=Rcell*(# of cells in series)

• Parallel configurations• Capacitance increases, Series Resistance decreases• CP=Ccell*(# of cells in parallel) RP=Rcell/(# 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.


Applications with a singleenergy 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)


Applications with twoenergy storage components

• Power vs. Energy design tradewhen 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


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.


Capacitance and ESR vs Frequency

ESR vs . Frequency

0,00E+00

1,00E-04

2,00E-04

3,00E-04

4,00E-04

5,00E-04

6,00E-04

7,00E-04

1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03

Frequency [Hz]E

SR

[m

Oh

m]

Capacitance vs. Frequency

0,00E+00

5,00E+02

1,00E+03

1,50E+03

2,00E+03

2,50E+03

3,00E+03

3,50E+03

1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03

Frequency [Hz]

Cap

acit

ance

[F

]


C and ESR Temperature Dependency

0,4

0,5

0,6

0,7

0,8

0,9

1

1,1

1,2

-60 -40 -20 0 20 40 60 80 100Temperature [°C]

ES

R [

mO

hm

]

1000

1200

1400

1600

1800

2000

Cap

acit

ance

[F

]

ESR BCAP0008 (DC)

Capacitance BCAP0008


BCAP Self Discharge

Self Discharge vs Temperature

30,0

40,0

50,0

60,0

70,0

80,0

90,0

100,0

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Time [days]

% U

(t =

0)

- 35 °C

+ 5 °C

+ 25 °C

+ 65 °C


BCAP Cycling Capacity

90 A CC, 1.15-2.3 V, 25 s, RT

50.0

60.0

70.0

80.0

90.0

100.0

110.0

0 20000 40000 60000 80000 100000

Cycle Number

Ch

ang

e in

Cap

acit

ance

[%

]

0.0E+00

2.0E-04

4.0E-04

6.0E-04

8.0E-04

1.0E-03

1.2E-03

1.4E-03

1.6E-03

1.8E-03

2.0E-03

ES

R [

Oh

m]

ESR

Capacitance


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


BCAP DC Life

Capacitance and ESR variation at U, T = 40 °C

50,0

55,0

60,0

65,0

70,0

75,0

80,0

85,0

90,0

95,0

100,0

105,0

0,0 100,0 200,0 300,0 400,0

duration [days]

% C

(t =

0)

2.5V 40°C

2.1V 40°C

2.3V 40°C

-40,0

-20,0

0,0

20,0

40,0

60,0

80,0

100,0

120,0

140,0

160,0

180,0

200,0

0,0 100,0 200,0 300,0 400,0

duration [days]

% E

SR

(t =

0)

2.5V 40°C2.1V 40°C2.3V 40°C


BCAP DC Life

0,0

20,0

40,0

60,0

80,0

100,0

120,0

0 100 200 300 400

duration [days]

% C

(t =

0)

2.1V 65°C

2.3V 65°C

2.5V 65°C

-40,0

-20,0

0,0

20,0

40,0

60,0

80,0

100,0

120,0

0 100 200 300 400

duration [days]%

ES

R (t

= 0

)

2.5V 65°C2.1V 65°C2.3V 65°C

Capacitance and ESR variation at U, T = 65 °C


Sizing Examples


Example sizing

1) Define System Requirements15 W delivered for 10 seconds

10V max; 5V min

2) Determine total energy needed: J=WS=10W*10sec=150J

a) Determine Capacitance based on: J=1/2CV2

b) Substitute the energy from above: 150J=1/2C(Vmax2-Vmin

2)

c) Solve for C: C=300/(102-52)=4F

3) Add 20-40% safety margin to cover I2R losses Csystem = 4.8F

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


Product Strategy

BOOSTCAP® Products

Product Family MC Product Family BC Product FamilyPC Product

Family

Product Type Energy Power Energy Power Energy

Product

Cells

Modules

Cells

Modules

Cells

Modules

Cells

Modules

Cells

Modules


Product Portfolio Offerings

Enhance application cost effectiveness by filling the product portfolio ladder - Initial focus: MC Series

3000 F

2600F

2000 F

1500 F

1200 F

650 F

Power Ladder

3000 F

2600F

2000 F

1500 F

1200 F

650 F

Energy Ladder

11 New Ultracapacitor Cells


New Product Portfolio for MC Series

Type MC Series BMOD Series

Cells 16 V Modules 48 V Modules

3000 F √ √

2600 F √ √

2000 F √ √

1500 F √ √

1200 F √

650 F √

3000 F √ √

2600 F √ √

2000 F √ √

1500 F √ √

1200 F √

650 F √

En

erg

yP

ow

er

29 New Products


Summary


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


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


Useful Links

• Useful links on Maxwell Technologies Web-site:• White Papers

• Technology Overview

• Sizing worksheet

• Application Notes

• Data Sheets

www.maxwell.com

ultracapacitors microelectronics high-voltage capacitors tecate training by: maxwell technologies -...

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