Arbin Instruments

High Precision Battery Test Equipment

+1 (979) 690 2751
sales@arbin.com
Request a Quote
Menu
News

Power Tools: What’s the difference between power and energy?

When it comes to batteries, often times energy and power density are thought to be one and the same - a battery with high energy density would be a powerful battery as well. In fact, energy density and power density are very different things. Energy density relates to the amount of energy that can be stored per battery unit whereas power density relates to the maximum amount of energy that can be discharged per battery unit. Although energy density is the more commonly used measurement to determine battery performance, power density is still an important metric to consider when talking about energy systems. Understanding the relationship between these two things is essential as it helps in determining what type of battery is necessary for different products. 

Energy Density vs Power Density

*https://www.tecategroup.com/products/ultracapacitors/ultracapacitor-FAQ.php

Essentially, the main difference between energy density and power density is that batteries with a higher energy density will be able to store larger amounts of energy, while batteries with a higher power density will be able to release higher amounts of energy a lot quicker. Depending on the type of tool being energized, varying degrees of energy density and power density will be required. Take a mobile phone, for instance, phones do not need enormous amounts of energy to stay functional, instead, they need energy to be discharged consistently over extended periods of time. This means they mainly need batteries with a high energy density. On the other hand, power tools such as jigsaws and circular saws, need batteries that can release a lot of energy in one go but at the same time require the battery to have a big gas tank, which means that batteries used to energize power tools need be high in both energy and power density. 

When testing batteries of power tools, they cannot be evaluated through the same means as phone batteries, as the nature of how these products are used are completely different. Phones are used at a relatively consistent rate and thus go through relatively consistent charge and discharge cycles: Your phone is left on and used throughout the day, it is then charged at night and the cycle is repeated again day after day. Power tools on the other hand, are often not used in regular patterns like phones are and instead are used in short bursts of high power output, making their discharge cycles a lot more sporadic and unpredictable. Thus, where phones can be tested through traditional battery cycling methods which track constant current and constant voltage charge and discharge profiles, a more dynamic system must be adopted when testing batteries for power tools which take into account the many variables that may come into play when testing these types of products. 

Dynamic Cycling

Other technologies also have more dynamic discharge cycles; batteries for electric vehicles is one such example. Test equipment, like Arbin’s, should be able to test irregular charge and discharge cycles. This allows power tools or EV batteries to be tested in real life scenarios. Arbin’s equipment is guaranteed to give accurate and true to life simulations no matter the type of product that is being tested. Using true bipolar circuitry, our test systems feature cross-zero linearity and zero switching time between charge and discharge which is crucial in being able to test batteries more dynamically and precisely. 

Looking at what dynamic cycles would mean for EVs, EV drive cycles have instantaneous transitions between accelerating up a hill, to regenerative braking when going down; braking at a stoplight that slightly generates battery charge to accelerating when it turns green, requiring a lot of power. 

Likewise, power tools must run at a constant rate, like a drill spinning, but then suddenly be able to continue when faced with resistance --  like when pressed into concrete or a dense wood to drill a hole. This discharge profile has large, but relatively brief periods of high power output and still needs to last several hours of this type of repeated operation.

With over 90 pre-defined meta variables and a dozen custom ones available to users, our testing systems can be fully defined and customized to provide as accurate simulations of battery usage as possible. Arbin’s “Simulation” software feature also provides an intuitive interface which allows you to directly upload your data profile into the program to simulate without any additional programming needed. 

Conclusion

The performance of a power tool is just as good as the battery it holds, therefore it is crucial that power tools are fitted with batteries that can provide the necessary performance according to the given function the tool is meant to fulfill. At Arbin, not only are we able to provide a battery testing system that is consistently accurate, our systems are the most responsive to simulating very dynamic battery life cycles, which is key to properly re-producing the unique real-world test profiles of power tools, electric vehicles, and other applications that need more that constant current.

 

Where are the electric planes and ships?

There is often much discussion around electric transportation replacing carbon-emitting vehicles but it is more often than not limited to road transportation such as motorcycles, passenger cars, buses, and trucks in mainstream conversations. Aircrafts and ships are usually not part of the conversation. However, when discussing strategies to reduce CO2 emissions from transportation, it is also important to factor in the aviation and shipping industries. The two sectors make up 2.4% and 2.5% of global CO2 emissions, respectively, and thus are not to be overlooked.

Due to the size and capacity of planes and ships, as well as how they are used, electrifying large vessels is not as easy as doing the same for cars or buses. The energy demand and thus battery capacity needed is much greater and battery technology has yet to reach a place where it can efficiently, both technologically and financially, replace conventional planes and ships. Despite the difficulties, various companies and organizations are currently developing and testing electric aircrafts and ships. There are both smaller fully electric vessels, and hybrid versions being tested for short-range travel, the first step into taking air and maritime travel closer to becoming fully electric.

The benefits of going electric

As with electric cars and buses, the benefits of going electric in air and maritime travel are numerous. The biggest reasons and often the most compelling factors are the environmental and health benefits. As previously mentioned, together they make up almost 5% of global carbon emissions. Reducing the impact of these industries on climate change is significant. Pollutants like nitrogen oxide from planes and sulphur from ships also lead to many adverse health risks and consequences. Reports have stated that pollutants from plane emissions have led to around 16,000 premature deaths every year. Other reports have found that shipping causes around 400,000 premature deaths due to lung cancer and cardiovascular diseases and around 14 million childhood asthma cases annually. Eliminating the need for fuel all together by electrifying planes and ships can greatly reduce the release of these harmful pollutants into the environment.

