Battery Manufacturing Research

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Gerard Adams
5 years ago
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1 Battery Manufacturing Research Date: October 17, 2012 Project title: Battery Manufacturing Research Amount requested: $2,000 Proposal author: Isaac Thompson Contact info: Academic department, year in school, undergraduate or graduate standing: Electrical Engineering, 1 st year Graduate School Sustainability themes Energy Transportation Purchasing Waste Management Sustainable Design Education and Curriculum Project summary This is a continuation of a battery project, which I have been a part of for 3 years now. The goal of this project is to enable the construction of larger batteries for future research. We have fabricated lithium iron phosphate batteries utilizing available equipment on UAF campus. In the past we utilized the Advanced Materials Group and Mechanical Engineering laboratories and equipment to make several 0.10 Amp hour rechargeable batteries. These batteries can be used for electric vehicles, unmanned aircraft projects, and storage systems for alternative energy systems. Utube of PI on machines: SAE Zero Emissions team tops Clean Snowmobile Challenge, earns NSF invite to Greenland sae- clean- snowmobile- challenge.aspx Project description The value to students is that we are currently purchasing batteries. If we can start a process of making them locally they will become less expensive and more widely used than unsafe lead acid batteries. The welder requested is the last piece of equipment needed to allow local fabrication of batteries. It can bond dissimilar layers of material (Aluminum and Copper) together to produce tabs for connecting the battery modules is superior to anything else available for the laboratory market. Once this is received the team will be capable of producing batteries locally. This project came about because of several projects currently taking place on campus. We are currently using many rechargeable batteries and we are seeking ways to make those projects more sustainable. The major goal is to create batteries for use. We can make small batteries that can be used on small devices. We can also gang these smaller batteries to make larger vehicle batteries that can be used in Unmanned Aircraft, Snowmobiles and smaller electric vehicles. The total cost for this item with shipping is $15,050. This will compliment the roughly $40,000 we have already put into this project. The remaining $13,050 will come partly from Greg Walker and partly from another grant, which I have received previously. Page 1 of 6

2 Once we start manufacturing the batteries we will have a better idea of how much savings will occur for the student competition usage. However, we also would like to make specially sized batteries that would fit the aircraft s internal structure. We also have the potential to experiment on making a battery, which is three times as energy dense than what is commercially available. Project value We believe this is good use of the SIREN fee money because it: (i) Allows cutting edge research to happen at UAF, (ii) Provides for better performance in student design competitions, which in turn (iii) Has the potential to advertise the school to future students, and (iv) Makes the degree more valuable and sought after by future employers. (v) Reduces carbon emissions on campus and in Alaska. (vi) On- site manufacture of cutting- edge batteries has great economic benefit (vii) This project could be turned into an Alaskan- based business (viii) Aims to make battery electric vehicles an option in the arctic environment We plan to reduce carbon with results from this research project. Locally manufacturing batteries will reduce transportation carbon costs. Use of more battery vehicles will reduce carbon as well. Many students will utilize the batteries on campus. Carbon reduction and cost savings can be calculated once we start making batteries. Implementation plan Date What will be done Responsible person RISE funds Nov- Dec 2012 Order and receive the PI $2,000 MSK 800 Jan-Feb 2013 Fabrication of batteries PI Mar-Apr 2013 Battery Testing PI May-June 2013 Continue Fabrication PI with different chemistries July 2013 Prepare final report PI Outreach Plan What outreach Venue Date Who will do it Article about Sun star Mid Feb Will contact Sun Page 2 of 6

3 project Public Service Announcement PSA Radio program Battery Vehicle Unmanned Aircraft using battery Cornerstone, Sun star, radio Mid Apr star staff PI KSUA, KUAC, KIAK May PI Snowmobile, March, April PI EcoMarathon Poker Flat March Advisor: Greg Walker Budget Item Cost MSK 800 Desk- Top Ultrasonic Metal Welder, 40KHz, 110V $14,300 Shipping $750 Total cost $15,050 Match, Gregory Walker, grant source $8,452 Previous funding. $4,598 Total Requested from RISE Fall 2012 $2,000 Budget justification We request funding to purchase a welder for battery manufacturing. Match funding for this equipment has been secured from Dr. Gregory Walker s UAV project ($8452). Obtaining this welder will allow us to weld up to 25 sheets of anode or cathode plates that make up the battery. Other means of welding is too harsh on the materials. Having this piece of equipment will allow us to make batteries with more internal plates and make the batteries more reliable. We are purchasing directly from the manufacturer. Two US importers want 18,000 or 19,995 for this same equipment. We currently have two battery sealers, a coating machine and a glove box to make the batteries. Qualification & Experience I am an Engineering graduate studying battery management systems at UAF. Previously, I competed in the clean snowmobile challenge and then traveled with the machine to Greenland. As part of the battery and snowmobile project, I am interested in being able to build my own batteries, so that I am not limited to form factors that are available off the shelf. I worked with Craig McKenzie and Amanda Mertes at the advanced materials group under a previous grant to design and build our own lithium iron phosphate cells. We were able to able to build simple cells of a single layer, although the sealing machine that we had access to wasn t capable of making a perfect seal, so the batteries did not last very long. In order to increase the practicality of the cells we are building and testing, we have purchased a vacuum- sealing machine, which allows us to seal the batteries securely. Page 3 of 6

4 My graduate thesis is on battery management systems, and I believe that this will be very useful in the design and build of new battery form factors. In addition to academic work, I have been involved in many other electric vehicle projects, including 2 years at the clean snowmobile challenge and two years at Shell Eco Marathon. Senator Mark Begich recently congratulated us, saying, two of the most important challenges facing Alaska, and the country as a whole, are how much and which types of energy we consume. Young engineers like you are just the innovators who will design the efficient technologies of the future. Technical advisers and collaborators Gregory W. Walker, Director, Unmanned Aircraft Program, (907) , Gregory.Walker@gi.alaska.edu. He has given us resources and support for this project to finally come a reality. Page 4 of 6

Attachments: Here are screen shots of the welder

Thursday, September 08, 2012 2:30 PM Subject: MSK

5 Attachments: Here are screen shots of the welder that is available from the USA importers. And an quote from Joy Zhang Original Message From:Joy Zhang Sent: Thursday, September 08, :30 PM Subject: MSK 800 Please check our FOB prices: MSK USD14,300/set Page 5 of 6

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