Aerospace Battery R&T at CEA
Florence Fusalba , CEA Program Manager
CEA at a glance
CEA = French Atomic and Renewable Energy Commission
Research &
Technology
Nuclear
Energy
Defence
Applications
Division
Nuclear
Energy
Division
Technological
Research
Division
French strategic
independence
French energetic
independence
French economic
competitiveness
TECHNOLOGY
Defense
Security
16000 employees
10 Research centers
4B€ annual budget
580 priority patents
filed / year
120 new high tech
companies created
Material Science Division / Life Science Division
SCIENCE
Fundamental Research
since 1984
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3 Business Units
1967 - Grenoble
Laboratory of Electronics and
Information Technologies
Staff 1800 - 240 M€
2003 - Paris
Laboratory of Integrated
Systems
and Technologies
Staff 800 - 70 M€
2005 - Grenoble / Chambéry
Laboratory of Innovation for
new Technologies for Energy
and Nanomatérials
Staff 1400 - 170M€
Micro-nanotechnologies
and system integration
Software-intensive
systems
New energy technologies
and nanomaterials
|
PAGE 3
CEA-TECH (Technological Research)
HUMAN
RESOURCES
4500 people
Total staff
BUDGET
500 M€/year
PATENTS
550 patent
applications per
year
CUSTOMER
PROFILE
145 International
customers
500+ SMEs
80% listed CAC40
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Our objectives
Reduce dependency on fossil fuels
Support industry
with viable
innovation
strategies
Provide solutions
to reduce GHG
emissions
THREE KEY DRIVERS
ENERGY EFFICIENCY
Energy storage
Buildings
Transport & electro mobility
Smart grids
RENEWABLE ENERGY
Photovoltaic
Solar thermal
Biomass
Hydrogen
MATERIALS
Efficient materials
Recycling
Low energy processes
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LITEN: key numbers
1400 MEMBERS OF STAFF
740 permanent
Average age < 40
30% Women
4 DIVISIONS
1048 PATENTS
Solar/building
235 PATENT APPLICATIONS 2013
Electric transport
350 INDUSTRIAL PARTNERSHIPS
Thermal/biomass/H2
BUDGET 170 M€
Nanomaterials / large surface
electronics
RESEARCH CONTRACTS
40% Large groups
60% SME
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OUTLINE
CEA BATTERIES FACILITIES
Customized Battery Developments to stand drastic conditions
R&D and Prototyping
Manufacturing & Testing
Pilot Platforms
CEA BATTERIES FOR AERONAUTIC APPLICATIONS
Small Batteries for Drastic Conditions
Applications to Beacons & Sensors
Batteries for More Electric Aircrafts
From APU to Propulsion
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PILOT : Production representative environment
Semi Industrial Line: Dry room ~ 1000m² (Dew points: -20°C & -40°C)
All materials &
components
electronically tracked
during the process
thanks to bar codes
-
A stabilized design to investigate chemistries with capability to produce prototypes in a production
relevant environment
Prototypes Performances stable, Manufacturing process definition established, Process flow
validated… Manufacturing yield compatible with an industrial transfer…
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BATTERY SYSTEM from TRL3 to TRL6-8
Electrical test benches:
High power ~300 channels
Low power (Includes
formation) 480 channels
Battery Modules & pack
assembly with emanagement
Semi automatic assembly with
full components tracking
Battery Modules & Packs Assembly ~500m²
ca. 20 to 40 battery packs (EVs sizes)/month
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EXAMPLE - Automotive ENERGY battery pack - 30 KWh
