If the United States could build an atomic
bomb and put a man on the moon, why aren't we all driving electric cars yet? "We
don't have EVs", explains GE's Herman Wiegman, because "we're not at war" – at
least in the traditional sense. The war that Americans are waging today is a new
type of struggle, "a war against ourselves" to reduce consumption. Fortunately,
forward-thinking engineers such as Dr. Wiegman are making a stand in this
struggle.
Last week, CR4's Moose spoke with Dr. Herman Wiegman
about his work with mobile electric power systems at General Electric's Research Center in Niskayuna, New
York. A native of New Hampshire, Wiegman got his
start by taking apart toaster ovens and listening to the Red Sox on an old
radio. After graduating from Worcester Polytechnic
Institute (WPI), he entered a difficult economy during the 1980s. Wiegman
subsequently enrolled in graduate school at the University of Wisconsin, where he "had a great time"
studying power conversion and power electronics. After stints with GE Research
and the aerospace industry, Wiegman returned to grad school and earned his
PhD. He returned to GE Research, a place where he had been
"exposed to a phenomenal breadth of technologies and
applications".
Energy Storage Systems: Challenges
and Opportunities
According to Herman Wiegman, developers of electric
vehicles face two major challenges. The first is the refinement of
electrical drive components (including high-reliability power electronics) and
highly-compact electric machines. The second is battery energy and
power density, which can be addressed "pretty well" with lithium,
a light-weight alkali metal which reacts with both air and water. Although safe
high-power lithium is available, a standard lithium laptop or cell
phone battery uses a cobalt-based cathode which encapsulates the
lithium ions. When temperatures rise above 140° or 150° C, however, these
structures can release their oxygen compound and collapse,
leading to safety issues.
Fortunately, companies such as General Electric are
working on what Wiegman calls "a host of emerging cathode technologies" with manganese spinels and other
nanomaterials. Manganese spinels encapsulate their oxygen
in a very strong bond and provide good temperature stability up to
350° – 400° C, making it unlikely that the
material will reach a state of uncontrolled energy release. Nanomaterials can
also provide "great lithium mobilities" that enable the lithium battery to have very high power density and low internal
resistance. They may also offer "other unexpected
properties" that macroscopic materials do not provide, such
as very slow strain during charge cycling, leading to very long life.
The "trick", Wiegman explains, is to find a
"balance of benefits" between reasonable cost, energy density, power
density, safety, and cycle life.
Cost and Sizing Considerations
Cost, of course, is an
important consideration. Traditionally, lithium products have cost much more
than battery systems which use other chemistries. According to
Wiegman, lead acid batteries cost $100 (USD) per kilowatt hour (kw/hr), but are
much "too heavy" and unable to attain reasonable range in EVs.
Nickel-metal hydride (NiMH) batteries were used in all-electric vehicles such
as the General Motors EV1, but the cost was
between $350 and $400 per kw/hr. Today, NiMH
batteries are being successfully used in high-power hybrid electric vehicles,
such as the Toyota HybridDrive family. Batteries which use an
automotive-quality lithium solution are promising, but top the list at $800 to
$1000 per kw/hr. Still, "there is light at the end of the tunnel", Wiegman
explains. The GE engineer believes that emerging technologies could slash the
cost of automotive-quality lithium batteries down to $400
kw/hr,
which will make electric drive vehicles competitive as fuel prices
climb.
Sizing a battery
for an EV or plug-in hybrid vehicle can be accomplished via the stored energy
measured in kilowatt-hours (kWh). According to Wiegman, each
kWh "gets you down the road about four miles", a distance
which translates into 250 watt hours per mile. This estimate is for a four-door sedan driving
along a city street. "If the EV runs it's heater, that consumption number goes up", the GE engineer explains from
his office in chilly upstate New
York.
Editor's Note: Click here for Part 2 of this
three-part interview.
Steve Melito - The Y Files
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