Planes and ships also contribute heavily to noise pollution. High levels of noise can also adversely affect human health leading to an increase in stress and cardiovascular diseases. It can also affect the delicate natural balance in wildlife by interfering with communication between animals. Some countries like the United Kingdom and Germany have introduced flight bans at night to reduce the effect of excess noise on communities around airports. As electric engines are much quieter than jet and diesel engines, going electric can alleviate these issues.

Looking beyond the environmental and health advantages of electric planes and ships, going electric can also be more cost efficient. Jet fuel is one of the biggest operating costs of airplanes. With the advent of renewable energy, the cost of electric energy will continue to decrease. Moreover, with fewer parts, electric engines are much easier to service than conventional engines. Together, these effectively reduce costs by at least 40% with lower maintenance and energy costs.

Why are electric planes and ships not yet mainstream?

One of the biggest reasons why we have yet to see electric ships and planes is the battery. Currently, batteries only store 1/40th of the energy content of the equal weight of jet fuel, taking it only 1/20th of the distance. Moreover, as fuel is consumed, the weight of the plane or ship decreases, burning less fuel at the same speed over time. However, the weight of batteries will not reduce as its energy is drained, thus requiring a consistent release of energy throughout the entire trip. 

The issue of charging is another huge question with larger vessels. While small planes and boats can land and quickly recharge after short trips, the option is not present during long-distance trips. Larger vessels with larger batteries would also take a long time to charge. In order to guarantee enough energy for a long-range trip, aircrafts and vessels would either have to carry more or larger batteries, or be able to generate energy onboard with renewable energy technology.

From the perspective of regulation, it’s difficult to standardize safety measures and requirements as air and maritime travelling involves cross-border cooperation. This is one reason why aviation and shipping industries are not often discussed in national climate plans. However, private players and companies are working to help these industries take the next step. 

Where are we now and what’s next?

As it was with cars and buses, the first step to electric planes and ships are hybrid models.  Companies like Ampair, an LA-based clean tech company, have created hybrid-electric aircrafts for short-range flights. The Ampaire 337 plane is a six-seater Cessna 337 Skymaster, retrofitted with an electric propulsion system, replacing one of the two combustion engines with a battery-powered electric motor. 

Private aircraft producer Pipstrel is one of the few companies that currently produce all-electric battery powered planes. Because of battery limitations, they are used mainly as training or light sport aircrafts. Until battery technology can catch up to the efficiency of jet fuel, it is likely that hybrid and all-electric planes will be limited to small, regional aircrafts. 

In maritime travel, Nowegian explorer cruise line, Hurtigruten, launched the first hybrid electric-powered expedition ship. The ship collects excess and unneeded energy from the engines and stores them in the batteries. When the engine needs extra energy, it would be drawn from the batteries. The ship is also able to run on battery power alone for limited periods. All in all, the batteries allow the engines to operate at optimum levels, reduces energy waste, and lowers carbon emissions by 20%.

Japanese corporations are also hoping to launch the first all-electric propulsion cargo ship by 2021. If they are successful in developing an efficient cargo ship, it would be ground breaking in reducing the amount of emissions from the shipping industry.

Demands on the battery are greater than ever before. As the sense of urgency increases, the hope of greener technology leans on battery development. Having safe and efficient battery testing equipment greatly enhances the research and development processes. Moreover, with larger vessels like planes and ships, so much more is at stake if a battery malfunctions or causes thermal runaway. Isolating the factors that cause these issues is key to developing batteries that will safely and efficiently service these vessels and take the aviation and shipping industries into the future.

How Comprehensive Battery Testing Can Help Decrease Battery Wastage in the Medical Field

Q-Core Medical Infussion pump

Introduction: Batteries in Medical Equipment

Various types of batteries are used in medical equipment. With its long life and high energy density, lithium batteries are the favored choice as both a primary source of energy in implanted and portable devices, and as a back-up in others. Equipment that use batteries can range from monitors and tools like surgical drills and robots, to critical devices such as defibrillators, transport ventilators, heart-lung machines and more. 

According to an FDA survey, 50% of issues in hospitals are battery related; equipment malfunctions and failures because batteries are not in good condition. Since these are mission-critical situations, batteries found in medical equipment are routinely switched out, even while they are still usable. As much as this practice reduces the risk of failure in critical moments, a lot of batteries go to waste. Comprehensive testing and accessible maintenance information is needed to reduce wastage while still ensuring that it will work when the time comes.

Why are batteries going to waste?

In order to ensure the dependability of devices with minimal maintenance, reliability-centered maintenance strategies are often used in the medical field. The goal of this approach is to preserve the functioning of the system and lower operational costs by reducing the need for invasive maintenance. This is accomplished by removing, changing, or upgrading the variables within a system before it can cause a failure. Cables, plugs, wires, batteries and other non-durable components of a device are changed regularly, even if they are still in good working condition. 

According to biomedical and clinical technicians, most batteries are switched out every 2-3 years and according to the date stamps provided by manufacturers, even though lithium batteries are typically designed to last 5 years or more. This is done as a safety precaution, but date stamping is not extremely accurate. With the possibility that batteries remain in storage before being used, most batteries are not used to the fullness of their potential before the expiration date. Although reliability is of the utmost importance in this field, reducing battery wastage is also an issue biomedical technicians and health care providers are seeking to address.

