Powerful hybrid storage system combines advantages of lithium-ion batteries and supercapacitors

March 1, 2017 by Joerg-Dieter Walz, Fraunhofer-Gesellschaft
Credit: Fraunhofer-Gesellschaft

A battery that can be charged in seconds, has a large capacity and lasts ten to twelve years? Certainly, many have wanted such a thing. Now the FastStorageBW II project – which includes Fraunhofer – is working on making it a reality. Fraunhofer researchers are using pre-production to optimize large-scale production and ensure it follows the principles of Industrie 4.0 from the outset.

Imagine you've had a hectic day and then, to cap it all, you find that the battery of your electric vehicle is virtually empty. This means you'll have to take a long break while it charges fully. It's a completely different story with capacitors, which charge in seconds. However, they have a different drawback: they store very little energy.

In the FastStorageBW II project, funded by the Baden-Württemberg Ministry of Economic Affairs, researchers from the Fraunhofer Institute for Manufacturing Engineering and Automation IPA in Stuttgart, together with colleagues from the battery manufacturer VARTA AG and other partners, are developing a powerful hybrid storage system that combines the advantages of lithium-ion batteries and . "The PowerCaps have a specific capacity as high as lead batteries, a long life of ten to twelve years, and charge in a matter of seconds like a supercapacitor," explains Joachim Montnacher, Head of the Energy business unit at Fraunhofer IPA. What's more, PowerCaps can operate at temperatures of up to 85 degree Celsius. They withstand a hundred times more charge cycles than conventional battery systems and retain their charge over several weeks without any significant losses due to self-discharge.

Large-scale production with minimum risk

The Fraunhofer IPA researchers' main concern is with manufacturing: to set up new battery production, it is essential to implement the relevant process knowledge in the best possible way. After all, it costs millions of euros to build a complete manufacturing unit. "We make it possible for battery manufacturers to install an intermediate step – a small-scale production of sorts – between laboratory production and large-scale production," says Montnacher. "This way, we can create ideal conditions for large-scale production, optimize processes and ensure production follows the principles of Industrie 4.0 from the outset. Because in the end, that will give companies a competitive advantage." Another benefit is that this cuts the time it takes to ramp up production by more than 50 percent.

For this innovative small-scale production setup, researchers cleverly combine certain production sequences. However, not all systems are connected to each other – at least, as far as the hardware is concerned. More often, it is an employee that carries the batches from one machine to the next. Ultimately, it is about developing a comprehensive understanding of the process, not about producing the greatest number of in the shortest amount of time. For example, this means clarifying questions such as if the desired quality can be reproduced. The systems are designed as flexibly as possible so that they can be used for different production variations.

Making large-scale production compatible with Industrie 4.0

As far as software is concerned, the systems are thoroughly connected. Like process clusters, they are also equipped with numerous sensors, which show the clusters what data to capture for each of the process steps. They communicate with one another and store the results in a cloud. Researchers and entrepreneurs can then use this data to quickly analyze which factors influence the quality of the product – Does it have Industrie 4.0 capability? Were the right sensors selected? Do they deliver the desired data? Where are adjustments required?

Fraunhofer IPA is also applying its expertise beyond the area of production technology: The scientists are developing business models for the marketing of cells, they are analyzing resource availability, and they are optimizing the subsequent recycling of PowerCaps.

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13 comments

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gkam
1 / 5 (5) Mar 02, 2017
It looks like the technologies will completely change the way we travel, and the industries which they support. Without the complex ICE, maintenance is almost gone.

There will be some great transformations, which will affect many folk, like the change-over from horse to auto.
TheGhostofOtto1923
3.7 / 5 (3) Mar 02, 2017
It looks like the technologies will completely change the way we travel, and the industries which they support. Without the complex ICE, maintenance is almost gone.

There will be some great transformations, which will affect many folk, like the change-over from horse to auto.
Funny, you sound just like president donald trump in his electric pen speech to congress.
Uncle Ira
4.3 / 5 (6) Mar 02, 2017
@ Otto-Skippy. True story. I send this as an email to somebody Tues about the upcoming Trump speech.

He's 70 years old.
He's done just about everything you can think of.
He's done so much stuff he's needs six hours a day everyday to tell people about all of it.
He's really generous with time and doesn't mind repeating all the great things he's done.
He can solve any problem with 140 characters or less.
He has spent his life working for the common good,
He knows just about anything.
He constantly has to deal with "fake" tales told by anonymous sources calling him a liar.
He never been wrong, only sniped at by people who don't know.
He knows the military better than ALL the generals.
He doesn't know Putin or even met the man.
He doesn't read books, gets his information from the "shows".
And he is always saying "I know stuff, I know things, more than anyone, I know how things work."
And he is always saying "I am doing my part, it's the world the leave to our children"
Uncle Ira
4.3 / 5 (6) Mar 02, 2017
P.S. for you Otto-Skippy. This part was cut off from the end,,,, the rest of the email.

Sound like anyone you know? No, it's not George, it's Trump.

