power system headquarters chief engineer tadashi...

© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

October, 2, 2013Power System HeadquartersChief Engineer

Tadashi Gengo

Large Format Industrial Batteries - It's Strategic Use and Development for an environmentally friendly transport system

© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2

Pikes Peak Hill climb Race 2012 / 2013 = EV No.1The team was No. 1 in the EV class competition, No. 5 overall. (9min 46.53sec, No2=10min 21sec)MHI Provides Rechargeable Lithium-ion Batteries for Electric Racing Car, Co-sponsoring Team (Tajima Motor) to Win in US "Race to the Clouds" Hill Climb

Batterymodule

Installation

APEV(Association for the Promotion of EV)

Chairman : Mr.Tajima

The number of members : 180 companiesKey member : MHI, Toyota Motor, Suzuki Motor, etc.

Mr.Tajima is chairman of APEV (Japan)MHI & Tajima cooperate

to promote Conversion EV

Winning Run

2013 10 02

Final Results (Unlimited / Time Attack / Electric classes) – June 30th 2013


Name Class Course Time AverageSpeed

Section 1 Section 2 Section 3 Section 4 Car

①APEV

NobuhiroTajima

Electric 9:46.530 73.654 1:46.281 2:20.368 2:48.194 2:51.687Tajima E-RUNNERPikes Peak Special

MHI MLiX Cells

②Hiroshi

MasuokaElectric 10:21.866 69.468 2:02.289 2:27.419 2:55.514 2:56.644

MitsubishiMiEV Evolution II

③GregTracy

Electric 10:23.649 69.270 2:00.452 2:27.585 2:56.981 2:58.631MitsubishiMiEV Evolution II

④Rod

MillenElectric 10:24.301 69.197 1:49.442 2:30.792 3:02.696 3:01.371

ToyotaTMG EV P002

Timing & Scoring provided by North Country T&S and LiveTiming.net.

2013 10 02

Images & Pikes Peak Course details

© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 42013 10 02


Manufacturer Tajima Motor Corporation

BodyChassis Aluminium Space Frame

Panel Carbon Fiber Composite

Motor GKN EVO eDrive systems Liquid Cooled 2 Motors

Battery Type MHI MLiX Lithium Ion BatterySpecification P140-HP 40Ah

Controls SIM-Drive

Drive TrainType 4WD

Differential Front/Rear : Hydraulic Control

Drive Shaft NTN Constant Velocity Joint

Suspension Type Front/Rear : Double Wishbone

BrakeDisk/Caliper Front/Rear : φ355mm Ventilated/4 pot

Pad Front/Rear : Winmax

Tire&Wheel

Tire Front/Rear : 330/750-20 GiTi Compete GTR1

Wheel Front/Rear : 20x11J HRE Wheels P43S Tajima Special

DimensionsL 5500 x W 1950 x H 1300 mm * Incl. Front/Rear

Wheel Base 2700mm

2013 Monster Sports E-RUNNER Pikes Peak Special

2013 10 02

General Information


7

14 Domestic Production Sites, where manufacturing begins,

for environmental preservation & improved productivity.

Outline of MHI

Total Assets 3,935.0 bill. yen(as of March 31, 2013)



2011 Orders Received & Sales by Business Segment (Consolidated)

Orders Received Sales

Power Systems(inc. Nuclear)

36.2%General

Machinery & Special Vehicles

11.5%

Air Craft &Space

Systems16.5%

Shipbuilding7.4%

Machinery & Steel Structures

20.6%

US$ 42,500mil[J.Yen 80.0/US$]

Others7.9%

Power Systems(inc. Nuclear)

36.7%

Air Craft &Space

Systems16.0%

Shipbuilding8.0%

US$ 37,500mil[J.Yen 80.0/US$]

Others8.7%

Machinery & Steel Structures

17.7%

General Machinery &

Special Vehicles13.0%



1Head OfficeShipbuilding & Ocean Development HeadquartersSteel Structures & Construction HeadquartersPower Systems HeadquartersEngineering HeadquartersNuclear Energy Systems HeadquartersMachinery HeadquartersAerospace Headquarters