What is lacking?

Predicting battery life is extremely challenging given that many factors affect a battery’s health over time. Manufacturers cannot completely predict how a battery would be used or misused. One person from the FDA expressed that manufacturers need to anticipate how these batteries and devices will be handled by the end-users, and not necessarily how they are ideally intended to be used.

Challenges and situations that may arise during use need to be factored into anticipating the wear-and-tear that the battery may face. With this information, better predictions on battery health and life can be made.

Another issue that is often pointed out by biomedical and clinical technicians is the lack of clear maintenance instructions available. This makes it difficult for technicians to know how best to manage and take care of the battery in order to make the best use out of it.

What can be done

In order for manufacturers to better provide accurate information to device users, more precise testing must be done on batteries in order to better understand them. High precision and high resolution equipment will allow manufacturers to see better how different factors and situations affect a battery. While testing the batteries as if they are being used and handled in day-to-day procedures, high resolution equipment will catch even the smallest changes, allowing manufacturers to better predict battery life and what would affect it. This would also make date stamping more accurate and reliable. 

According to hospital biomedical and clinical engineers, some of the most common problems with battery devices include overcharging, undercharging, and incorrect replacement. Thus, having software that allows you to be flexible and customizable with tests profiles will also help to simulate real-life situations and how the battery might be used. This would help manufacturers anticipate the damage that could be done to the battery. All this information would then assist manufacturers in confidently providing more comprehensive information and clearer maintenance instructions for users.

Conclusion

Battery manufacturers are often apprehensive about developing batteries for medical equipment due to concerns over liability. However, with the right test equipment, these concerns can be minimized. With accurate and precise hardware it would be easier for manufacturers to predict battery life as well as inform users how best to extend it. In this way, batteries can be ready to handle any emergency situation and battery wastage can be reduced.

"Q-Core Medical Infussion pump" by amos boaz is licensed under CC BY-NC-ND 4.0

5 Key Features of Reliable and Efficient Battery Test Equipment

Test equipment should facilitate rather than frustrate the testing process. Good equipment allows researchers to pick up the smallest of changes during the experiment. Durable and reliable equipment have a mixture of qualities that work together for an accurate and efficient testing process. Outlined below are 5 key features of good battery testing equipment.

  1. High resolution Resolution refers to the smallest change in measurement that can be detected by the equipment’s sense and control circuitry. Higher resolution allows for higher clarity in the data. For instance, Arbin’s equipment has 24-bit resolution, compared with the industry standard of 16-bit. This allows the slightest changes in voltage and current to be visible to a greater number of digits. This is crucial as significant changes and patterns in measurement would be missed with lower resolution equipment. 

  2. High Precision High precision equipment means that there is less noise/fluctuation in the equipment’s measurement. Precision also indicates the consistency and repeatability of the instrument’s measurement circuitry. Miniscule changes in the data are lost when there is too much noise. The lack of precision also prevents consistent and repeatable results from experiments. This makes it extremely difficult to see trends early in the cycle life, and see the differences between early cell degradation.
  3. Accuracy Accuracy refers to the trueness of the test equipment measurement. In other words, the closeness of the average sample to its true value. Good accuracy is best evaluated when the equipment also has high resolution and precision. Without the clarity and clean readings, the accuracy specification alone is much less meaningful. 

  4. Minimal temperature fluctuations The temperature of the test equipment will inevitably affect its measurement. Good equipment minimizes this impact. Temperature stabilization is achieved through the design of the equipment. For example, Arbin’s equipment makes use of shunt designs and high quality materials that are resistant to temperature fluctuations. Internal thermal control mechanisms also isolate sensitive components and tightly regulate temperature. Since temperature is a component that greatly affects the functioning of a battery, these features that regulate temperature are essential in maintaining control over the testing process. Temperature fluctuations are easily visible with high resolution and high precision equipment, allowing researchers to catch these changes.

  5. Robust Materials As with any research equipment, ones made with quality material and quality construction stand the test of time. Reliable battery test equipment is resistant to corrosion and temperature and can hold calibration well. Since battery-testing can be quite long-term, reliable equipment should be able to stay consistent throughout the entire testing process. Equipment that fails or breaks down in the middle of the testing cycle will greatly hinder the research and development process.
    The benefits of high quality battery test equipmentHigh quality test equipment is needed to accelerate the battery development process. Industries like the Electrical Vehicle (EV) industry benefit greatly from high precision test equipment like Arbin’s that can detect the smallest differences between cells and materials early in the cycle life. EV batteries are projected to last 8-10 years, but a long test cycle slows down the development process. EV batteries can then fall behind the development speed of the other parts of the vehicle. Reliable, high-precision test equipment allow researchers and manufacturers to accelerate the testing and development process, and allow them to advance faster with materials research and battery development.
    High quality test equipment accelerates development by providing reliable and precise data for the research process. All the above features are complementary and work best together. For more in depth information on how to evaluate battery test equipment click here.

 

Electric Vehicle (EV) Revolution

As climate change becomes an increasingly pressing issue, the call for sustainable and environmentally-friendly solutions continue to mount. One industry where this has been quickly gaining traction over the years is transportation. Electric vehicles used to be an infeasible, luxury solution to managing climate change. However, with the advancements in battery technology and support from government bodies, a future full of electric vehicles is becoming more and more accessible. The research and development of EVs from private cars and scooters to buses, ships, and planes are allowing more and more people to invest in and use environmentally-friendly transportation options.