2012
Raw material
CEA Cell
Module
30 KWh
83 Wh/kg
Assembly
585 cells
13 modules in series
90kW discharge
40 kW charge
150 km estimated
Pack
Conditioning
Michelin test track with highway,
gravel road, paved road, round
about, hard braking… 11000Km
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CEA BATTERY FOR AERONAUTIC WATCH DISTRESS MODE
BATTERY (1.2AH) OF 250WH/KG OPERATING AT LOW T° IN
POWER MODE
A World Premiere
It is the first battery manufactured in series from an accumulator
of more than 250Wh/kg. This specific energy is reached thanks
to an Silicon-based electrochemistry allowing to offer an
exceptional autonomy, power-rate and safety
BREITLING EMERGENCY II
2008-2010
2008
Project Kick Off
2013
2009
2010
R&D
Proof of Concept in
Representative
Environment
At -20°C, high performances up
to 2C rate
70% of the capacity recovered
at -20°C
UL1642 standard compatibility
Cospas-Sarsat : 121 & 406MHz
(24h at AT & 20-22h EOL (2
years) at -20°C 121MHz off)
2013
Commercialization
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OUTLINE
Batteries for Drastic Conditions
For Sensors Powering to Reduce Aircraft
Maintenance
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Sensor Battery for Aeronautic (Helicopter & Air Plane)
EADS, Dassault, Eurocopter, Goodrich Actuation Systems, CENARO, etc… Small Battery in
Hard Casing, thin (<1.5mm) & hermetic (low pressure environment), vibration resistant
Power source characteristics to be aimed for wings strains
sensoring:
Development of a high energy density battery
Thickness
less than 1.5 mm
Surface
57*55 mm (2/3 of the smart tag area)
Adapted to the aircraft or helicopter geometry
Very long life expectancy
10 years
Resistant to very severe environmental conditions:
Large range of temperature
-50°C to 95°C
Corrosive environment
Mechanical strain (vibrations, acceleration…),
50 to 1100mbars
Operational on a large range of pressure
Compatibility with the other components of the SMART TAG,
Compatibility with the final integration process
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TRIADE
BATTERY FOR AERONAUTIC (HELICOPTER & AIR PLANE)
Battery Specifications:
LiFePO4/Graphite Technology: Stable & Safe
Nominal voltage 3.2V ; [2,6 - 3,7V]
Capacity : 180mAh
Stacked inner electrochemical core:
Mechanical conception: 57mm x 55mm x 1,5mm
Stainless steel casing
High tightness
Laser welding
Glass-metal connections
Direct pins connections to the electronic PCB to withstand mechanical vibrations,
acceleration…
Specific electrolyte to operate at both low & high temperatures
TRL 4-6 Technology Development-Demonstration
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ASTRAL: Aerospace CEA Li-ion Sensor Battery
NCA / Graphite
(CEA electrodes)
Technology
Nominal Capacity (mAh)
450
Nominal voltage (V)
3.6
Nominal Energy (Wh)
1.62
Cut-off Voltages (V)
Rigid and highly hermetic packaging,
laser welded…
Tightness of the casing < 10-8 mbar.L.s-1
Connections thanks to straight pins and
use of wedge
Thermal cycling qualified
Vibration & Centrifugation (100G)
qualified
3.0 - 4.0
Internal Resistance (mΩ)
175
Overall dimensions without pins (mm)
Volume (cm3)
7.6
Mass (g)
15.5
Volumetric Energy Density (Wh/L)
213
Gravimetric Energy Density (Wh/kg)
105
100
4,2
Capacity %
4
Tension (V)
3,8
3,6
3,4
Technology DevelopmentDemonstration
80
60
40
3,2
20
3
0
0
2,8
TRL 4-6
30 x 30 x 8.4
0
10
20
30
40
50
Temps (jours)
