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1DISTRIBUTION A: Approved for public release. Distribution unlimited. 19 October 2011

Air Force Research Laboratory

Integrity Service Excellence

Timothy J. Haugan, Ph.D.

Research Physicist

Propulsion Directorate

Air Force Research Laboratory

Design of SMES

Devices for Air and

Space Applications

12 Oct 2011

2DISTRIBUTION A: Approved for public release. Distribution unlimited.

• D. Latypov, J. V. Holle, BerrieHill Research Corp.

• Acknowledgments: AFRL/RZP Power Division

and Air Force Office of Scientific Research

Authors, Acknowlegements

• Air and Space Applications

- 0.2 MJ for INVENT energy management

- 5-50 MJ for Directed Energy

- 0.2 to 2 GJ for Electric Aircraft power

• SMES Design Criteria and Optimization

- Weight

- Volume

- Energy and Power Densities (mass specific)

- Machine and Lifecycle Cost

- Efficiency (charge/discharge cycle)

- Operability and Logistics

Outline: Introduction

E. Shaffer (Army RDECOM), “Power and Energy Tutorial”, DEPS Nov 2010

Ragone Chart

E. Shaffer (Army RDECOM), Power and Energy Tutorial, DEPS Nov 2010

Ragone Chart

BNL YBCO wireSMES - 30 MJ

SAFT Li Battery 30 MJ (Discharge)

Chevy Volt Li-Battery 38 MJ (Discharge)

(Charge)

~ NbTi or BSCCO wire

(Charge)

Base chart from ASC „10

Ragone Chart

IEEE Power and Energy Magazine, pp. 32-41, jul/august 2009

lower?

Energy Storage Power Ratings

0.2 MJ Systems:

Integrated Vehicle and Energy

Management (INVENT)

0.15 m

More Electric Aircraft

http://www.ece.cmu.edu.pdf

Boeing 787 Electrical Systems

http://www.ece.cmu.edu.pdf

INVENT Energy Management

J. Wells, et al, “Electrical Accumulator Unit for the Energy Optimized Aircraft,” SAE

International Journal of Aerospace, v. 1(1): pp. 1071-1077, 2008

Electrical Accumulator Unit: stores and controls power coming back onto

the bus off of the load

Loads: electromechanical actuators (EMA), electrohydrostatic actuators

(EHA), directed energy weapons (DEW), advanced radar

Power Fluctuations on

Modern Electric Aircraft (MEA)

J. Wells, et al, “Electrical Accumulator Unit for the Energy

Optimized Aircraft,” SAE International Journal of Aerospace,

v. 1(1): pp. 1071-1077, 2008

- Power: Pulsed transients of 150 kW can occur

in about 10 ms

- Regenerative Power: up to 150 kW „waste heat‟

- Duty Cycles: 25-100%

- Switching frequencies: 0-20 kHz

Representative Transient Power Profile

Power back

onto bus

Peak P

pu = power/avg

Power Draw

Avg Load

5 - 50 MJ Systems:

Directed Energy

0.25 m

0.75 m

DEPS 2010 Conference Proceedings , General Atomics AeronauticalDistribution “A”: Approved for public release; Distribution unlimited

Hybrid Power for Laser

Weapons

58 MJ Electrical Energy

500 kW Li Batteries for DE Power

Energy: 58 useable, ~ 200 MJ actual (?)

Discharge time: 30-60 secRecharge Time: 10-15 min

Weight: - Total ~ 500 kgCost: ~ $0.5-1 M (?)

Charge time: 6- 6.5 hrsWeight: ~ 170 kgCost: ~ $13K

37 MJ System*

Li Batteries Chevy Volt

http://gm-volt.com/2010/07/19/chevrolet-volt-battery-warranty-

details-and-clarifications/

* Actual = 58 MJ, however useable = 38 MJ

Brookhaven National Lab

SMES YBCO-wire ~ 30 MJ

• Charge/Discharge Time : 1 sec

• Mass: ~ 250-300 kg dominated by wire;

wire mass could drop ~ 5-10 x with new wire architecture (?)

• Cost: YBCO ~ $2.1M (will reduce < $2M in future)

0.25 m

0.75 m

38 MJ Li-BatteryChevy-Volt

58 MJ Li-BatterySAFT

30 MJ AFRL YBCO-wire SMES

Energy 38 MJ* 58 MJ* 30 MJ

Power 136 kW 500 kW > 30 MW

Charge Time 6-6.5 hrs 10-15 min ~ 1 sec

Discharge Time 280 sec** 30-60 sec ~ 1 sec

Mass 170 kg ~ 500 kg*** ~ 320 kg

# Cycles Lifetime ~ 3000-4000 ~ 30,000 > 200,000 (?)

Efficiency ~ 96 % ~ 98 %

Price (rough) $ 13K ~ $ 0.5-1 M ~ $ 1-2 M

Issues Very long charge time

Fire hazard Withstand g-forces and vibration (?)

* For Li batteries, only useful capacity = ~ 60% of total capacity is shown;

e.g. for Chevy Volt actual capacity = 58 MJ but only 30-90% of the cycle can be used

** Not sure if fire hazard for this discharge rate

** Includes fire suppressant system

Energy Storage Comparison

30-60 MJ Class

BNL YBCO wireSMES - 30 MJ

SAFT Li Battery 30 MJ (Discharge)

Chevy Volt Li-Battery 38 MJ (Discharge)

(Charge)

~ NbTi or BSCCO wire

(Charge)

Base chart from ASC „10

Ragone Chart

0.2 - 2 GJ Systems:

Aircraft Power

Electric-Aircraft: YUNTEC Int. e430

Impacts:

- Flight Efficiency: ↑ 25% or more

- Fuel Cost : ↓ 10x

- Maintenance: only a few parts

- Ownership Cost : extremely low

- Noise: ultra-quiet

- CO2 emission: potentially zero

- Other: vertical lift, distributed, etc..