The growth of the EV industry

The EV industry is growing at a rapid pace. In 2018, the number of electric cars increased by 2 million to 5.1 million globally. While China leads the way in number, Norway and other Nordic countries lead the way in electric car adoption. Electric cars make up 46% of the market share in Norway. Iceland comes in second at 17.2% and Sweden third at 7.9%.
The adoption of electric alternatives in other forms of transport is not as rapid, but some big companies are making steps towards an electric future. For instance, Amazon recently ordered 100,000 electric delivery vans from start-up Rivan by 2030. The number of electric buses being procured in Europe, India, and Latin America is also on the rise, showing the integration of EVs into the public as well as private sphere.

It has been more difficult to break into the market of electric medium-to-heavy duty trucks as there have been doubts whether batteries can efficiently power them. With Tesla launching the semi-truck, and other truck makers taking notice, manufacturers are starting to take steps to enter this business. There is also movement towards electrification in shipping and aviation, with electric ships and planes under development. All this shows that there is a growing interest and willingness to invest in a future of electric vehicles.

Countries’ commitment to zero-emissions

Various regions and countries are setting clear targets and goals to reduce carbon-emissions, and supportive government policies and initiatives are facilitating this. For instance, countries such as the UK and France aim to ban all sales of new gasoline and diesel powered vehicles from 2040; in Norway, all new passenger cars sold from 2025 should be zero emission vehicles; and in  .

Globally, 95% of all electric cars are sold in only ten countries which are China, the US, Japan, Canada, Norway, UK, France, Germany, the Netherlands, and Sweden. As EVs become more affordable and standard of living continues to rise in urbanizing nations, this percentage is likely to change.

How electric cars can be adopted: Norway

Norway is leading the way for zero-transmission transportation. A huge reason for this success is substantial incentives from the government. These include VAT exemptions and cheaper ferry, parking, and toll fees for electric vehicles. Charging stations are also publically available along major roads. These initiatives form the administration are crucial to creating an environment that can support electric transportation. Even if all cars were electric, the infrastructure to support this must be present. In Norway, 98% of electricity production comes from renewable sources, ensuring that this move towards green-energy is all-rounded.

How the EV industry is moving forward

The battery is still the key component of the fully electric car that needs to be improved. Prices of lithium-ion batteries have decreased drastically over the past 8-years, dropping from USD1160/kWh in 2010 to USD176/kWh in 2018. The price is expected to continue to drop in the years to come. This drop is slowly making electric cars more affordable. Companies are also conducting continuous materials research, reducing the cost of batteries by developing more cost efficient ratios of materials while still maintaining battery safety and stability. With continuous breakthroughs in battery technology and calls for genuine action against climate change growing louder and louder, the demand for electric vehicles will only continue to grow.

To learn more about testing EV batteries click here.

ARBIN_EV-REVOLUTION

India’s Creative Potential in the Electric Vehicle (EV) Industry

Introduction

India is one of the leading Asian countries in electric vehicle adoption. Currently, the country aims to have 30% of its road vehicles be electric by 2030. Not only is this a step toward a greener future, it is also to address one of the country’s top issues -- pollution. India is one of the top polluting countries in the world, by reducing the amount of tailpipe emissions on the roads, it hopes to rectify this problem.

The rate of EV adoption is much slower in industrializing nations like India than in industrialized ones. With less income and supporting infrastructure, people are less likely to invest in electric alternatives. However, with the push from the government as well as public desire to tackle the issue of pollution and climate change, the situation has presented opportunities for the government as well as companies to come up with creative solutions that address the specific needs and circumstances of the country. This would also set an example for other urbanizing Asian economies and pave the way for further EV adoption across the continent.

The challenges of converting to EVs

As cities grow, the number of vehicles on the road increases, leading to more and more roadside pollution. This has become a pressing health concern in India. In 2017, over 1.2 million deaths were attributed to overexposure to pollution. A survey has found that 90% of car owners in India are willing to make the switch to an electric alternative to address this. The same survey also pointed out the need for government initiatives to facilitate the adoption of EVs, including the building of infrastructure as well as financial incentives such as subsidies and reduced road tax.

India’s 2030 goal is ambitious considering EVs currently only make up 1% of road vehicles. The high upfront price of EVs is one of the biggest roadblocks to its adoption, not only in India, but around the world as well. With the country looking to decrease reliance on foreign imports and stimulate local manufacturing, high import duties are in place for EVs, making it near impossible for foreign manufacturers to break into and entice the Indian market. Moreover, the lack of charging facilities is also a huge cause for hesitation, with drivers often concerned about mileage and reliability of EVs.

Creative opportunities

However massive these roadblocks seem, they offer opportunities to develop creative technological solutions to address India’s specific circumstances. Various companies are taking initiatives to tackle the growing pains of the electrification of mobility in the country.