Headquarters and Divisions Domestic Offices, Research & Development Centers

Domestic OfficesResearch & Development Centers

MHI Organization in Japan

2 General Machinery & Special Vehicle Headquarters (Sagamihara)3 Air-Conditioning & Refrigeration Systems Headquarters (Nagoya)4 Machine Tool Division (Ritto)

1 Yokohama Dockyard & Machinery Works2 Nagoya Aerospace Systems Works3 Nagoya Guidance & Propulsion Systems Works4 Kobe Shipyard & Machinery Works5 Takasago Machinery Works6 Hiroshima Machinery Works7 Shimonoseki Shipyard & Machinery Works8 Nagasaki Shipyard & Machinery Works9 Mihara Machinery Works10 Sagamihara Machinery Works11 Nagoya Air-Conditioning & Refrigeration Machinery

Works12 Ritto Machinery Works13 Iwatsuka Plant

Works


1

2

3

4

5

1

246

6

7

8

3

9

10

11

12

13

2013 10 02

10

MHI continues worldwide optimal distribution of management resources.

MHI Global Network


11

Energy Aircraft Space Ship & Ocean Transportation

Material HandlingEnvironment

Automotive

Industrial Machinery Infrastructure

Living

Leisure

Power systems

Products Portfolio


12

N. America

30.1%

C&S. America

8.3%

Africa

1.8%

Middle East

3.8%

Asia

36.3%

Europe

17.2%

Oceania

2.5%

Overseas Sales



Contents

0. Introduction

１．The Factory

２．The Cells

３．The Applications

４．The Future

2011: Electric Bus verification2011: Electric Bus verificationMW-class Energy Storage System

Fundamental technology and element R&D

2010 : Field tests for micro-grid in isolated islands*

1988 : R&D with Kyushu Power Electric Co.,Inc

2006 : Field tests for home use

2008 : Field tests for stabilization of PV output

2009 : Field tests for the Eco Sky House* (Yokohama)

Since 2010 : Field tests of 100kW-class ESS for PV power stabilizing

2010 : Launch of the cell production plant

2009 : Domestic lease sale for Hybrid folk lift etc.

MHI lithium-ion battery History

*Eco Sky House ; MHI’s super-power-saving house

* In Kuro-Shima and Take-shima


15

Huge Potential to utilize energy in efficient way.

Forklift

Mobile Stationary

LRT

EV Bus Crane

Mega Storage(Grid Stabilization)

Battery Container

House use

EV

Lithium ion Battery ‘’MLiX’’


16

Lifters

Battery Fork Lifts etc.Wheel Loader etc.

Hybrids

Power train OEM Rail

Transportation Applications

イメージ

Industrial Infra-structure

Construction Machinery

Existing Electric Mover

Image

Small Excavator Systems

EV Buses

Large Excavator Systems


Ship

Conversion EV

AGVs

2013 10 02


1. The FactoryNagasaki Shipyard old establishment

Lithium ion battery verification plant

18

Slit/PressSlurry Making

CuttingComponent AssemblyWelding etcTesting

Printing/Drying TechnolotgyMaterials

Electrode coating

Electrolyte etc.

Charge/ Discharge

Production Process of Lithium Battery

Assembling Technology

To Customer

Fuel Handling Technology



2. The Cell

20

Cell Specification

185Wh Cell

Capacity 50Ah

Voltage 3.7V

EnergyDensity

132Wh/kg266Wh/L

MaxCurrent

100A（Conn.）300A（10sec）

Power(DC resistance)

3360W（SOC50％，25 , 10s）

Size W110×D38×H166.5mm

Weight 1.4kg

Appearance Specification

Application

Storage・Large Scale Storage・Grid Control・Ancillary Service

Transportation・Various Cars・Industrial Machinery

EV, Plug-ins etc. Higher capacity and power cell under way


21

Utilized Cell and Cell Lineup Item

P140P140-Std. (Mass Prod.) P140-HP(Sample) P140-HC(Sample) P060-HP(Sample)