Specifications Combustion

Engine

(typical)

All-Electric

(glider-style)

Fuel Cost

@ 100 kW

~ $50/hr ~ $3/hr

Motor Efficiency ~ 10-15 %

@ 100 kW

9 gal/hr 90 MJ/hr

Fuel Weight 70 lbs 150-300 lbs

(Li-Polymer)

2 passenger aircrafthttp://yuneeccouk.site.securepod.com/Aircraft. html

4 Passenger Aircraft @ 100 kW

http://www.wired.com/autopia/2011/08/pipistrel-taurus-g4-electric/

http://www.ens-newswire.com/ens/oct2011/2011-10-04-01.html, other…

Electric Aircraft: Pipestrel G4 Taurus

Capacity: 4 passenger

Battery Size: 270 MJ / 2 hr

Battery Weight: ~ 450 lbs per 270 MJ

(one source 1100 lbs)

Battery Type: Li-polymer;

non-insurable fire hazard

Fuel Efficiency: ~100 miles/gallon (!)

Fuel Cost: $3/hr (!)

Other Specifications

Motor: 150 kw

Motor Efficiency: 95% (includes controller)

Drivetrain+Propeller Efficiency: ~ 60-70% ? (gearbox needed)

Total Empty Weight = 1250 lbs (without battery)

Max. Possible Weight: 3300 lbs

NASA $1.35M Winner Green Flight Challenge

Largest prize in aviation history

“EADS VoltAir all-electric aircraft

concept unveiled in Paris”

European Aeronautic Defense and

Space Company N.V. (EADS) –

parent company of Airbus

Battery Size: 20-100 GJ

Electric-Aircraft: EADS VoltAir

http: http://www.earthtechling.com/2011/06/eads-voltair-concept-the-ev-of-the-skies/

http://www.gizmag.com/eads-voltair-electric-airliner/18988

• “VoltAir's two next-generation lithium-air batteries would power

two highly efficient superconducting electric motors…”

• “… as batteries approach and exceed energy densities of 1000

Wh/kg within the next two decades.”

H. D. KIMH. D. KIM

Hybrid-Electric Aircraft:

NASA Subsonic Airliner (~2030)

- Fuel Efficiency: +70%

- Potential World-Market Pull: $400B/yr savings

30 MW Superconductor

Electrical Generator

~ 6 MW Superconductor

Electrical Motor TurboFans

Superconductor

Power Transmission

C.A. Luongo, et al, IEEE Trans. Appl. Supercond. 19(3), 1005 (2009)

SuperconductorApplications Needed

Generators 30-40 MW

Motors 4-6 MW

PowerTransmission Cables

5-70 MW,DC 270V

Power Inverters 1-30 MW

Power Electronics 30-40 MW

Recent NASA contract awards of $12.6M

@ http://www.aeronautics.nasa.gov/nra_awardees_10_06_08.htm

Design Criteria Summary

0.2 MJ INVENT 5-50 MJ Directed Energy

0.2-2 GJ Electric DriveAircraft

High Duty Cycle 10 4 1

AC Loss 10 8 1

High Efficiency 7 8 10

Low Weight/Volume 5 8 10

Operability/Logistics 9 7 6

Cost 7 9 10

Rating Scale: 10 is highest and 1 is low for importance (approximate)

JE vs Applied Field –

km-length Wires @ 4-5K

http://magnet.fsu.edu/~lee/plot/plot.htm

0 5 10 15 20 25 30 35 40 45

Applied Field (T)

YBCO Insert Tape (B|| Tape Plane)

YBCO Insert Tape (B Tape Plane)

MgB2 19Fil 24% Fill (HyperTech)

2212 OI-ST 28% Ceramic Filaments

NbTi LHC Production 38%SC (4.2 K)

Nb3Sn RRP Internal Sn (OI-ST)

Nb3Sn High Sn Bronze Cu:Non-Cu 0.3

YBCO B|| Tape Plane

YBCO B Tape Plane

RRP Nb3Sn

Bronze

Nb3SnMgB2

SuperPower tape

used in record

breaking NHMFL

insert coil 2007

18+1 MgB2/Nb/Cu/Monel

Courtesy M. Tomsic, 2007

427 filament strand with

Ag alloy outer sheath

tested at NHMFL

Maximal JE for

entire LHC NbTi

strand production

(–) CERN-

T. Boutboul '07,

and (- -) <5 T data

from Boutboul et al.

MT-19, IEEE-

TASC’06)

Complied from

ASC'02 and

ICMC'03 papers

(J. Parrell OI-ST)

4543 filament High Sn

Bronze-16wt.%Sn-

0.3wt%Ti (Miyazaki-

MT18-IEEE’04)

SMES Power Density

• Power Density ≤ B2/(2*μo), so YBCO wire can

achieve much higher power densities by

making small magnet coils = 25-30T (?)

• YBCO wire is 5-7x stronger than BSCCO or

LTS, which is needed for high-field magnets.

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