1. Battery Systems for Electric Bicycles
Ralph J. Brodd
Broddarp of Nevada, Inc.
Henderson, NV

2. Overview
The US bicycle riders are finally being accepted on the road, but reluctantly.
The drive to reduce greenhouse gas emissions has helped change opinions toward bicycles.
Three sources of energy storage, gasoline, batteries and ultracapacitors are available for transportation applications.
Li-Ion Batteries provide significant range and power improvement over lead acid with lighter weight while reducing greenhouse gas emissions.

3. NAS Study Key Findings
Battery and fuel cell cars cost competitive long-term with gas powered vehicles
Li-ion battery costs should drop by 80% over time
Electric drive costs scale with reduced power demand due to lightweight materials and other load reductions
PHEVs will always command a significant cost premium and incremental fuel savings will diminish.
Cars could achieve 94 mpg (56 g/km) in 2050 for U.S. fleet with midrange assumptions
Fundamental technology breakthroughs expected to further help increases efficiency and reduce cost

4. Battery Power Systems
Two sources of energy storage, batteries and ultracapacitors are available to replace gasoline in transportation.
1. Lead Acid – Lowest in energy storage and cost
2. Nickel Metal Hydride – Higher energy density,
more expensive, abuse resistant
3. Li-Ion Batteries - provide significant range and power improvement over lead acid with lighter weight. (choice for electrification of bicycles)
4. Ultracapacitors – Extremely high power output but lower energy storage capability

5. DOE JCEASAR PROGRAM
U.S. Secretary of Energy Steven Chu formed a multi- partner national laboratory team led by Argonne National Laboratory has been selected for an award of up to $120 million over five years to establish a new Battery and Energy Storage Hub as the Joint Center for Energy Storage Research (JCESR) for DOE battery programs
THE PROGRAM will combines the five DOE national laboratories with five universities, and four private groups aimed at 1) rapidly identifying revolutionary advances in battery performance, (2) advancing next generation battery and energy storage technologies for electric and hybrid cars and the electricity grid as a critical part of an all-out energy strategy to reduce America’s reliance on foreign oil and lower energy costs for U.S. consumers.

6. Electric Vehicles
All forms of electric vehicles are critically dependent on battery performance and cost.
Today, limited range and long charging times remain barriers to consumer acceptance.
Battery costs are projected to drop steeply and battery vehicles as production volume of battery powered vehicles increases, potentially less expensive than ICEVs by 2050.
All advanced battery technologies now under development face serious technical challenges.
These factors likely may limit all-electric vehicles mainly to local driving.

7. Criteria for Success
Cell assembly process is cost competitiveTrained workforce available
Active materials available at world market prices.
State-of-the-art plant equipment available
Product meets international standards
Sizable stable market is available to sustain itself.
Research identifies next generation product.
Control circuitry to enhance safety and long life.

8. Present Status of Battery Systems
Significant activity worldwide to reduce greenhouse gas emissions and develop new high energy battery systems for transportation and energy storage
Battery powered electric bicycles have been very popular overseas, but have not experiences the same rapid growth in the US.
Conversion from gasoline to electrical propulsion became of interest in the US in recent years due to strong government pressure to reduce green house emissions.
Best example is the Tesla Roadster that uses the Lithium- Ion battery based propulsion system.
Significant government spending on developing electric propulsion

9. Present Situation
Limited availability of trained personnel in new production technology.
Who are you going to sell to, limited market?
Strong competition from overseas.
Several new promising cell chemistries that could provide a vehicle to enter the market.
Flow batteries making headway in the US.
Fuel Cells or Fool Cells? Need a Market first!

10. Overview
The US bicycle riders are finally being accepted on the road, but reluctantly.
The drive to reduce greenhouse gas emissions has helped change opinions.
Three sources of energy storage, batteries and ultracapacitors are available.
Li-Ion Batteries provide significant range and power improvement over lead acid with lighter weight.