 

Two and three-wheeled EVs

More than 80% of road vehicles and 95% of EV sales in India are two-wheelers. There has also been a shift to three-wheeled electric rickshaws, with drivers themselves initiating the switch. With smaller batteries, two and three-wheeled vehicles are more affordable than cars. The government is pushing that all new three-wheeled vehicles should be electric by 2023, and by 2025 for two-wheelers. This has offered startups and companies the opportunity to build ecosystems that support and regulate the change. For instance, the start-up SmartE, rents e-rickshaws to drivers, while charging and maintaining the vehicles at their own lots. Given the transportation culture and affordability of smaller vehicles, this is a good beginning to the shift towards a fully electric future.

Locally developed and manufactured batteries

One of the common issues with EVs in India are the batteries. With a much hotter climate than western nations, batteries overheat much more easily, a common issue pointed out by various parties. Moreover, with the government is pushing “Make in India” initiatives in an attempt to encourage local manufacturing, there is opportunity for research and development into batteries that are adapted to the needs and environment of the country, with less competition from foreign manufacturers. In this way, the batteries used in EVs would be much more reliable for the Indian climate and remove some hesitation towards adopting battery-powered vehicles

Shared mobility solutions

Studies have shown that there is a shift towards shared mobility services in India, away from typical car-buying habits, especially among the younger generation. This has pushed motor companies to invest in shared-mobility solutions. India is poised to be a leader in this type of shared-economy, especially in mobility. With the government pushing companies like Uber and Ola to make 40% of their fleets electric by 2026, electrification in shared-mobility is one key frontier in India’s journey to clean roads.

Battery swapping

Battery swapping is seen as a less disruptive solution for charging EVs, addressing the issue of the lack of space for charging facilities where vehicles can park and charge when needed. It also address concerns over the time it takes to charge EV batteries. For instance, Ola has 14 battery swapping stations where e-rickshaw drivers can swap batteries, making the process as fast as refueling at a petrol station.

Conclusion

India’s ambitious plans for electrification have opened up and encouraged a wide range of opportunities for technological innovation and creative problem solving. The country’s specific transportation culture and environment makes this process of electrification very different from that of the West, with two and three-wheelers and shared-mobility rather than private cars leading the way. It has allowed the beginning of an ecosystem of cooperation between companies, startups, and the government to support and facilitate electrification. With these business models, this could set an example for other Asian countries in similar situations, exhibiting the potential of the EV industry.

Learn more about the battery test solutions provided by Arbin for both cell and pack development.  
Arbin Instruments has a large sales and service network across India partnering with Metrohm India Private Liminted to serve our clients in the region.

Nobel Prize in Chemistry Honors Lithium-ion Battery Researchers

By Katherine Howell

John B. Goodenough, M Stanley Whittingham and Akira Yoshino are awarded the Nobel Prize in chemistry by The Royal Swedish Academy of Sciences for their work on lithium-ion batteries. These scientists paved the way for rechargeable devices that we use in our everyday lives. 

Among the laureates is Dr. Goodenough, a professor at UT Austin, who we are proud to support along with battery researchers around the world with our industry leading high precision battery test equipment.

"The Nobel Prize in Chemistry 2019 rewards the development of the lithium-ion battery. This lightweight, rechargeable and powerful battery is now used in everything from mobile phones to laptops and electric vehicles. It can also store significant amounts of energy from solar and wind power, making possible a fossil fuel-free society" as said in the RSAS press release.

For more information regarding their work on lithium-ion batteries visit nobelprize.org. 

Lightsaber Battery Analysis

How recent electric vehicle battery research has created a battery suited for a lightsaber.
By Richard Rogers

Star Wars Episode V: The Empire Strikes Back (1980) Directed by Irvin Kershner. Performances by Mark Hamill and David Prowse. Via starwars.fandom.com [1]

Introduction to Lightsaber Lore

Few objects have captured our imagination the way lightsabers have. The iconic weapon from a galaxy far, far away has become a symbol of battles between good and evil, light and dark. The glowing blade is instantly recognizable and reveals the nature of its wielder. Lightsaber color identifies whether they are seeking peace and harmony as a Jedi, or strength and power as a Sith. These colors, and the blade itself flow from a Kyber crystal in the hilt which powers the weapon [2].

The lightsaber blade is an energized plasma capable of cutting through most any material [3].  Traditionally, Jedi go on a quest very early in life to find the crystal and build their first lightsaber.  Kyber crystals are said to be Force-sensitive and bond with the Jedi who wield their power; taking on a color based on the nature of the individual Jedi.  Kyber crystals can also be subjugated through the Force in the case of a Sith or dark-side user, which causes the crystal to turn red [4].

The Force is a “mysterious energy field created by life that binds the galaxy together.”  Those who are sensitive to the energy of the Force like Jedi and Sith are granted powerful abilities.  The Force is also known to have a will of its own, which is not fully understood by scholars [5].

Star Wars Episode I: The Phantom Menace (1999) Directed by George Lucas. Performances by Ewan McGregar and Liam Neeson. Via starwars.com [9]

We know lightsabers need to be re-charged on occasion since the Star Wars Visual Dictionary reveals they have external charging ports, and Qui-Gon tells Obi-Wan in Episode 1, “You forgot to turn your [lightsaber] power off again didn’t you?  It won’t take long to recharge, but this is a lesson I hope you’ve learned...” [6] This confirms they contain a rechargeable energy storage device (battery).  In the Star Wars universe, we know this energy storage source as a “diatium power cell” [7, 8], but how does it compare to our lithium-ion battery technology today?  How close are we to being able to power the iconic weapon that has captured our imagination for over 4 decades?