Self-discharge equivalent to
conventional Li-ion technology :
about -1%/month
60
25
50
75
100
Cycle_Index
Good cyclability : over
80 cycles in “profile of
use” conditions
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MORE ELECTRIC AIRCRAFT: HELICOPTER
High Power Batteries development for Helicopter Hybridization
(autorotation powering, fuel saving, engine starting in addition to
power supply of the distribution network…)
Prior criteria: High Power density (W/kg) &
Safety
ca. 100kW 10-30sec
ca. 200 cycles
Low self-discharge
Stable/Safe behavior
Very good low temperature capability
2 solutions are expected to fit with the
application:
LMO-LTO from KERS for very high
power (60C discharge rate)
LFP/G (CEA PG0 reference) for 40C
discharge rate
CEA PG0 Reference :
Lithium Iron Phosphate
technology
U = 2.0V – 3.6 V
Nominal Capacity = 10 Ah
Weight = 0.5 kg
Ri @25°C : 0.8 mΩ*
Diam. 50mm Length 125mm
*Ri at 1KHz 100%SOC @25°C
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CEA AIRCRAFT Lithium ion Battery R&T
Today…
Next…
Examples :
Product/TRL
Auxiliary Power Unit (APU) start on
the ground & serve as a backup for
electronic flight systems /
Commercial
Electric Propulsion / Prototype
Battery System
Cells
Specifications
High Power / Low Energy
C-rate discharge
Nominal Energy ~ 4 kWh
Nominal Voltage = 20–32.2 V
Pack Weight ~ 40-50kgs
Pack specific energy ~40-50Wh/kg
High Energy / Medium Power
3 to 4C-rate discharge
Nominal Energy ~ 20kWh
Nominal Voltage = 200-250V
Pack Weight ~ 130kgs
Pack specific energy ~140Wh/kg
2 Packs 8S1P with LCO Cells 2.5–4V
Cells ~90-100Wh/kg
2 Packs 59S1P with NMC Cells 2.7-4.2V
Cells ~150Wh/kg
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HIGH ENERGY BATTERY FOR SOLAR ELECTRIC AIRCRAFT
2012 & 2013
High Energy Battery (C/2 max)
Prismatic Soft Pouch
10 x 140 x 140mm
310Wh/kg (@C/8) 44Ah
NMC/Si-C technology 3.4V
Voltage: 200 – 300 V
Energy: 38 KWh
Temp. range: 15 – 45 °C
4.5
Cycle C/8 @ 40°C
[4.3-2.5V] 10x140x140mm
Voltage (V)
4
Soft packaging
150 mm
3.5
3
2.5
2
~ 9 mm
0
145 mm
100
200
Energy density (Wh/kg)
10.140.140 cell
Nominal capacity:
Unom:
Mass:
Energy density:
Internal resistance (cell) (1kHz)
43 Ah @ C/8 initial
3,4V
490g
300 Wh/kg @C/8 initial
4mOhm
300
EADS Show Room
EADS Show Room
Le Bourget meeting show 2013
Le Bourget meeting show 2013
Electrical specifications
Temperature Range:
Max charging voltage
Min discharge voltage:
Imax charge (TBC)
Imax discharge (TBC)
-20/ +45°C
4.3-4.4V
2.5V
8A
11A
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HIGH POWER Roadmap overview (Cell Level)
2014
2016
Auxiliary power unit
(APU)
Propulsion
(hybrid)
Propulsion
(full electric)
High Safety
durability
Power density
durability
Energy density
Power capability
GEN
1
GEN
1
GEN
1
LFP-G hard casing
100 Wh/kg - 1 kW/kg
5000 cycles
LFP-LTO hard casing
50 Wh/kg - 2 kW/kg
>10000 cycles
NMC-G
200 Wh/kg - 400 W/kg
1000 cycles
GEN
2
GEN
2
GEN
2
LFP blend-G
130 Wh/kg - 3 kW/kg
5000 cycles
Blend-LTO
70 Wh/kg - 6 kW/kg
10000 cycles
NMC-Si/C
250 Wh/kg - 900 W/kg
300 cycles
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CEA contact: florence.fusalba@cea.fr
Commissariat à l’énergie atomique et aux énergies alternatives
Centre de Grenoble | 38054 GRENOBLE Cedex 09
T. +33 (0)4 38 78 29 20 | F. +33 (0)4 38 78 51 98
Direction de la Recherche
Technologique
Liten
Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019
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