11. Battery Power Systems
Four sources of energy storage, batteries and ultracapacitors are available.
1. Lead Acid – Lowest energy storage and cost
2. Nickel Metal Hydride – Higher energy density,
more expensive, abuse resistant
3. Li-Ion Batteries - provide significant range and power improvement over lead acid with lighter weight.
4. Ultracapacitors – Extremly high power but lower energy storage capability

12. The US Can Be Competitive
A study by Brodd and Helou in JPS that showed clearly that cell manufacturing at $0.10/Wh is possible in the US. Longer term a cost of $0.05/Wh is possible.
The Tesla giga-factory is clear evidence that cells/batteries can be made at competitive prices in the US given a clear market opportunity.
US Department of Energy has mounted a significant effort to develop new high energy battery system.
Formed JCEASAR consortium centered in Argonne National Lab to consolidate and direct activity at all national labs.
Yearly spending in the range of billion dollars/year to develop new high performance battery fuel cell systems
Overall direction for project from Washington

13. Criteria for Success in the U.S.
Cell assembly process is cost competitive.
Trained workforce available
Active materials available at world market prices.
State-of-the-art plant equipment available
Product meets international standards
Sizable stable market is available to sustain itself.
Research identifies next generation product.
Control circuitry to enhance safety and long life.

14. Present US Transportation Situation
Presently a limited market, who are you going to sell to?
Limited availability of trained personnel in battery production technology.
Strong competition from overseas.
Several new promising cell chemistries that could provide a vehicle to enter the market.
First generation Li-Ion cells in the market
Fuel Cells - Need a Market First to spur development!
Flow batteries making headway in the US.

15. DOE Funds New R&D Concept
Argonne National Laboratory has been awarded of up to $120 million/year over five years in the form of Energy Storage Hub to establish a new high performance-low cost battery systems in co-operation with the other DOE laboratories. The Hub, to be known as the Joint Center for Energy Storage Research (JCESR)
This Hub will combine the R&D firepower of five DOE national laboratories, five universities, and four private firms in an effort aimed at achieving revolutionary advances in battery performance.
This activity for advancing next generation battery and energy storage technologies for electric and hybrid cars and the electricity grid are a critical part of President Obama’s all-of-the- above energy strategy to reduce America’s reliance on foreign oil and lower energy costs for U.S. consumer .

16. Strong Government Support
The high energy density and good cycle life has made the Li-Ion Battery , the battery of choice to power new electronic based systems.
The DOE has formed a consortium of the national laboratories to identify and develop new higher energy Li- Ion battery systems termed the program (5X the energy density, 5X the cycle life and 5X lower cost).
At the same time, DOE has funded the development of new systems in universities and private industry including the development of several flow battery systems, now popular for energy storage systems in Australia, Japan and Europe. The discussion will include an overview of promising new systems for automotive and energy storage applications

17. ANL Consortium
Ideas for new battery products are a dime a dozen, the key issue is how one identifies and converts an idea/concept/invention to a product that people will purchase.
The market plays a critical role and must embrace the new technology by providing demand for the product and income to the producer.
The first criterion is that salable product has to satisfy a need in the marketplace.
Second is that the product can be produced and yield a reasonable profit and a third, that the market is large enough to recover the investment and realize a good profit.
The cost, while listed second, often is the key issue in determining the size of the potential market. One must be able to recover the cost of developing the product and producing the product in a reasonable period of time.

18. Cost of EV Batteries and Fuel Cells (NAS Study)
$/kWh

19. The US Can Be Competitive
Given a large market, a study published in Journal of Power Sources by Carlos Helou and Brodd, showed clearly that competitive Li-Ion cell manufacturing is possible in the US.
The Tesla giga-factory is clear evidence that cells/batteries can be made at competitive prices in the US given a clear market opportunity and reliable production and supply sources.

20. Present Situation
Limited availability of trained personnel in new production technology.
Who are you going to sell to, limited market?
Strong competition from overseas.
Several new promising cell chemistries that could enhance battery performance vehicle ready to enter the market.
Flow batteries finally making headway in the US.
Fuel Cells or Fool Cells? Need a clear market first!

21. Summary
The set goals will be difficult but not impossible to meet IF supported by strong national policies coupled with commercialization of advanced battery technology.
No one pathway is adequate by itself to meet the goals; at least two pathways (maybe more) will be needed depending on technological and commercial success.
Even if the goals are not completely met, partial success can still yield valuable benefits.
Committee Report “Transitions to Alternative Vehicles and Fuels (2013)” is available on the NRC website. Transitions to Alternative Vehicles and Fuels ( 2013 ) –

22. Thank you for your attention