DOE–BCS TSD commentsBCSTSDcommentsDecember 6, 2010Wayne Morris AHAMLarry Albert PTICSL’s• For Appliances, each CSL represents al l ft h lleveloftechnology– CSL 0 – “bad” NiCd–CSL 1–“good” NiCd• Better conversion efficiency, lower standbyB i•etter maintenance power management• Still limited by inefficiency of chemistry itselfCSL 2Liion––-• Cell has no maintenance power and better chargeacceptanceCSL’s• Appliances have both NiCd and Li-ion in themarket– NiCd still major proportionC i 75% f t l•Comprises75%ofprotools• Over 90% of small appliances• No market driver other than retailersMi i l tilit d t–Minimalutility advantage• For non-appliances (electronics), most are Li-ion•These share the same Product ClassesThesesharethesameProductClasses• We believe that there are some negativeconsequences resultingfrom this combinationgExample - Product Class 3 – 23,116K total shipped2008CSL(ICSL1CSL2'CSL3App1icadonShipments(10001';)jIl')1Portable'Playe.rs7J406,43,60-2C:.':lJ1f'li!c.14.206(l,800.1IiI!...U;;..l:':>-3TloyRide-On\lehicles311.:5.5_,0-4RCToys2,31.10,4--DIYPo'el'Too]:;15310.75,4_J(Extellul1)-6Handhe]d'\1,3,738.821.:"')-,'-;-7DIYPov-erToo]:;20.0]1.11,](Illte21'al)-8StickV'aCUl1JllS86338.S11...._.2-9Aim-MaUres.Ptnnp250...,31.10,4-10Dniver.alBattery24028.15.41,6Chargers.-11WiJreles:;..Spea'kel's'62,,31.10,4-12ReMS(Hobby125J',.1.10,4Gum.de)-",)-13Blenders6]2,31.10,4-14Mixers58J:.31.10,4-lI?igltedAVf'rage10.05.4LO-Example – PC 3• Roughly half the shipments are from DVDplayers and camcordersplayersandcamcorders– Virtually all Li-ion – low UEC• These should only be considered in CSL 2– But these are included in CSL 0 and CSL 1• Distorts CSL 1 because this mixes good NiCd Applianceswith Li-ion consumer electronicswithLiionconsumerelectronics• No energy savings in going to CSL 1 for these products– But shipments of these products are includedG d NiCd lii t Lii–GoodNiCdappliances compare agans-on consumerelectronics– Li-ion based consumer electronics should bel d d f CSL 1excludedfromCSL1Scaling• Scaling proposed at public meetingi th li bilit f CSLimprovesthe applicability ofCSLover awide range of power levels–Appropriate for Eb levels higher the rep. unit• High correlation of data to regressionI it f l l l–Inappropriateforlowerlevels• Effect of fixed losses dominate at lower levelsEvidenced by lower correlation•Evidencedbylowercorrelation• Propose “break” at rep. unit for lower Eb’sOriginal Regression AnalysisArea ofConcern24-hourEnergyvs.BatteryEnergyProductClasses2-62,500.00,-------------------------------------200.00600.00800.001,000.001,200.00BatteryEnergy(Wh)Proposed – “break” at representative unit40.00-PU35.00_PC430.00UnitEnergyConsumptionvs.BatteryEnergyProductClasses2,3&4'"BatteryEnergy(Wh)y=1.4364XYy 0.9655)(+Kly'0.39.2.2)(+K95100LCC–benefit overstatementbenefitoverstatementUsage and life in PC 3&4• Usage in PC 3&4 – power tools not accurate– Pro -is: 2.70 should: 1.43• Why: 2 charges/ workday, 10 charges/7 days= 1.43– DIY detachable - is: 0.64 should: 0.29•Why: 2 charges/week 2charges/7days = 0 29Why:2charges/week,2charges/7days=0.29• Life – some lifespans are overstated–Wearout based on usage–at old usages life isWearoutbasedonusageatoldusages,lifeiscurtailed– Market life at “normal” usage is no more than 5 yearsLCC – benefit overstatementU fil i PC 2Usage profilesinPC2• Usage of MADB appliances in PC2 isdramatically distorted by inclusion of consumerelectronics in PCelectronicsinPC– Currently 0.55 charges/day• Most MADB appliances see onla few chargesy ga month (0.1 charges/day at the most)• Many electronics in the product class areh d l ti kchargedseveraltimes a week• Consider segregating MADB’s from non-MADB’sfor this PCforthisPCLCC–cost understatementCost of conversion to CSL 2 – Lithium• Holding Safety and utility constant– Charging Safety –• analysis maynot have considered uniform safetyacross allyCSL 2 products and associated costs• UL 2575 should correct this in time– Drives redundant, cell-by-cell monitoring and controlEnergy savings should not be an incentive to lower safety•Energysavingsshouldnotbeanincentivetolowersafety– Utility• Same performance: use of power cells rather than energycells-– Eb lower for power cells – more cells for same capacity• Same Cycle life – requires discharge control– Analysis does not consider cost impact of discharge controlSafety-Charge controlChargecontrol•Specified in UL2575SpecifiedinUL2575– While standard is not design proscriptive,state of the art usually requires:stateoftheartusuallyrequires:• Independent, redundant control• Cell-by-cell monitoring• Some manufacturers follow this already–Unclear if cost analysis was sensitive to theseUnclearifcostanalysiswassensitivetothesedifferences between productsUtility-Cycle LifeCycleLife•Pro tool users expect long cycle lifeProtoolusersexpectlongcyclelife• Typically 800 – 1000 cycles from NiCdLii ith t di h t l 250•-ion withoutdischarge control:250• Equivalent cycle life can be achieved withdischarge control– Requires circuitry on load side– Not included in analysis as focus was onchargingTypical Ni-Cd SystemN di h lNodischarge controlMOTOR10A Cycle Life test 18V NiCd with 6V cut-off2.5,--___________________________..,"515•""•5Channelproblemat••startup,•<I•-•05•••0•0200400600800t000t200CYCLENUMBER1·'1.'2"I18V 1.5Ahr Pack10A life with 5V cutoffLi-ion SystemElectronic Discharge control turns off at lowElectronicDischargecontrolturnsoffatlowcell voltage – extends lifeHi currentsolid statedeviceMOTORControlElectronics10A Cycle Life – 18V Li-ion with tool cut-off3-2.5•2•05ooI00200300••400-500CYCLENUMBER&600ItIP100223.566AhIIP100223·570AhI-••••-•.....-...-•7008009001000Multi-voltage ChargersvoltageChargers•Common in power toolsCommoninpowertools• Supported in TPH t h dl i St d d ?•HowtohandleinStandard?– Especially when voltage range crosses PCb diounaries• We made suggestions in supplementalcomments– Scaling helps