And yeah, I came up with all that, all by myself because I am stuck on this boat and am missing Mardi Gras.

Later, Ira.

I really did sent to a Physorg poster in an email.
TheGhostofOtto1923
4 / 5 (4) Mar 03, 2017
"Teddy Roosevelt, John F. Kennedy, Franklin D. Roosevelt, Ronald Reagan and Bill Clinton all possessed psychopathic characteristics."
http://elitedaily...1108247/

-Perhaps a psychopath is just what we need as premier spokesmodel at a time of pending superdisasters. Perhaps that is why he is there. Perhaps obama was there because only an uberliberal could give away $1T credibly.

All psychopaths are not created equal. Trump has a corporate empire while george has a birdman certificate hanging on the wall.

Trumps success probably has a lot to do with a very pragmatic ability to assemble excellent teams of super-capable individuals to do all the work.

"...they are able to execute very complex routines designed to elicit from others support for what they want. In this way, many psychopaths are able to reach very high positions in life."

-Some can, some cant. Imbeciles can be psychopaths as well, which we know.
TheGhostofOtto1923
3.7 / 5 (3) Mar 03, 2017
Re the article I linked, I think it takes a far too forgiving approach to the malady. For instance

"psychopaths on the extreme end of the spectrum lack one of the most important qualities to strong and effective leadership: empathy. If you can't relate to others and don't have a high degree of emotional intelligence, you're not in a good position to guide other people."

-I think that the need for leaders to be empathic is a myth. As heinlein said, you can never trust an honest politician. Their decisions might be subject to fleeting emotions and sympathies.

I think the best leaders are actors especially in democracies. Theyre there because of their proven ability to convince people they are doing right and not for their ability to actually do right.

Hey oprah is considering running did you know it? Glenn beck was discussing alternatives yesterday. Other democrat names: tom hanks, will smith, matt damon, and of course Morgan Freeman.

Fight fire with fire non?
Da Schneib
5 / 5 (3) Mar 03, 2017
The main problem Trump has is he can't command loyalty among most people.

Now, back to your regularly scheduled program, this article is notably lacking in details about how the supercapacitors are to be technically combined with Li-ion batteries. There's a lot of hand-waving about Industrie 4.0 without any explanation of what it is or what it does. This is very reminiscent of ISO 9000, which if you will note sank without a trace during the first decade of this century.
Whydening Gyre
5 / 5 (2) Mar 03, 2017
The main problem Trump has is he can't command loyalty among most people.

Now, back to your regularly scheduled program, this article is notably lacking in details about how the supercapacitors are to be technically combined with Li-ion batteries. There's a lot of hand-waving about Industrie 4.0 without any explanation of what it is or what it does. This is very reminiscent of ISO 9000, which if you will note sank without a trace during the first decade of this century.

Ya. I wasn't sure if it was about batteries or a manufacturing schema...
antialias_physorg
4.2 / 5 (5) Mar 03, 2017
The main problem Trump has is he can't command loyalty among most people.

How would he? Competent people command loyalty. If you find someone who continually fails any and all fact checks then that's not the hallmark of a competent person.
TheGhostofOtto1923
3.7 / 5 (3) Mar 03, 2017
And yeah, I came up with all that, all by myself because I am stuck on this boat and am missing Mardi Gras.
BTW ira you sound a little despondent today. Are you feeling a little despondent? Maybe this will pick up you.
https://youtu.be/VL7XS_8qgXM

-Makes me smile-
Uncle Ira
4.2 / 5 (5) Mar 03, 2017
Are you feeling a little despondent?
Non, not me. I am fine and dandy.

Maybe this will pick up you.
https://youtu.be/VL7XS_8qgXM
Yeah, I hear that from the day I was born. I am not a big fan of the Hilly-Bill music but it makes me smile too, thanks for thinking of me.

I like the Cajun traditional music,,,, The Balfa Brothers, BeauSoleil, Rufus Thibodeaux, the Savoy family, Lee Benoit and the such like

I also like the zydeco and Big Sleazy style blues and jazz.
Whydening Gyre
5 / 5 (1) Mar 03, 2017
And yeah, I came up with all that, all by myself because I am stuck on this boat and am missing Mardi Gras.
BTW ira you sound a little despondent today. Are you feeling a little despondent? Maybe this will pick up you.
https://youtu.be/VL7XS_8qgXM

-Makes me smile-

Ghost,
You have a good grasp of the irony in synchronicity...:-)
(and vice versa)
Eikka
not rated yet Mar 09, 2017
-I think that the need for leaders to be empathic is a myth. As heinlein said, you can never trust an honest politician. Their decisions might be subject to fleeting emotions and sympathies.


That's only an issue for, and written from the perspective of other politicians who are expecting their colleagues to behave without a conscience so they can continue to be manipulated by money and power. It's about making sure everyone's on the same page when it comes to abusing their authority against the public.

From the public's point of view, a politician is a representative of the public will and therefore should share the values of those they represent, including their sense of empathy. Of course, if you're representing the special interest of a bunch of banksters then you're expected to be a sociopath.

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