DEVELOPMENT OF AN INTEGRATED HIGH ENERGY DENSITY CAPTURE AND STORAGE SYSTEM FOR ULTRAFAST SUPPLY/EXTENDED ENERGY CONSUMPTION APPLICATIONS DRAGOS DINCA Bachelor of Science in Electrical Engineering Cleveland State University May 2004 Master of Science in Electrical Engineering Cleveland State University December 2006 submitted in partial fulfillment of requirements for the degree DOCTOR OF ENGINEERING at the CLEVELAND STATE UNIVERSITY May 2017 We hereby approve the dissertation of Dragos Dinca Candidate for the Doctor of Engineering degree. This dissertation has been approved for the specialization of Electrical and Computer Engineering and CLEVELAND STATE UNIVERSITY’S College of Graduate Studies by Hanz Richter, Dissertation Committee Chairperson – Department & Date Taysir H. Nayfeh, Dissertation Committee Member – Department & Date Lili Dong, Dissertation Committee Member – Department & Date Majid Rashidi, Dissertation Committee Member – Department & Date Petru S. Fodor, Dissertation Committee Member – Department & Date April 27, 2017 Student’s Date of Defense This student has fulfilled all requirements for the Doctor of Engineering degree. Chandrasekhar Kothapalli, Doctoral Program Director This accomplishment is dedicated to my family. ACKNOWLEDGEMENTS I would like to thank my adviser, Dr. Hanz Richter, for his guidance, advice, and support which helped me complete the work of this dissertation. Thanks to Dr. Taysir Nayfeh, for the opportunity to work at the Industrial Space Systems Laboratory (ISSL). The technical experience and business acumen gained at the ISSL shaped my professional career. I would like to thank the dissertation committee members for their service and guidance: Dr. Lili Dong, Dr. Majid Rashidi, and Dr. Petru Fodor. Thanks to the colleagues at the NASA Glenn Research Center for their support: Bob Scheidegger, Carol Tolbert, Tony Baez, Ray Beach, Jim Soeder, and Fred Wolf. I would like to thank Dr. Daniel Raible for his guidance during this academic endeavor. I would like to thank my colleagues at the ISSL for their camaraderie: David Avanesian, Tom DePietro, Harry Olar, Andrew Jalics, Nick Tollis, Anita Wiederholt, Ishu Pradhan, Brian Fast, Sagar Gadkari, Amanda Beach, Scott Darpel, Maciej Zborowski, and Michael Wyban. Special thanks to my wife, Ioana, for her unconditional love. And thanks to my brother, Daniel, and uncle, Victor, for believing in me. My deepest appreciation goes to my parents, Viorica and Teofil, for their courage and sacrifice to offer our family better opportunities in a new world. Most of all, I would like to thank God for all blessings. DEVELOPMENT OF AN INTEGRATED HIGH ENERGY DENSITY CAPTURE AND STORAGE SYSTEM FOR ULTRAFAST SUPPLY/EXTENDED ENERGY CONSUMPTION APPLICATIONS DRAGOS DINCA ABSTRACT High Intensity Laser Power Beaming is a wireless power transmission technology developed at the Industrial Space Systems Laboratory from 2005 through 2010, in collaboration with the Air Force Research Laboratory to enable remote optical ‘refueling’ of airborne electric micro unmanned air vehicles. Continuous tracking of these air vehicles with high intensity lasers while in-flight for tens of minutes to recharge the on-board battery system is not operationally practical; hence the recharge time must be minimized. This dissertation presents the development and system design optimization of a hybrid electrical energy storage system as a solution to this practical limitation. The solution is based on the development of a high energy density integrated system to capture and store pulsed energy. The system makes use of ultracapacitors to capture the energy at rapid charge rates, while lithium-ion batteries provide the long-term energy density, in order to maximize the duration of operations and minimize the mass requirements. A design tool employing a genetic algorithm v global optimizer was developed to select the front-end ultracapacitor elements. The simulation model and results demonstrate the feasibility of the solution. The hybrid energy storage system is also optimized at the system-level for maximum end-to-end power transfer efficiency. System response optimization results and corresponding sensitivity analysis results are presented. Lastly, the ultrafast supply/extended energy storage system is generalized for other applications such as high-power commercial, industrial, and aerospace applications. vi TABLE OF CONTENTS Page ABSTRACT ....................................................................................................................... v LIST OF TABLES .......................................................................................................... xii LIST OF FIGURES ....................................................................................................... xiii NOMENCLATURE ....................................................................................................... xxi CHAPTER I. INTRODUCTION ..................................................................................................... 