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Electrochemical Double Layered Capacitor Development and Implementation System

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Electrochemical Double Layered Capacitor Development and Implementation System Electrochemical Double Layered Capacitor Development and Implementation System By Gavin P. Strunk Submitted to the graduate degree program in Department of Mechanical Engineering and the Graduate Faculty to the University of Kansas in parital fulfillment of the requirements for the degree of Doctor of Philosophy. ______________________________________ Dr. Terry N. Faddis, Chair ______________________________________ Dr. Carl Luchies, Committee Member ______________________________________ Dr. James Miller, Committee Member ______________________________________ Dr. Sara Wilson, Committee Member ______________________________________ Dr. Xinmai Yang, Committee Member Date Defended: The Dissertation Committee for Gavin P. Strunk certifies that this is the approved version of the following dissertation: Electrochemical Double Layered Capacitor Development and Implementation System ______________________________________ Dr. Terry N. Faddis, Chair ______________________________________ Dr. Carl Luchies, Committee Member ______________________________________ Dr. James Miller, Committee Member ______________________________________ Dr. Sara Wilson, Committee Member ______________________________________ Dr. Xinmai Yang, Committee Member Date Approved: ii ABSTRACT Electrochemical Double Layered Capacitors (EDLC’s) are becoming a more popular topic of research for hybrid power systems, especially vehicles. They are known for their high power density, high cycle life, low internal resistance, and wider operating temperature compared to batteries. They are rarely used as a standalone power source; however, because of their lack of energy density compared to batteries and fuel cells. Researchers are now discovering the benefits of using them in hybrid systems. The increased complexity of a hybrid power source presents many challenges. A major drawback of this complexity is the lack of design tools to assist a designer in translating a simulation all the way to a full scale implementation. A full spectrum of tools was designed to assist designers at all stages of implementation including: single cell testing, a multi-cell management system, and a full scale vehicle data acquisition system to monitor performance. First, the full scale vehicle data acquisition is described. The system is isolated from the electric shuttle bus it was tested on to allow the system to be ported to other vehicles and applications. This was done to modularize the system to characterize a wide variety of full scale applications. Next, a single cell test system was designed that allows the designer to characterize cell specifications, as well as, test control and safety systems in a controlled environment. The goal is to ensure safety systems can be thoroughly tested to ensure robustness as the bank is scaled up. This system also includes simulation models that provide examples of using the simulation to predict the behavior of a cell and the test system to validate the results of the simulation. This information is then used by the designer to more effectively design sensor ranges for the bank. iii Finally, a multi-cell EDLC management system was designed to implement a bank. It incorporates 12 series EDLC cells per control module, and the modular design allows expandability in parallel and series to fit any application and number of cells required. Lastly, test procedures were run to validate the proper operation of the systems. iv ACKOWLEDGEMENTS I would like to extend a special thanks to my graduate advisor, Dr. Terry N. Faddis, for his guidance and support during this research. He has truly given me an unmeasurable amount of valuable experience and knowledge. I would also like to thank my committee members, Dr. Carl Luchies, Dr. James Miller, Dr. Sara Wilson, and Dr. Xinmai Yang. They have all given excellent advice and support throughout my time at the University of Kansas. Next, I would like to thank the University of Kansas Transportation Research Institute and the University of Kansas Medical Center for providing me with funding for my research. Finally, I would like to thank my family and friends whose support has been vital to my success. I would like to give special thanks to my parents, Richard and Benita, for their advice, support, and encouragement. To my sister Sara, your support was also very much appreciated. Thanks. v TABLE OF CONTENTS LIST OF FIGURES ..................................................................................................................... viii NOMENCLATURE ........................................................................................................................x 1. INTRODUCTION .....................................................................................................................1 1.1. Hybrid Electric Vehicles and Control ............................................................................1 1.2. Current Power Sources ..................................................................................................3 1.3. Problem Identification ...................................................................................................5 1.4. Research Objective ........................................................................................................6 1.5. Future Impact .................................................................................................................8 1.6. References ......................................................................................................................8 2. ELECTRIC SHUTTLE BUS DATA ACQUISITION RETROFIT ........................................11 2.1. Introduction ..................................................................................................................11 2.2. Design Requirements ...................................................................................................12 2.3. Data Acquisition System..............................................................................................13 2.4. Sensor Selection ...........................................................................................................19 2.5. Software .......................................................................................................................21 2.6. Test Procedures ............................................................................................................24 2.7. Results ..........................................................................................................................25 2.8. Conclusion ...................................................................................................................35 2.9. Recommendations ........................................................................................................36 2.10. References ....................................................................................................................37 3. EDLC TEST SYSTEM ............................................................................................................38 3.1. Introduction ..................................................................................................................38 3.2. EDLC Properties ..........................................................................................................40 3.2.1. EDLC Voltage .........................................................................................................40 3.2.2. EDLC Current .........................................................................................................41 3.2.3. EDLC Temperature .................................................................................................42 3.3. Simulation ....................................................................................................................43 3.3.1. Constant Voltage Model ..........................................................................................43 3.3.2. Constant Current Model ..........................................................................................47 3.4. Physical Test System ...................................................................................................50 3.4.1. Hardware Configuration ..........................................................................................50 3.4.2. Software Configuration ...........................................................................................52 3.4.3. Measurements ..........................................................................................................54 3.4.4. Programmable Load ................................................................................................55 3.5. Results ..........................................................................................................................58 3.6. Conclusion ...................................................................................................................62 3.7. References ....................................................................................................................65 4. EDLC MANAGEMENT SYSTEM ........................................................................................66 4.1. Introduction ..................................................................................................................66 vi 4.2. Hardware System .........................................................................................................68 4.3. Software System ..........................................................................................................73
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