Andrew Lamb November 9 th , 2015 Magefekt Product Sales - - PowerPoint PPT Presentation

C h a n g e t h e Wo r l d

• n

e i d e a a t a t i m e

Andrew Lamb

November 9th, 2015

Magefekt

• Product Sales
• Engineering Consultancy
• www.magefekt.com

Tonight

Think differently

• Batteries are a store of amp hours
• Most tasks require amps not Volts
• Think of the user’s needs not the Battery Data

Sheet

• Make it safe
• Make it reliable

What is a Battery ?

• A battery is a chemical cell containing an

electrolyte with two distinct chemical

• potentials. The portion of each potential is

determined by the ingress and egress of current.

• The recoverable amp hours multiplied by the

potential (i.e.Volts) can be used to deliver energy.

What is Voltage

• Voltage is the activation threshold within a

solid state device. Examples:

• Voltage is the activation energy within an LED.
• The top speed of an electric motor
• The break down voltage of a device.

Energy Density

• A battery car has the energy

capacity of a Soft Drink Can

• f petrol.

Energy Density

Discharge / Energy Density

• In an electric drive

application Voltage limits the speed of a motor.

• As the voltage drops

the top speed will drop.

• Operational speed

during normal use therefore determines Voltage required.

Charge / Discharge Cycle

• Lithium Batteries

have a smaller drop in Voltage during an

• perational cycle

than lead.

Energy Density

• Given that energy is

the area under the charge discharge curve then the energy between the curves is lost when the higher voltage is not required.

Why is this important ?

• The only thing that is fixed in the operational

cycle of a Battery is the Amp Hours in and

• ut.
• Current is the torque that gets you up the hill.
• Current is what is converted to light in LED’s
• Current is what comes out of a solar panel.

Practical Application

• The client wanted to

increase the range of their high dependency chairs from 10km to 30km at 10km/h .

• Magefekt achieved 40km

at 10 km/h with 60% reduction of the original battery weight and half the size.

Family

3.5+ lt/100

Daily Commuter

Below 3 lt/100

Family and Tow

14+ lt/100

Motor Vehicles

Private vehicle needs

• Family and Tow
• Takes the Family, luggage and tows as far as you

want to go

• Mitsubishi Challenger 10 to 14 lt/100km
• Family
• Takes the Family
• I use a Toyota Prius 3.6 to 5 lt/100km
• Commuter
• Takes 1.1 occupants
• Idea’s Live Here

What is the market?

• There are 3 000 000 Suburban Households
• More than one Car
• Work commute is under 40km.
• Rush hour has a vehicle occupancy of 1.1
• The Commuter Car is the solution to public

transport where the Train Stations are not an

• ption.
• The Commuter Car Market is larger than the

Domestic Vehicle Production in the last 10 years

Domestic

• The question is what do we need
• Domestic demand can be counter cyclical to solar power

generation.

• It is therefore important to minimize the domestic consumption

and move the load to align with power availability.

• Temperature management (air conditioning), washing

machines and dishwashers should be used during peak solar generation times.

• Excess solar power generated can be stored in batteries for

night use. Unlike Lead, Lithium has excellent storage characteristics such as: fast charging, high discharge capability and long life

• Solar installation pumping

sewage at Rye.

The system is independent with Grid Backup for battery charging. Battery assembly consists of 2 x Adverse Environment 74 Ah 24V units. The system is monitored remotely and expected to have 10 year service intervals.

Magefekt is looking at safety

• This is then being used in our design and

sourcing of batteries.

• Magefekt has collected over 600 failed and end of

life Lithium Batteries

• We are progressively analyzing their failure modes
• We are collecting the data and pushing to reduce the

failure of batteries

Safety

• Whilst LiFePO4 is not the highest capacity

cells, the thermal runaway of 270C makes it the least likely to cause issues.

• Magefekt design considers eddy current

prevention, thermal management and integrated fusing to reduce the likelihood of thermal runaway from a short.

Consequence & Mechanism

• The Aurora Solar Car caught

fire in Spain.

• The battery pack was

managed by total voltage

• ver 40 parallel modules.
• An open circuit failure at low

voltage within the module was not visible within data resolution.

• Consequently an overcharge

failure is the most likely cause.

Open circuit failures

• Incorrect setting, poor process

control or Contamination can lead to joint failure. Tabs are folded up so loads will pull on Welds

• A single cell was found in the

cycling of an Aurora Pack. This lead to bench top simulations showing that an over charge on a warm day will cause a thermal incident.

Short Circuit through membrane

• Trim debris is carried

through the process and contaminates plates and membranes

• Under mechanical

pressure and the membrane is damaged and eventually shorts

Magefekt Choice

L i t h i u m I r

• n

P h

• s

p h a t e : LiFePO4 cathode, graphite anode LFP or Li-phosphate

Voltage, nominal 3.20V, 3.30V Specific energy (capacity) 90–120Wh/kg Charge (C-rate) 1C typical, charges to 3.65V; 3h charge time typical Discharge (C-rate) 1C, 25C on some cells; 40A pulse (2s); 2.50V cut-off (lower that 2V causes damage) Cycle life 1000–3000 (related to depth of discharge, temperature) Thermal runaway 270°C (518°F) Very safe battery even if fully charged Applications Portable and stationary needing high load currents and endurance Comments Very flat voltage discharge curve but low capacity. One of safest Li-Ions. Used for special markets. Elevated self-discharge.

Reliable

• Magefekt goes back to the basics
• Why do batteries fail.
• Design defect
• Quiescent current through Battery management

systems

• Battery Management system failures
• Membrane Defects
• Water Ingress
• Poor manufacturing
• Poor application

Size

• Bigger is not better
• Lithium batteries are reliant on diffusion

membranes.

