Charging Ultracapacitors

Bram Bruekers & Bart Corstiaans June 17, 2003

Emergency supply with ULTRA CAPACITORS for HF-R ballast

2Philips Lighting, Lighting Electronics, HID Outdoor :

• Introduction• Present emergency ballast• Overall design• Ultra capacitor• Charge converter• Conclusions and

recommendations• Discussion

Length of presentation +/- 50 minutes

• Agenda

• Introduction

• Present emergency ballast

• Overall design

• Ultra capacitor

• Charge converter

• Conclusions and recommendations

• Discussion

Agenda

PDC, Eindhoven


• Philips Lighting• Problem situation• Problem theorem• Project assignment• Project goal• Method of investigation

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

• Problem situation• Ni-Cd batteries are used in the

present emergency ballast. These involve very high costs.

• Checking • Replacing

• Project assignment• Design an emergency ballast

prototype using ultra capacitors

• Problem goal• Investigate if ultra capacitors

can be used for emergency lighting systems. Ultra capacitors have many advantages compared to the currently used batteries, but certainly also disadvantages

• Method of investigation• Study present emergency ballast• Behavior ultra capacitors• Topology• Calculations • Simulations• Implementations• Measurements

Introduction

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion



Agenda

PDC, Eindhoven


• Emergency standards• Schematic• Measurements

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Present emergency ballast

PDC, Eindhoven


Emergency standards• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven

• Dimming light• One or three hour emergency

lighting time• 1 lux at a half meter• Ni-Cd have to be checked and

replaced


Schematic

battery-charger

mainsdetectio

n

communication ballast

batt

ery

pack

DALI

fluorescent lamp

mains 230V~ 50Hz

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven

Present emergency ballast


Measurements• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven




• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Agenda

PDC, Eindhoven


• Specifications• Block diagram

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Overall design

PDC, Eindhoven


Specifications • Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

• Vin = 230Vac at 50-60Hz

• Pin_max 240W

• Charge time about five minutes

• Vout = 400V

• Pout_emergency = 10W

• DALI which provides a dim level for the fluorescent lamp

• EMI friendly

PDC, Eindhoven


Charge Convert

er

UltraCaps

Controller

MainsDetector

+Logic

supply

Mains 230V~ 50Hz

300-400V0…10V

LogicSupply

2 LED outputs

DALI

FlybackConverter

Dim level

on/offon/off

Vcaps

DALI BUS

• Detailed block diagram of the designed emergency ballast

Block diagram• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven

HF-R DALI ballast

EmergencySupply with ultracaps

Mains 230V~ 50Hz Fluorescent

lamp

300- 400V

DALI

• Simplified block diagram of the designedemergency system


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion



Agenda

PDC, Eindhoven


• What is an ultra capacitor?• Equivalent circuit diagram• Calculations• Advantages and disadvantages when using ultra capacitors

• Expectations

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Ultra capacitor

PDC, Eindhoven


What is an ultra capacitor?• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

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• Doubled layer electrolyte capacitor • BCAP0010 2600F & 2.5V

• Very low ESR

-500

0

500

1000

1500

2000

2500

3000

3500

1,00E-02 1,00E-01 1,00E+00 1,00E+01 1,00E+02 1,00E+03

Frequency [Hz]

Ov

erd

rac

ht

[F

]

BCAP0010

0,0000

0,0001

0,0002

0,0003

0,0004

0,0005

0,0006

0,0007

0 0 1 10 100 1000Frequency [Hz]

ES

R [

Oh

m]

•IMAX=600A


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Specs of four ultracaps in series:

•Ltotal = 150nH = Lwire total + 4 ESL

•Ctotal = 650F

Equivalent circuit diagram

PDC, Eindhoven

Specs of one ultracap:

• ESR = 0.7m• C = 2600F• Rleak = 17k


Calculations• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven

E = ½CV2 = ½ 650 102

= 32500Ws = 9Wh

8.2

8.2 Wh 49.2 minutes

t

VCI


Advantages and disadvantages when using ultra capacitors

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

• Advantages:• Emergency time of one hour instead

of three hour• Fast chargeable• On the fly testable• Longer lifetime

PDC, Eindhoven

• Disadvantages:• Expensive • Dimensions


Expectations• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

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• Currently costs € 0.03 per Farad, € 78

Expected costs € 0.01 per Farad, € 26

• Capacity will increase• Currently afwijking per batch is 10%

Expected afwijking per batch is <5%


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

But what if?

