Tecate Training
By:
Maxwell Technologies - San Diego
Ultracapacitors l Microelectronics l High-Voltage Capacitors
About Maxwell
Capacitor Manufacturer since 1965
www.maxwell.com
Maxwell is a leading developer
and manufacturer of innovative,
cost-effective energy storage
and power delivery solutions.
Certifications:
ISO 9001:2000
ISO/TS 16949
ISO 9002
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Manufacturing facilities:
US, Europe, Asia
Table of Content
1.
2.
3.
4.
5.
6.
7.
8.
When can I use an Ultracapacitor?
What is an Ultracapacitor?
Ultracapacitor Market
Ultracapacitor Applications
Sizing your System
Sizing Examples
Guidelines to Designing an Ultracapacitor System
Summary
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Power vs Energy
What is the difference between Power and Energy?
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Application Model
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Peak Power Shaving
Peak Power Shaving
• Ultracapacitors provide peak power ...
Available
Power
Required Power
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Ultracapacitor Peak Power
Back-up Power
Back-Up Power Support
• Ultracapacitors provide peak power…
...and back-up power.
Available Power
Required Power
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Ultracapacitor Backup Power
What is an Ultracapacitor?
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
What is an Ultracapacitor?
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
Dielectric
C = er A/d
Minimize (d)
Maximize (A)
Electrolyte
E = 1/2 CV2
Film foil
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Electrode
ECDL
Separator
Technology Comparison
Available
Performance
Charge Time
Discharge Time
Energy (Wh/kg)
Cycle Life
Specific Power (W/kg)
Charge/discharge
efficiency
Lead Acid
Conventional
Ultracapacitor
Battery
Capacitor
1 to 5 hrs
0.3 to 30 s
10
-3
0.3 to 3 hrs
10 to 100
1,000
<1000
0.7 to 0.85
0.3 to 30 s
1 to 10
>500,000
<10,000
0.85 to 0.98
10
-3
Ultracapacitors l Microelectronics l High-Voltage Capacitors
to 10
-6
-6
s
to 10 s
< 0.1
>500,000
<100,000
>0.95
Technology Comparison (page 2)
1000
Fuel
Cells
10h
100
Energy Density/[Wh/kg]
0,1h
1h
36sec
LiBattery
Lead Acid
Battery
10
Ni/Cd
3,6sec
U/C
Double-Layer Capacitors
1
36msec
0,1
Al-Elco
0,36sec
0,01
10
100
1000
Power Density/[W/kg]
Ultracapacitors l Microelectronics l High-Voltage Capacitors
10000
Ultracap vs Battery Technologies
Efficiency
4
Charge Acceptance
Self Discharge
Pb-AGM
3
Temperature Range
Availability
2
NiMH
Li Ion
1
Environment
Ultracaps
Cycle Stability
0
Recycling
Energy Density
Safety
Power Density
System Cost
Energy Cost
Power Cost
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Ultracapacitor Market
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Ultracapacitor Market
Ultracapacitor World Market
Consumer Products
Industrial
Transportation
Digital Camera
UPS
Hybrid Bus/Truck
PDA
Windmill
Engine starting
Toys
Stationary Fuel Cell
Light Hybrid
Memory back-up
Automation/Robotics
Local Power
Rail
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Ultracapacitor Applications
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Applications
Automotive
Traction
 14/42 V systems
 HEV
 Electrical Subsystems
 Regen braking
 Voltage stabilization
 Diesel engine starting
Large Cells
Consumer Electronics
Industry
 Power quality
 Pitch systems
 Actuators
 AMR
 PDAs
 Digital cameras
 2-Way pagers