Dimensions mm

Material - NCM/Graphite NCM/Graphite NCM/Graphite NCM/Graphite

Weight kg 1.4 1.4 1.5 0.85

Volume cm3 700 700 700 400

Nominal Ah Ah 50 40 -60 20

Nominal Voltage V 3.7 3.7 3.7 3.7

Nominal Energy Wh 185 148 -222 74

Range of Use V 4.15-2.70 4.15-2.70 4.15-2.70 4.15-2.70

Internal Resistance @25 、10sec mΩ 0.9 0.60 1.2 1.0

Energy DensityWh/L 266 211 309 185

Wh/kg 132 107 144 100

Continuous Current@25 A 100 150 100 100

Max Current@25 、10sec A 300 500 200 300

Self discharge@25 %/M > 2 > 2 > 2 > 2

Cycle Life@25 、0-90% - > 3,500 > 3,500 > 3,500 > 3,500


166.5

11038

166.5

11038

110

132

28

22

Prismatic/Stacked Cylindrical/Winding Prismatic/Winding Prismatic/Winding

Inside element

Merit

Life, ReliabilityLarge capacity designHigh energy densityHigh efficiency packing

ProductivityProductivityLarge capacity designHigh efficiency packing

ProductivityLarge capacity designHigh efficiency packing

Demerit ProductivityLifeCell capacity limited

LifeEnergy density limited

LifeEnergy density limited

Metal caseLaser welding

Life, Reliability ↑, Package design ↑Productivity ↓

Al pouchHeat seal

Cost ↑, High energy density ↑Life, Reliability ↓, Cell capacity ↓

Resin case Life, Reliability ↓, Productivity ↓

MLiX approach (Green zone) : High efficiency assembly line required

Cell Format and Characteristics



Discharge profile @ 25

2.0

2.5

3.0

3.5

4.0

4.5

0 10 20 30 40 50 60

Cell Vo

ltage

/ V

Discharge Capacity / Ah

Discharge performance (25)

0.2C(10A) 0.5C(25A)

1C(50A) 2C(100A)

4C(200A) 6C(300A)

8C(400A)

Charge : 1C‐CC/CV, [4.15V/1A cut]Discharge : CC, [2.70V cut]Ambient : 25

6C Discharge > 95% vs. 0.2C

2013 10 02


2.0

2.5

3.0

3.5

4.0

4.5

0 10 20 30 40 50 60

Cell Vo

ltage

/ V

Discharge Capacity / Ah

Discharge performance (1C)

25 0

‐10 ‐15

‐20

Charge : 1C‐CC/CV, [4.15V/1A cut]Discharge : 1C‐CC, [2.70V cut]Ambient : Charge 25,

Discharge each temp.

Discharge profile @ 1CA

2013 10 02


Charge profile @ 25

0

50

100

150

200

250

300

350

0

10

20

30

40

50

60

0 50 100 150 200 250 300 350

Charging

Current / A

Charge

Cap

acity

/ Ah

Charging Time / min.

Charge performance (25)0.2C(10A) 0.5C(25A)

1C(50A) 2C(100A)

4C(200A) 6C(300A)

Charge : CC/CV, [CC 4.15V,CV 1A]*3hrs Rest before chargeAmbient : 25

2013 10 02

0

20

40

60

80

100

120

0 1000 2000 3000 4000 5000 6000

Recovery Discharge Cap

acity

/ %

Cycle Number

4.15V‐2.70V@25@1C

4.15V‐2.70V@45@1C

Cycle Condition‐Charge : CC/CV, 4.15V/1A cut‐Discharge : CC, 2.7V cut‐Ambient temp. : each temp.Recovery Capacity check‐Charge : 1C‐CC/CV, 4.15V/1A cut‐Discharge : CC, 2.7V cut‐Ambient temp. : 25


Cycle Performance @1C

4.0-2.7V@25@1Ｃ

For 100% to 0% discharge 80% Ah ----- about 4,000 cycle 70% Ah ----- about 5,000 cycle

For 90% to 0% discharge 80% Ah ----- about 5,000 cycle 70% Ah ----- about 6,000 cycle