Lightsaber’s belonging to (L to R) Qui-Gon Jinn, Obi-Wan Kenobi, and Anakin Skywalker. Star Wars Episode I: The Visual Dictionary, and Star Wars The Visual Dictionary by Dr. David West Reynolds

Analyzing the Lightsaber

A previous study by Dr. Rhett Allain calculated the amount of energy required by a lightsaber using the scene from Star Wars Episode I, where Qui Gon Jinn is cutting through a large metal door.  The thermal energy needed to melt steel or other hypothetical material can be calculated.  Liberal estimates have been used since we do not know the true material properties of the blast doors, nor do we know how long it would take to cut through the door.  The generous estimates used to calculate the power requirements for the lightsaber yield ~2.016x10^8 J of energy and 28kW of power [10].

A battery with this power small enough to fit in a lightsaber hilt is far beyond any technology we have today in our milky way galaxy.  However, these studies fail to account for a key component in the lightsaber and icon of the Star Wars universe: Kyber crystals.  Accounting for the Kyber crystal creates a very different picture which may be closer to reality than we thought.  Kyber crystals do not generate energy, but they exponentially amplify and channel energy through the Force so lightsabers only need a small diatium power cell for operation. 

The [internal battery] is only needed to provide marginal energy to activate a lightsaber, conceptually similar to how a battery and spark plug initiates the engine of a car.

Kyber Crystal & The Force

Since Kyber crystal’s channel and amplify Force energy, the battery (diatium power cell) in a lightsaber is not required to meet the power demands alone.  It is only needed to provide marginal energy for activation, conceptually similar to how a battery and spark plug initiates the engine of a car.  This also explains why non-Force users can wield a lightsaber without channeling the Force since the crystal and lightsaber will still have a marginal amount of energy from the diatium power cell, but only a true Jedi or Sith bound with the Force can unleash the full potential of the weapon.

Their connection to the Force is what allows Kyber crystals to power the lightsaber’s plasma blade and the magnetic field that contains it.  Once a lightsaber is activated from the energy stored in the diatium power cell, Kyber crystals act as a conduit to power the weapon through the Force and continually recharge the internal power cell (battery).

Humanity has not yet discovered a crystal capable of channeling a nearly limitless source of cosmic energy like the Force, but a recent study [11] published in Wiley’s Angewandte Chemie (Applied Chemistry) scientific journal has shown a new type of crystals known as “CBGO” that are over 13x more efficient than widely used potassium dihydrogen phosphate crystals.  CBGO crystals are capable of “causing abrupt changes to energy that passes through them,” and can double the frequency of a laser beam [12].  This supports the concept of the “right” crystal being able to amplify energy to power a great weapon.

Rogue One: A Star Wars Story (2016) Directed by Gareth Edwards. Performances by Spencer Wilding. Via TheForce.net [13]

We do not know exactly how the Force works in the Star Wars universe, but we have several examples to help measure its power.  Dr. Rhett Allain calculates the power displayed by Darth Vader through the Force to lift people [14], and engineer Randall Munroe calculates the power Yoda used to lift Luke’s X-Wing fighter out of the swamps of Dagobah [15].  These two cases show 3kW and 19.2kW of power, respectively.  This is already close to the 28kW of power needed by Qui Gon Jinn to cut through the blast door with his lightsaber in The Phantom Menace; further confirming it is primarily powered by the Kyber crystal channeling cosmic energy from the Force, not the diatium power cell.

Star Wars Episode V: The Empire Strikes Back (1980) Directed by Irvin Kershner. Performances by Frank Oz. Via starwars.com [16]

Therefore, the question about Earth’s battery technology to power a lightsaber is not about power density to pack 28kW in the size of a flashlight, but cycle life since lightsaber “batteries” can be recharged, but are expected to last more than a lifetime. 

The question of battery technology to power a lightsaber is not about energy density to pack 28kW in the size of a flashlight, but cycle life.

Battery Trends Lead by Electric Vehicle (EV) Research

The batteries that power our gadgets here on Earth have historically been limited to 100’s of cycles or in the low 1000’s in some extreme cases.  This limit of cycle life is not sufficient for a lightsaber, nor is it sufficient for modern electric vehicles and grid storage applications facing us today.  Over the past decade tremendous advancements have been made with lithium-ion and other battery chemistries.  Researchers are aiming for batteries with cycle life in the 10,000’s and 100,000’s range, which would begin to match the performance seen from lightsabers.

One of the biggest challenges to battery researchers is how long it can take to test a battery that is expected to last 10,000+ cycles.  When a battery was only expected to last 1000 cycles, traditionally it would be tested for a few hundred charge/discharge cycles to give an accurate prediction of life, however, now that batteries need to last 10,000+ cycles, using conventional charge/discharge cycles to estimate cell degradation becomes too time consuming and bottlenecks the development process.  Advancements in battery technology have been relatively slow over the past decade in part due to how long it takes to perform research on new materials and predict battery degradation over a lifetime of 10,000+ cycles.

A New Hope

There is hope!  Not only have EV battery researchers been working on new battery materials, they have also been working on new methods to test batteries to speed up the development process.  Ford Motors partnered with battery test equipment manufacturer, Arbin Instruments, and Sandia National Lab to develop and utilize new “high-precision battery test equipment” that would be capable of seeing the smallest changes happening in a battery [17,18]. 