PDC, Eindhoven

Vultracapacitors = 10V, Rload = 0.033Ω

I = 10/0.033 = 333A

P = V • I = 10 • 333 = 3330W


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion



Agenda

PDC, Eindhoven


• Specifications• Quasi resonant converter (QRC)

• Transformer• Control• Overall simulations & measurements

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Charge converter

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Specifications

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• Input• Mains in = 230VAC +/- 10% at 50-60Hz• No requirements for mains harmonics

reduction• Galvanically isolated logic on / off input

•Output• Galvanically isolated from mains• IOUT = 24A• VOUT = 0…10V• POUT_max 240W when output voltage is

10V• Maximum on time : 5 minutes• EMI friendly• Output overvoltage protected


• Circuit diagram• Equivalent schematic• Working• Calculations• Simulations• Components

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Quasi resonant converter (QRC)

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

QRC, Circuit diagram

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

QRC, Equivalent schematic

PDC, Eindhoven


0 tx1 T/2 tx2 T Time

I OUT

I

I V_HB’

V_BH’0

tx1 T/2 tx2 T Time

I OUT

I

I V_HB’

V_BH’0

tx1 T/2 tx2 T Time

I OUT

I

I V_HB’

V_BH’0

tx1 T/2 tx2 T Time

I OUT

I

I V_HB’

V_BH’0

tx1 T/2 tx2 T Time

I OUT

I

I V_HB’

V_BH’

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

QRC, principle

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

QRC, calculations

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

QRC, simulations

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• Requirements • Copper foil or litzwire• Transformer with integrated Lr

• Small leakage transformer• Placing Lr at primary side

• Placing Lr at secondary side• Summary

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Transformer

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•Turns-ratio of 8•Lr = 50 uH or Lleakage = 50 uH

•Iprimary = 10 Amppeak-peak

•Iseconday = 90 Amppeak-peak, maximum

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Transformer, Requirements

PDC, Eindhoven


Copper foil or litzwire ?• Agenda

• Introduction


• Overall design

• Ultra capacitor



• DiscussionLitzwire :

- Relatively low current- Litzwires parallel for high

currents- Almost no Skin-effect- different winding layouts

possible

Transformer

Copper foil :- High current- Equalizing currents when parallel - Thin foil to minimize Skin-effect- Special foil needed to create high

leakage

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

3 mm Plastic isolator

Secondary7 mm

9 mm

12.6 mm

PrimaryPQ 35 / 35 core

+ Only one magnetic component needed+ Compact design+ Good galvanically isolation

- Possibly a bigger core size- Locally high temperatures- Special foil needed to create high leakage

Transformer with integrated Lr

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion+ Coresize can be smaller+ Low power dissipation+ Compact design

- External inductor needed

Secondary

Primary

PQ 35 / 35 core

Low leakage transformer

PDC, Eindhoven


Placing Lr at primary side• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion+ Smaller transformer possible

+ Relativly low current through Lr

- Extra magnetic component (PQ 20/16 core)- More volume

Secondary

24 : 3

41.6 uH

7 uH

Primary

Transformer

Transformer

PDC, Eindhoven


Placing Lr at secondary side• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion + Smaller transformer possible

- High current through Lr

- High dissipation- Thick litzwire needed

Secondary

24 : 3

781 nH7 uH

Primary

Transformer

Transformer

PDC, Eindhoven


Summary• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Integrated Lr possible, bigger core or special construction needed.External primary inductor is a good option. Secondary inductor difficult to realize due to high currents.

Transformer

PDC, Eindhoven


• Current feedback• TEA1610 swingchip

• Max/min freqs• Max/min currents

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven

Control


• Simulated schematic• Waveforms

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Simulations

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• Schematic • Waveforms• Performance

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Measurements

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Schematic

PDC, Eindhoven


• Schematic • Waveforms• Performance

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Overall simulations & measurements

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Schematic

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Waveforms

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Output current : 31 down to 15 A Frequency range : 61…206 kHzEfficiency : 90-94% maximum

• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Performance

Charge times: VIN= 240V 5 minutes and 2 secondsVIN= 320V 4 minutes and 32 seconds

VIN= 360V 4 minutes and 24 seconds

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion



Agenda

PDC, Eindhoven


• Possible to charge four ultracaps in series within five minutes

Conclusions andrecommendations• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion



Agenda

PDC, Eindhoven


• Agenda

• Introduction


• Overall design

• Ultra capacitor



• Discussion

Discussion

PDC, Eindhoven

Why don’t you just…..?

What will happen if…..?

What was meant by…..?

Is it possible to…..?

Thank you for your attention!

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