Improved

2013 10 02


Storage Performance @4.15V

0

20

40

60

80

100

120

0 2 4 6 8 10 12

Recoavery Discharge Cap

acity

/ %

Storage Term / year

4.15V@25

4.15V@60

Storage Condition‐ Charge : 1C‐CC/CV, 4.15V/1A cut‐ Ambient : each temp.Recovery Capacity CHeck‐ Charge : 1C‐CC/CV, 4.15V/1A cut‐ Discharge : 1C‐CC, 2.70V cut‐ Ambient : 25

80% Ah ----- about 8years @ 2570% Ah ----- about 12years @ 25

2013 10 02


３．The Applications


The Vehicles

© 2013MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 30

Testing Facilities

Manufacturing Facilities

ITS Related Products

Powertrain Components

Turbocharger

Air-Conditioning System

Engine ValvesTransmission Parts

Lithium-ion Battery EV/HEV Motor & Inverter

CompressorHVAC Module Wind TunnelVehicle Crash Simulator

Laser Exhaust Gas Analyzer

Electric Injection Molding MachineDry Cut Hobbing Machine

Electronic Toll Collection System

MHI Automotive Related Products

2013 10 02

31

Battery Management System

Battery Management Systems are ready for Vehicle Systems

＜Functions＞

BMU (Battery Management Unit)・ SOC calculation・Watching the input/output current・Communication with Vehicle control system・Communication between BMU-CMU・Auto addressing of CMU

CMU (Cell Monitoring Unit)・Observe battery cells（Over charge / discharge, over heat）・Cell balancing (by BBU circuit)・Communication between BMU-CMU

Alarm ChargerVehicle

controller Maintenance

tool

CMU

CPU

Voltage

Temperature

4cells module

4 cells module

・・・・

4 cells module

BBU

Load

Temperature of the battery box

BMU


Style ：Series ParallelCrane ：ParallelFeatures：Small engine to reduce gas emission

MHI-made lithium-ion battery adoptedMHI-made inverter equipped

Application of car control technology

※calculation of ５t class-car operating 300days, 8hrs/day

GRENDiA EX Hybrid （４～５ton）

CO2 reduction :１４.６ｔ per year※39% higher fuel-efficiency than engine

cars.

Hybrid folk lifts ＆ AGV

Battery module A lighter, smaller than lithium-ion batteries and clean, easy-maintenance unmanned transporter. Due to its quick charge availability and high operational efficiency, it is possible to reduce the number of vehicles.

AGV image

AGV（Automated Guided

Vehicle）

MHI Engine/Battery Hybrid Forklift Trucks were launched on October, 2009

32© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2013 10 02

33

Make the Market “Green”

PV can supply green electricity

Battery Forklift(small)

Hybrid Forklift(small～middle)

Electric Turret

Optimum Application mix can make the market green and economical



Lithium Battery Folk Lift

MHI&Nichiyu developed Lib forklift .

MHI&Nichiyureleased at International

Industrial exhibition

2013 10 02

35

Electric Bus Operation (funded by Japanese Gov. )

Next Field Test will be in Fukuoka

①Great circle route

②Littele circle route

【route】

【Featture of Electric bus】Spec. : Non- step type

Pure electric driven large size route busBattery : Lithium ion battery 60kWhMax output : 160kWPassenger : 65 passengersRange : 30kmCO2 reduction: 50t ／year・car (Compare to conventional diesel bus, run by recyclable energy power)

4～5 km Average route distance for major

domestic public buses

10～15 cars

Quick charge/battery change station

Recharge terminal at Kyoto City Hall Square

【Operation mage】Li-ion Batt (Exchange) (fix at test) Motor

Air cond.Inverter

Li-ion Batt(fix )

【Merit of Electric bus】

① Cost for drive : 1,300k\／Y・car less② CO2reduction : ５０t-CO２／ Y・car less③ Poisonous gas : No emission, low noise, low heat emission

El bus on test

Battery pack

Outline of project

・Feb.2011 Verification operation started, at actual bus route in Kyoto.・March 2011 Verification operation started, at actual route in Aomori

【Field test 】Electric Bus


36

E-Bus in Canada (Demonstration in Year 2012)


Bus is being increased to 3

2013 10 02

Hybrid Crane Development

・Various Crane Manufacturers are developing Hybrids with Diesel Generator

・With MHI 50Ah Cells within SOC30～50% operation of the system was achievable

Example of Hybrid Transfer Crane P140×8cell module ×20 packs・Load 40ton・Max Power 300kW