This breakthrough in battery test equipment technology [19] has made new test methods and data analysis possible.  Seeing the smallest changes happening in a battery allows both researchers and AI [20] to create new and improved metrics for battery prediction very early in its life and accelerate the process of bring new battery materials to market. 

Drive provide for EV battery packEV battery testing has also trended away from constant charge/discharge cycles and more to very dynamic real-world cycle profiles including temperature control.  Studies have shown that batteries must be tested in a way consistent to their eventual application to gain an accurate prediction of their long-term performance [21].  Electric vehicle applications have been one of the strongest driving forces behind battery research over the past decade.  Therefore, governments around the world have created several standardized, but highly dynamic cycle profiles used to test electric vehicle batteries [22].  Most EV manufacturers have also developed their own real-world test profiles and metrics to evaluate their battery technology. 

New battery materials beyond lithium-ion are also being studied.  Silicon, Sodium, Sulfur, solid state batteries, and metal-air batteries are all receiving attention in recent years as possible next-generation solutions.  A recent breakthrough in metal-air batteries has improved the battery cycle life from <100 to over 3,000 [23].  This is merely one example of the many brilliant scientists who are continually expanding the boundaries of battery chemistry and performance.  Continued technical leaps like this are what we need to reach the goals for EV batteries, and lightsaber cycle life.

So, Do We Have the Battery Technology for A Lightsaber?

We have learned the following:

  • Lightsabers are powered by a Kyber crystal, and their internal energy storage source (diatium power cell) is merely used for activating the plasma blade, not powering it.
  • The internal diatium power cell of a lightsaber is rechargeable.
  • Diatium power cells must have tremendous cycle life to outlast many of their wielders (at least 50-100 years).
  • The need for longer-lasting EV batteries over the past decade has raised cycle life goals similar to what lightsaber’s require.
  • One of the main challenges for longer-lasting batteries is how long it takes to test during the development process to predict 10,000+ cycles of life.
  • The US government and leading industrial players [Ford, Arbin, Sandia] have supported major technological advancements in the test equipment used by battery researchers over the past 5 years that will accelerate the development process and cycle life metrics.
  • True high-precision battery test equipment allows researchers to see trends and signs of degradation early in testing that are not discernible with inferior test equipment.

The conclusion is a conditional yes, modern lithium-ion and other advanced chemistry batteries can achieve the cycle life required by a lightsaber and are only improving.  The rate of improvement is expected to increase as true high-precision test equipment becomes more widely used, and as AI begins to analyze data.  However, lightsabers will still require a Kyber crystal to amplify and channel cosmic energy of the Force, which has not yet been discovered in our galaxy. 

Arbin Instruments is the leading manufacturer of true high-precision battery test equipment, and the only source when battery currents are greater than 2A.  Leading industry partners around the world are utilizing this technology to accelerate battery research.  Learn more about how advanced battery test equipment empowers new research on Arbin’s website:  https://www.arbin.com/evaluating-battery-test-equipment-intro/.

SOURCES

[Read more...]

Safe Testing for EV Batteries

Why researching Electric Vehicles batteries has never been safer

Advancement in battery testing equipment has made the process of battery testing safer. With more [precise and accurate testing equipment], the smallest changes in a battery can be detected before it becomes a critical issue. Improved equipment also allows for a more stable and controlled testing environment, making the [research and development process] much more efficient.

The safety concerns with EV batteries

While electric vehicles (EV) have been on the road for a while, questions regarding the battery’s stability and safety still come up. A few of the major, key issues with EV batteries are flammability, gases, and trauma to the battery cell.

As with any device that uses lithium-ion batteries, flammability is a huge concern with EV batteries. There have been cases where EVs have experienced thermal runaway events with catastrophic failures. Battery fires require special equipment to extinguish, and if one’s not careful, the batteries can reignite even after the fire is put out.

Common electrolytes found in batteries are mixtures of carbonates and a dissolved salt. In the event of a thermal runaway, decomposing electrolytes lead to a formation of gases within the cell, increasing pressure within the battery, leading to the release of toxic gas.

Trauma and impact to the battery pack can also greatly affect its capabilities and compromise its stability and safety. EVs have been reported to spontaneously combust days after being in an accident, showing how the risks are real if batteries are not properly monitored.  This is equally true during testing; even in a lab environment.

How Arbin’s equipment is designed to test EV batteries

Arbin’s equipment allows batteries to be tested using dynamic cycling. Traditional batteries are mainly tested with constant current charge/discharge profiles. On the other hand, EV batteries need to charge and discharge dynamically, based on the car’s action.

Arbin’s systems make putting the battery through a dynamic cycle easy. Using [Arbin’s software], standardized test profiles, such as USACB's FUDS profile can be easily uploaded into the testing system, allowing batteries to be safely and efficiently tested according to regional, national, and international standards just by uploading a text file of time-vs-power or time-vs-current data to simulate the drive cycle.  [LEARN MORE]  High quality and precise testing equipment detect the slightest change in the battery, allowing researchers to detect any issues early on in the testing process and know better what materials and situations affect battery health and life. Researchers can catch these changes and make appropriate adjustments to the battery before it becomes a critical issue. It also allows manufacturers to create comprehensive safety guidelines for use of the battery.  Battery test equipment from other manufacturers has been shown to significantly average the output of a dynamic drive profile and fails to accurately reproduce the real-world requirements.