 Scanners
 Toys
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Small Cells
Today’s Markets
Electric Rail Pack
Braking Energy Recapture Diesel engine
starting
Wind power plant pitch systems
Burst power
TRACTION
Ultracapacitors l Microelectronics l High-Voltage Capacitors
INDUSTRY
Small cell applications
Digital cameras, AMR, Actuators, Memory
boards
CONSUMER
Ultracapacitors l Microelectronics l High-Voltage Capacitors
SITRAS® SES - Solution
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
Application: Time shifted delivery of the stored braking energy for vehicle reacceleration
Solutions: Possible with either stationary or on-vehicle energy storage system
Advantage: Cost savings through reduced primary energy consumption
Ultracapacitors l Microelectronics l High-Voltage Capacitors
SITRAS® SES - Benefits
Saved energy
kWh/h
50

Reduction of
the power
need by 50
kW

Energy
saving of
340.000 kWh
per year and
per
installation

thermal limit
68 kWh/h
40
30
20
10
0
04.08.01
07.08.01
Ultracapacitors l Microelectronics l High-Voltage Capacitors
10.08.01
13.08.01
MITRAC of Bombardier Transport
MITRAC energy saver
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Wind Turbine Pitch Systems
 Modern wind turbines
consist of threebladed 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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Switch box
including 2600F
ultracapacitors
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
Fuel Cell Powered Fork Lift
•
•
Fork lift equipped with a
fuel cell
Cell system and an
ultracapacitor module
•



Ultracapacitors l Microelectronics l High-Voltage Capacitors
BOOSTCAP module:
48 BCAP0010
112 V, 55 F
40 kW peak power
Sizing Your System
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Data sheet
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Data sheet
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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 load
Id = discharge current
Vf = voltage 5 seconds after removal of load.
td = time to discharge from initial voltage to minimum voltage
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Basic Equations
Definition of Capacitance:
Charge = current * time: Q = I*t
Solving for voltage:
Dynamic Voltage:
Stored Energy
At initial voltage Vo,
At final voltage Vf,
C = Q/V
C = I*t/V
V = I*t/C
dV/dt = I/C
E = ½ C*V2
(1)
(1a)
(2)
(3)
(4)
Eo = ½ C*Vo2
Ef = ½ C*Vf2
Delivered energy = Eo – Ef
Ultracapacitors l Microelectronics l High-Voltage Capacitors
ΔE =½ C*(Vo2 – Vf2)
(5)
Voltage & Current vs. Time
C = 15 farad; Resr = 100 milliohm
Vo = 48V; I = 30A
50
50
2 –I*dt/C
dV/dt
==V
I/C
dV
dV
ΔEtotal=½
dV
I*dt/C
C*(V
==;Q/C
I*R
I*R
Vf2esr
)
esr
o =+esr
Voltage
45
40
Resr
i
40
Voltage (V)
45
-
35
+
30
+
C
-
35
25
Current (A)
Vo
20
30
15
Vmin
25
10
5
Current
20
0
-5
-4
-3
-2
-1
0
1
2
3
Ultracapacitors l Microelectronics l High-Voltage Capacitors
4
5
6
Time (sec)
7
8
9
10
11
12
13
14
15
Vf
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.
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Applications with a single
energy 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)
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Applications with two
energy storage components
• Power vs. Energy design trade
when 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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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.