Large Systems(Could be Secondary Use)

Verification Unit in Nagasaki

39

Supervisory Curcuits （BMU,CMU）

Characteristics•Cell Balancing•Over Charge Check •Over Discharge Check•Over Current Check•Cell Temperature Check•System Temperature Check

If Abnormal Condition

Signal to System and Stop

Check Process

Each Cell Check

CMU(Cell Monitoring Unit)

CPU

Voltage

Temperature

BMU（Battery Management Unit）

Module （4 Cells）

モジュール

・・・・

モジュール

BBU

System

Temperature

Inverter

Input/Output

Module

Module


40

Modularized Design

System Specification

2MW / 500kWh system (15 min. )

Number of container units:- 40ft battery units 2 pc- 40ft PCS unit 1 pc


Fast Charger with Battery

41

5-6 various systems in operation in the world

Example


42

Charging at a Mall

Quick installation of largeScale storage system

PV Panels

PV cable

Pit（high voltage）

Utilizing PV and grid, optimization of “green” and “availability” in a large parking lot could be guaranteed.


43

Example of Specification(older)

Capacity1.5kW （Output）1.8kW （Input）

Duration 8h

Voltage1φ3W AC101/202V

（50/60Hz）

Efficiency 83% (86%)

Size W600×D550×H1625mm

Application Storage for Apartment/Housing etc.

Actual Home of Filed Testing(Eco-Skyhouse@Yokohama)

1.5kW System in the Field(older version)


Module

Rack System

Apartment withPV and Storage System

Possible to utilize PV output or night power whenever necessary.Developing HEMS※ to make the system more efficient.※Home Electric Management SystemFunctionsEmergency Power(Lift、Water Pumps etc.), Renewables Peak Shifting, Overall Power Peak Shifting , Interconnection with Community Management

Capacity 100kW/120kVAVoltage 200VCapacity 34kWh/Rack

Response 20ms（0→100%）

SupplementalP/Q.ControlStand Alone

Size W1150×D750×H2000mm

Regulate frequency by ESS（Area Regulation）

Equip wind farms of 100MW class with storage system.

Load Dispatch Center (LDC)will generate grid control signal based on frequency deviation.

ESS will discharge accordingly.

ESS

60Hz Generation

DemandRenewables

Wind Farm(20MW/15min)

Grid

AGC : Automatic Generation Control

Frequency

Δ f (Hz)

AGC(+MW)

AGC(+MW -MH)

LDCLDC : Load Dispatch Center

Grid Connection for Wind Farm etc.


Wind Integration －Intermittency, Short term fluctuation of PV outputＥＳＳ will reduce the short term fluctuation i.e. Shorter than 20 minutes.In Japan, the allowable fluctuation within 20 minutes is 10% of the Windfarm capacity.Can be utilized on lower voltage grid to reduce load on OLTC（On Load Tap Changer）

Grid Connection for Wind Farm / Solar etc.

Grid B

Grid A

WF 45MW

ESSPLC

6．5MW 15min

16 16.5 17 17.5 18

16 16.5 17 17.5 18

16 16.5 17 17.5 18

Renewables


PV

Transmission Congestion Relief

An automatic management system will keep the congestion within hadware limits of the Grid.

If congestion in the grid is experienced, ESS will absorb electricity

If the ESS can not fully absorb the electricity, the generators have to be stopped.So, with the ESS, the generators will experience less stops doe to congestion.

Renewables Heavy Grid

Grid B

6MW+19.6MW

Network MngmntDisp

2MW 15min

Emergency DG16MW

ESS

Control Signal(+MW,-MW)

Grid A Demand8-31MW

Control Signal（-MW)

GT 10MW

Wind


PLC

47

PV System（Isahaya）

View (at Factory)

Application Renewables Output Smoothening

商用電源

系統連系

スイッチ

～

―

―～

―～

―

―

―

―

―

―

―

―～

―

～

―

負荷

太陽光発電

10kW 10kW 10kW

Contact

Grid

100kW PV

PVOutput

Output

100kW Load

100 kWStorage

Lithium Battery SystemOutput

NEDO has been developing since 2006 Lithium ion battery storage systems for Grid use. MHI is collaborating since September, 2010 on the smoothing of PV output which is one of the rather fluctuating power sources.

© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.2013 10 02

48

-PV

-PV + ESS

-Target of Smoothing

Out

put P

ower

(kW

)

Time (hour)

Field Test for Grid Stabilization detail (1)


49

Energy Storage System2MW

System

40ft ×3

1MWSystem

40ft ×1 20ft ×1

0.5MWSystem

40ft ×1

1MW System

＊This system can output active and reactive power on demand.

Configuration

System Operation (initial condition)

-2MW system-1MW system-0.5MW system

Output (kW)

Out

put d

urat

ion

(min

)

Specification

0.5 MW System 1 MW System 2 MW SystemOutput Capacity 0.5 MW 1 MW 2 MWStorage Capacity 204kWh 408kWh 816kWh

Operating Capacity 162kWh 324kWh 648kWhVoltage AC 300 V

Frequency 50/60 HzAmbient Temperature -20 - 40

Dimension 40 ft 12,192x2,438x2,896 12,192x2,438x2,896 12,192x2,438x2,89620 ft 6,096x2,438x2,896

Configuration 40 ft x 1 40 ft x 1, 20 ft x 1 40 ft x 3Weight approx,. 22t approx,. 22tx1, 12tx1 approx,. 22tx2, 16tx1

· Initial Condition· Transformer is scope of customer· Dimension do not include door knobs etc.· HVAC will be selected based on ambient condition· Weight is just estimate·



4. The Future

51

Toyota・Energy Management （Housing）

・Eco-housing（ＨＥＭＳ）

・ＥＶ Charging・ＥＶＶ２Ｈ

Yokohama・Energy Management（Building）

・Eco-Housing（ＢＥＭＳ)・ＥＶ Charging

METI-NEDO area level implimentation

Keihanna(MHI is involved)・Energy Management (community)・Eco-housing・EV Charging・EV Bus

Japan is leading the world with innovations

Kita-Kyushu(MHI is involved)・Smart Meters・Energy Management (industrial)・ＨＥＭＳ、ＢＥＭＳ

2013 10 02© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

522012 07 04

52

Products relating to Smart Grid City

SVC

SVRBTB

BTB

BTB

Products Supply Side

Demand side

LRT EV BUS EV

Energy ManagementCommunity/Building / Residential

Wind Turbine

Nuclear

IGCCPower Generation

for base load

CSP Hydro ESS

Peak GTMiddle/Peak Generation

GTCCGas Engine

Charging StationQuick Charging Station

Heat Pump ESS for Residential

Control Center（Arbitrage）

Energy Storage System for CommunityData gathering Smart meter

Renewable Energy

ITSゲート

ITSControl Center

3G

HEMS / BEMS

Geothermal

Transportation &

Energy Infrastructure

SVR

52

532012 07 04

Clean Energy City with Energy Storage

Containerized SystemsConterized Systems

Battery ForkliftsHybrid Forklifts

Elecgtricty supply ship

House En ergy Management

Energy Management System

Event Area

Commercial Area

pier

Market

Construction Area

Off shore

No idling of ships in harbour

EV, Hybrid Cranes

For Markets

For Events

For Houses

For Harbours

For

Buldings

For construction sites

Energy Storage will make the environment clean


Li-ion Battery Life Cycle use Image


A: Initial Value for e-Mobile Use

B: 2nd Value for Energy Storage System Use

C : Residual Value for Scrap

D : Value of Recycled MaterialCell Manufacturer

Management CenterLease & Service JV

(Future)

Scrap & Recycle

• Lithium Battery is a winning technology among all battery for both e-mobile & energy storage use

• “Life Time Cycle Business” will be a key for clean and sustainable community

Life Time Cycle Business = Business to utilize all values (A+B+C+D) from a Battery

Li-Battery Energy Storage System

Electric Vehicles

2013 10 02

552012 07 04

Thank you very much for your attention!

power system headquarters chief engineer tadashi...

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