1 1.1 Dissertation Contributions and Organization .............................................. 7 II. BACKGROUND: HIGH INTENSITY LASER POWER BEAMING ................ 9 2.1 Wireless Power Transmission ................................................................... 10 2.2 HILPB Enabling Technologies ................................................................. 17 2.2.1 High Intensity VMJ Photovoltaic Cells ........................................ 18 2.2.2 High Intensity Lasers .................................................................... 21 2.2.3 Directed Energy Systems .............................................................. 22 2.2.4 HILPB Power Receiver ................................................................. 27 2.3 HILPB: Author’s Contribution and Technology Status............................ 29 2.3.1 HILPB Experimental Results – Optimal Operating Laser Wavelength ............................................................................................... 29 vii 2.3.2 High Power Laser Laboratory at CSU’s ISSL .............................. 34 2.3.3 Current Status of the HILPB Technology ..................................... 36 III. ULTRAFAST ENERGY CAPTURE & HIGH ENERGY DENSITY SYSTEM .......................................................................................................................... 40 3.1 Electrical Energy Storage ......................................................................... 41 3.1.1 Battery Energy Storage ................................................................. 46 3.1.2 Ultracapacitor Energy Storage ...................................................... 50 3.2 Problem Definition, Objective, and Scope ............................................... 55 3.2.1 The Solution: Hybrid Energy Storage System .............................. 55 3.3 Literature Review...................................................................................... 57 3.3.1 Hybrid Battery-Ultracapacitor ESS in the Transportation Industry ..................................................................................................... 58 3.3.2 Hybrid Battery-Ultracapacitor ESS in the Power Grid Industry ... 63 3.3.3 Ultracapacitor Applications........................................................... 66 3.3.4 Summary of Findings and Conclusion .......................................... 67 IV. POWER SYSTEM DESIGN AND DEVELOPMENT IN SUPPORT OF HILPB .............................................................................................................................. 71 4.1 1st Generation HILPB End-to-End Power System .................................... 71 4.2 2nd Generation HILPB End-to-End Power System ................................... 79 4.3 Power Management and Distribution for the FQM-151A Aircraft .......... 85 viii 4.3.1 Battery Charging and Control Subsystem ..................................... 87 4.3.2 Control and Data Handling Subsystem ......................................... 89 4.3.3 Integration into the FQM-151A Pointer Aircraft .......................... 91 V. SYSTEM MODELING, SIMULATON, AND DESIGN OPTIMIZATION .... 94 5.1 Requirement Definition for the Energy Storage System On-Board the MUAV .................................................................................................................. 95 5.2 Development of an Optimization Routine for the Energy Capture Elements .............................................................................................................. 101 5.2.1 Objective Function Derivation .................................................... 101 5.2.2 Formulating the Objective Function ........................................... 108 5.2.3 Implementation of the Optimization Routine.............................. 111 5.2.4 Optimization Results using Genetic Algorithms ......................... 113 5.3 Model Development, Simulation, and Duty Cycle Optimization ........... 117 5.3.1 Simulation Environment and Component Models ...................... 117 5.3.2 Modeling and Simulation Results ............................................... 120 5.3.3 Intermittent Optical Energy Transmission: Duty Cycle Optimization ........................................................................................... 125 5.4 System Optimization for Maximum End-to-End Power Transfer Efficiency ............................................................................................................ 133 5.4.1 System Design Optimization ......................................................