Ultra_caps_4-5-06_presentation.pdf

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Ultracapacitors Microelectronics High-Voltage Capacitors

Guidelines on How to Design-inUltracapacitors into your Applications

John DispennetteApplication EngineerMaxwell Technologies

Guest Speakers

Tom Bartley Bryan SealManager of New Business VP of EngineeringISE Corporation SmartSynch




Today’s Agenda

AGENDA

Maxwell TechnologiesGuidelines and Considerations for Using Ultracapacitors in yourApplication Design

SmartSynchDesign Considerations and Benefits of Integrating UltracapacitorsIn Automated Meter Readers

ISE CorporationDesign Considerations and Benefits of Integrating UltracapacitorsIn Heavy Duty Hybrid Drive Systems

Q&A Session




Guidelines and Considerations forUsing Ultracapacitors in your

Application Design

Maxwell is a leading developer and manufacturer of innovative,

cost-effective energy storageand power delivery solutions.




Ideal Ultracapacitor ApplicationsExamples

• High reliability back-up powersolutions.

• Short term bridge power -transfer to primary long termbackup or orderly shut down.

• Power quality ride-through -voltage sag compensation.

• Power buffering - largemomentary in-rush or powersurges.




Ultracapacitor Application DesignConsiderations

• When designing-in Ultracapacitors into yourapplication you need to take into consideration:

Power RequirementsEnvironmentLife Requirement




Application Power Requirements

• Step 1:

Size the system based on power and/or energy

• Need to know the following• Maximum system voltage

• Minimum allowable application voltage• Typical current or power needed• Peak current or power needed• Load duration

Web sizing tool availablehttp://www.maxwell.com/ultracapacitors/support/maxwell_model_3.xls




General Sizing

• Maximum voltage defines minimum series capacitors

• Vsys

= VC1

+ VC2

+ …

• Minimum voltage defines capacitor utilization

• E=½C(V o2-Vf

2)

• Typical/peak current plus load duration helps define

capacity

• CdV = Idt




Voltage Linear with Current

-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

V o l t a g e

( V )

0

5

10

15

20

25

30

35

40

45

50

C u r r e n

t ( A )

-

R

esr

+

+C

-

i

Vo

VminVf

What is the maximum voltage window allowable?

Does the application require a constant voltage?

E=½CV 2

Boost or buck regulation




Application Environment Considerations

• Step 2:

Defining the system environment

• Need to know the following:• Typical and extreme ambient conditions• Environment produced by the ultracapacitor• System management for safety and reliability




Performance f(T)

0.0

0.5

1.0

1.52.0

-50 -30 -10 10 30 50 70

Temperature (C)

R e l a t i v e P e r f o r m a n c e

Capacitance Resistance

Product performance stable overwide temperature range

C(T) C from T(-40,70)

R(T) ~R from T(0,70)

R(T) ~1.5R @ -40 oCR(T) ~1.1R @ -10 oC

Web sizing tool adjustsbased on temperatureselection




Is cooling required?

Product Thermal Profiles

0.0

0.2

0.4

0.6

0.8

0 100 200 300 400 500

Current, I (amps)

D u

t y c y c

l e , d

f

10

20

30

40

T

Capacitor self heating can be calculated for each productT=I2Resr R thdf

Where:

I = currentResr = capacitor ESRR th = thermal resistancedf = duty cycle fraction

T + ambient < 65 oC

Charts assume:free convection, 25 oC

Charts available per product:http://www.maxwell.com/ultracapacitors/support/thermal_charts.xls




Safeguards for Operation

• Protect capacitor or system from over voltage• Over voltage typical failure is OC

• Protect capacitor/capacitor from voltageimbalance• Active or passive balancing

• Protect ancillary components from potentialcurrent in/out of capacitor• Fusing may be advisable




Application Life Requirements

• Step 3:

Make adjustments based on EOL specifications

• Based on• Criteria identified in step 2• Minimum safety margins specified in application




Factors Influencing Life

• Key life considerations are nominal voltage andnominal temperature

• Voltage derating may:Offset high ambient requirementsExtend component life performance

Protect from voltage imbalance




System Integration

• Step 4:

Identify system integration interface requirements

• Special consideration in application examples• SmartSynch – Automated Meter Reading (AMR)• ISE – Series Hybrid Drive




Design Considerations andBenefits of Integrating

UltracapacitorsIn Automated Meter Readers




SmartSynch ® SmartMeters

• A global leader in wireless, advancedmetering technology for the electric utilityindustry

• 50 major utility customers throughout NorthAmerica

• 90,000 wireless smart meters sold

• Service an estimated $9 billion of revenueand 25,000 Megawatts annually

• Completely under-the-glass solution





SmartSynch Wireless SmartMetering

• SmartSynch was first in the AMR industry to incorporateultracapacitor technology in a limited power sourceapplication.

• SmartSynch owns a patent (6,819,226) for ultracapacitors in

fixed telemetry devices.

• Ultracapacitors are used to provide short burst currents to RFmodems higher than the native meter power supply cannormally source.

• Ultracapacitors are used as a backup power source forSmartSynch SmartMeters during utility power outages.





Why Ultracapacitors instead of batteries?

• Relatively inexpensive

• Storage capacity meets the power required to transmit data.

• Requires no special charging regimes

• Operates well over AMR’s complete temperature range




Design Considerations and

Benefits of IntegratingUltracapacitors

in Heavy Duty Hybrid Drive

Systems




Designing With Ultracapacitors for High Power

• Understand requirements

• Decide how to charge

• Analyze operation

• Review design safety

• Look at heating effects again & start over




Understand Requirements

• Voltage - How many capacitors in series• Energy Storage - 1/2 CV 2

• Power - Maximum, profile, duty cycle• Resistance - ESR & Interconnects• Heating - I2R

• 300 amps at 10 milliohm = 900 watts• Packaging• Form factor - shape, weight, accessibility• Cooling - air, liquid

• Voltage - balancing equalization• Support structure - shock, vibration, mounting• Assembly, service




Decide How To Charge

• A discharged cap looks like a short circuit

• Limit the current

• Decide the charge time

• Decide the charge level

• Consider heating effects

• Determine type of switches




Analyze the Operation

• Charge/Discharge duty cycle• Heats fast, cools slow

• Component limitations - Maxwell spec• Package limitations - placement, circulation

• Balancing Equalization• Variations result in voltage differences across series

connected caps after a number of duty cycles• Is there a charge holding requirement and/or

leakage spec?• How is the stored energy discharged?• What is the end of life?






Resources

Maxwell Technologies www.maxwell.comSmartSynch www.smartsynch.comISE Corporation www.isecorp.com

For more information about Ultracapacitors:

Ultracapacitor Datasheets:http://www.maxwell.com/ultracapacitors/products/datasheets.html

Whitepapers:http://www.maxwell.com/ultracapacitors/support/papers.html




Resources

Don’t forget to download your copy of the

Ultracapacitor Product Guide

Click here: http://www.maxwell.com/pdf/uc/app_notes/ultracap_product_guide.pdf

Ultra_caps_4-5-06_presentation.pdf

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