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Capacitance and ESR vs Frequency
ESR vs . Frequency
3,50E+03
7,00E-04
3,00E+03
6,00E-04
2,50E+03
5,00E-04
ESR [mOhm]
Capacitance [F]
Capacitance vs. Frequency
2,00E+03
1,50E+03
4,00E-04
3,00E-04
1,00E+03
2,00E-04
5,00E+02
1,00E-04
0,00E+00
1,00E-02
1,00E-01
0,00E+00
1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03
1,00E+00 1,00E+01 1,00E+02 1,00E+03
Frequency [Hz]
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Frequency [Hz]
C and ESR Temperature Dependency
2000
1,2
1,1
1800
0,9
1600
0,8
1400
0,7
0,6
1200
ESR BCAP0008 (DC)
0,5
Capacitance BCAP0008
1000
0,4
-60
-40
-20
0
20
40
Temperature [°C]
Ultracapacitors l Microelectronics l High-Voltage Capacitors
60
80
100
Capacitance [F]
ESR [mOhm]
1
BCAP Self Discharge
Self Discharge vs Temperature
100,0
90,0
% U (t = 0)
80,0
70,0
60,0
- 35 °C
+ 5 °C
50,0
+ 25 °C
40,0
+ 65 °C
30,0
0
2
4
6
8
10
12
14
16
Time [days]
Ultracapacitors l Microelectronics l High-Voltage Capacitors
18
20
22
24
26
28
30
BCAP Cycling Capacity
Change in Capacitance
[%]
110.0
2.0E-03
1.8E-03
1.6E-03
1.4E-03
1.2E-03
100.0
90.0
Capacitance
80.0
70.0
ESR
60.0
50.0
0
20000
40000
60000
Cycle Number
Ultracapacitors l Microelectronics l High-Voltage Capacitors
80000
1.0E-03
8.0E-04
6.0E-04
4.0E-04
2.0E-04
0.0E+00
100000
ESR [Ohm]
90 A CC, 1.15-2.3 V, 25 s, RT
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
BCAP DC Life
Capacitance and ESR variation at U, T = 40 °C
105,0
200,0
100,0
180,0
95,0
160,0
140,0
90,0
120,0
% ESR (t = 0)
85,0
% C (t = 0)
2.5V 40°C
2.1V 40°C
2.3V 40°C
100,0
80,0
75,0
70,0
80,0
60,0
40,0
65,0
20,0
2.5V 40°C
60,0
0,0
2.1V 40°C
55,0
-20,0
2.3V 40°C
50,0
-40,0
0,0
100,0
200,0
300,0
duration [days]
Ultracapacitors l Microelectronics l High-Voltage Capacitors
400,0
0,0
100,0
200,0
300,0
duration [days]
400,0
BCAP DC Life
Capacitance and ESR variation at U, T = 65 °C
120,0
120,0
2.5V 65°C
2.1V 65°C
2.3V 65°C
100,0
100,0
80,0
% ESR (t = 0)
% C (t = 0)
80,0
60,0
60,0
40,0
20,0
40,0
0,0
2.1V 65°C
2.3V 65°C
2.5V 65°C
20,0
-20,0
0,0
-40,0
0
100
200
duration [days]
Ultracapacitors l Microelectronics l High-Voltage Capacitors
300
400
0
100
200
300
duration [days]
400
Sizing Examples
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Example sizing
1) Define System Requirements
15 W delivered for 10 seconds
10V max; 5V min
2) Determine total energy needed:
a) Determine Capacitance based on:
b) Substitute the energy from above:
c) Solve for C:
J=WS=10W*10sec=150J
J=1/2CV2
150J=1/2C(Vmax2-Vmin2)
C=300/(102-52)=4F
Csystem = 4.8F
3) Add 20-40% safety margin to cover I2R losses
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Product Strategy
BOOSTCAP® Products
Product Family
Product Type
Energy
Power
BC Product Family
Energy
Power
PC Product
Family
Energy
Modules
Cells
Modules
Cells
Modules
Cells
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Modules
Cells
Modules
Cells
Product
MC Product Family
Product Portfolio Offerings
Enhance application cost effectiveness by filling the product portfolio
ladder - Initial focus: MC Series
Power Ladder
Energy Ladder
3000 F
3000 F
2600F
2600F
2000 F
2000 F
1500 F
1500 F
1200 F
1200 F
650 F
650 F
11 New Ultracapacitor Cells
Ultracapacitors l Microelectronics l High-Voltage Capacitors
New Product Portfolio for MC Series
Power
Energy
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
√
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Summary
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
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
Ultracapacitors l Microelectronics l High-Voltage Capacitors
Useful Links
• Useful links on Maxwell Technologies Web-site:
•
•
•
•
•
White Papers
Technology Overview
Sizing worksheet
Application Notes
Data Sheets
www.maxwell.com
Ultracapacitors l Microelectronics l High-Voltage Capacitors