It is also possible to have the EV battery pack’s battery management system (BMS) fully control the Arbin tester charge/discharge via [CANBus protocol]. This software is not limited to cutoff limits or safety conditions like other brands of test equipment, but can also be used as dynamic control values.

Temperature stability is also key in testing EV batteries. As mentioned before, overheating batteries is a serious safety hazard. Creating a stable thermal environment in which batteries can be tested is crucial to safe testing. It is also imperative to contain any problems in the event of a thermal runaway or cascade failure so as not to affect other batteries within the test chamber.

Arbin Battery Test Chamber

[Arbin’s multi-chamber equipment] isolates each battery cell or pairs of cells during testing, creating a safer and contained test environment that maintains temperature stability. Each chamber is thermally isolated and can have its own unique temperature set point so as to keep batteries from affecting each other during testing. This is a safer and more accurate testing method to see how temperature affects batteries.

Conclusion

Batteries are a critical component of the increasing global need for energy storage, including electric vehicles. Thus, testing processes must be able to meet the demands of the research needed for the technology to develop. Better testing equipment not only accelerates the testing process, allowing manufacturers to innovate and improve at a greater speed, but also makes testing and the creation of batteries safer overall.

Batteries in Space

What makes batteries used in space different?

Batteries used in space undergo extensive research, testing, and development to an even greater degree than batteries used on earth. In such high risk situations, the failure of batteries is extremely dangerous. The process of changing batteries can also be a taxing mission. It took astronauts 6.5-hours to change a set of batteries of the International Space Station. Due to the extreme conditions of space, batteries need to be custom made to fit each mission, environment, and temperature, as well as have the ability to perform its function well in these circumstances, so as not to jeopardize the safety of people involved.

What kind of batteries are used in space?

As on earth, rechargeable lithium-ion batteries are currently the favored choice in space. Using the International Space Station as an example, the batteries used to power the station are recharged with solar energy from the sun and the energy stored is used when it is in orbital darkness -- when the station is in the earth’s shadow and not in direct sunlight.

In 2017, NASA began the process of replacing the nickel-hydrogen batteries on the Space Station with lithium-ion ones. Nickel-hydrogen batteries were initially used in space technology because of their long battery life and ability to withstand many charge and discharge cycles without significant degradation. However, the extra process of battery conditioning was necessary in order to combat the cells’ “battery memory” which sees a battery lose a portion of its capacity if not fully charged and discharged every cycle.

Lithium-ion batteries were a welcomed upgrade to the 20-year old station. Being more light-weight and energy-efficient, just one lithium-ion battery was needed to replace two nickel-hydrogen ones, a vast upgrade in energy and volume densities. The new batteries are also not susceptible to battery memory, negating the need for conditioning. Nonetheless, each type of battery still has its own drawbacks. Lithium-ion cells are more sensitive to overcharging, overheating, and cases of thermal runaway. Thus, battery testing is crucial and any battery used in space must be subjected to rigorous testing before being certified safe for use in space.

The difference between batteries used in space and common batteries

The lithium-ion batteries currently on the Space Station are extremely heavy-duty and made to last much longer than the average battery used in everyday life. The average rechargeable lithium-ion battery found in common appliances such as cell phones lasts about three to five years, or 500-1000 complete charge cycles; the batteries used in electric vehicles are made to last eight to ten years and a few thousand charge cycles; batteries on the Space Station have been designed to last for ten years and 60,000 lifecycles. The standards for batteries is space in much higher. Strict and comprehensive testing is needed to meet these requirements.

Testing batteries made for space

Since batteries release energy through chemical reactions, the environment in which they operate affects their performance. Because of the extreme conditions of space, batteries need to undergo intense testing under a number of different conditions in order to be certified for use.

For instance, batteries need to be tested under vacuum conditions. Research has found that overcharging the battery did not lead to thermal runaway, whereas an external short circuit test did. These results are the exact opposite of the same tests being performed in ambient pressure environments. Batteries are also often put under abuse tests to understand the worst case scenarios as well as the steps necessary to avoid these situations and properly manage the battery.

Moreover, based on the mission, batteries need to function in circumstances not encountered on earth. For example, some missions require batteries to work in extreme low temperatures of -20 to -100°C. Temperature greatly affects the rate of charge and discharge, thus it has to be made certain that the batteries can function at these temperatures.

As with any battery, overheating and overcharging are huge safety concerns. Proper battery management systems and [battery testing equipment] must be used in order to ensure the safety and stability of a battery, most especially in space where the stakes are high. In these circumstances, precise and reliable test equipment is critical.

Space technology on earth

While uses of such a heavy duty battery as used in space is rarely necessary on earth, the innovations made in space technology have a trickle down effect, eventually capable of being used in everyday life without us even realizing its origin. Cameras now commonly found in mobile phones, DSLR cameras, and other portable devices can be traced back to NASA scientist Eric Fossum, whose work in miniaturizing cameras for interplanetary missions made is possible for cell phones to have good quality cameras.

Thus, any innovation from research on space technology and batteries used could one day help and benefit the masses, improving the batteries and appliances we use in everyday life.

Conclusion

Continuously improving and innovating at the battery testing level is also crucial to the research and development of batteries. When testing equipment can keep up with materials research and dynamic charge/discharge profiles to mimic how appliances and technologies would use batteries, better predictions and assessments can be made. If the heavy duty [battery technology of space] is one day incorporated into everyday technology, commercial battery testing equipment should be able to meet this demand.