• Membranes defects are described in terms of

defects per square meter.

• The more area of membrane in a cell the larger

the likelihood of a defect being in the cell.

Packaging

• Prismatic
• Plastic
• Polymers are water absorbent by nature, Nylon 3% and Acetal 0.3%.
• This allows water to pass through the packaging to react with the lithium,

distorting the graphite resulting in swelling

• Steel
• Steel offers resistance to water ingress but use of valves negates the

advantages and flat side offers no resistance to swelling.

• Satchels
• Satchels have no structural support and whilst metalized still allow

water ingress

Packaging

• 18650
• 18650 offers the structural integrity of a steel can

and cylindrical structure. In a nail test the penetrator is deflected.

• 26650
• The 26650 has all the advantages of the 18650

with a higher capacity. Carefully selected supply of 26650 cells underlies the magefekt product range.

High Performance Packs

• The LiPo shown was designed

for high energy density, low heat and medium life.

• Each parallel section was

monitored through opto coupling to isolate voltages.

• The pack was left in the factory
• vernight, condensation

formed on the packaging, ingressed and reacted.

What have I not talked about

• Magefekt Batteries
• No charge shelf life of two years
• First balance at two years
• Run Cold
• Impact Resistant
• High rate of thermal diffusion
• Submersible in adverse environments
• Capacity of 80% at 3000 cycles

Thank you Thank you

Ma g e f e k t T e a m Ma g e f e k t T e a m

Why Electric

• Each time we fill the car around

60c per liter leaves Australia.

• Reducing Fuel consumption

reduces the national debt.

• If three million cars Saved 3.2 Lt

per day we would save $5.7.

• Localize and minimize the

energy.

Trust the Maths

• Load and systems are

balanced .

• If the model does not

match your data then find

• ut why.

L i t h i u m N i c k e l Ma n g a n e s e C

• b

a l t O x i d e :

• LiNiMnCoO2. cathode, graphite anode

NMC (NCM, CMN, CNM, MNC, MCN similar with different metal combinations)

Voltage, nominal 3.60V, 3.70V Specific energy (capacity) 150–220Wh/kg Charge (C-rate) 0.7–1C, charges to 4.20V, some go to 4.30V; 3h charge typical. Charge current above 1C shortens battery life. Discharge (C-rate) 1C; 2C possible on some cells; 2.50V cut-off Cycle life 1000–2000 (related to depth of discharge, temperature) Thermal runaway 210°C (410°F) typical. High charge promotes thermal runaway Applications E-bikes, medical devices, EVs, industrial Comments Provides high capacity and high power. Serves as Hybrid Cell. Favorite chemistry for many uses; market share is increasing.

L i t h i u m C

• b

a l t O x i d e : LiCoO2 cathode (~60% Co), graphite anode LCO or Li-cobalt.

Voltage, nominal 3.60V Specific energy (capacity) 150–200Wh/kg. Specialty cells provide up to 240Wh/kg. Charge (C-rate) 0.7–1C, charges to 4.20V (most cells); 3h charge typical. Charge current above 1C shortens battery life. Discharge (C-rate) 1C; 2.50V cut off. Discharge current above 1C shortens battery life. Cycle life 500–1000, related to depth of discharge, load, temperature Thermal runaway 150°C (302°F). Full charge promotes thermal runaway Applications Mobile phones, tablets, laptops, cameras Comments Very high specific energy, limited specific power. Cobalt is

• expensive. Serves as Energy Cell. Market share has stabilized.

L i t h i u m Ma n g a n e s e O x i d e : LiMn2O4 cathode. graphite anode Short form: LMO or Li-manganese (spinel structure)

Voltage, nominal 3.70V (some may be rated 3.80V) Specific energy (capacity) 100–150Wh/kg Charge (C-rate) 0.7–1C typical, 3C maximum, charges to 4.20V (most cells) Discharge (C-rate) 1C; 10C possible with some cells, 30C pulse (5s), 2.50V cut-off Cycle life 300–700 (related to depth of discharge, temperature) Thermal runaway 250°C (482°F) typical. High charge promotes thermal runaway Applications Power tools, medical devices, electric powertrains Comments High power but less capacity; safer than Li-cobalt; commonly mixed with NMC to improve performance.

L i t h i u m T i t a n a t e : Graphite cathode; Li4Ti5O12 (titanate) anode LTO or Li-titanate

Voltage, nominal 2.40V Specific energy (capacity) 70–80Wh/kg Charge (C-rate) 1C typical; 5C maximum, charges to 2.85V Discharge (C-rate) 10C possible, 30C 5s pulse; 1.80V cut-off on LCO/LTO Cycle life 3,000–7,000 Thermal runaway One of safest Li-ion batteries Applications UPS, electric powertrain (Mitsubishi i-MiEV, Honda Fit EV) Comments Long life, fast charge, wide temperature range but low specific energy and expensive. Among safest Li-ion batteries.

L i t h i u m N i c k e l C

• b

a l t A l u m i n u m O x i d e : LiNiCoAlO2 cathode (~9% Co), graphite anode NCA or Li-aluminum

Voltage, nominal 3.70V (some may be rated 3.80V) Specific energy (capacity) 100–150Wh/kg Charge (C-rate) 0.7–1C typical, 3C maximum, charges to 4.20V (most cells) Discharge (C-rate) 1C; 10C possible with some cells, 30C pulse (5s), 2.50V cut-off Cycle life 300–700 (related to depth of discharge, temperature) Thermal runaway 250°C (482°F) typical. High charge promotes thermal runaway Applications Power tools, medical devices, electric powertrains Comments High power but less capacity; safer than Li-cobalt; commonly mixed with NMC to improve performance.