Transcript Process Planning and Its Integration with Design and

A New renewable Energy
Generating Power from EPAM
(Electroactive Polymer Artificial Muscle)
Professor Kesheng Wang
Department of Production and Quality Engineering
Norwegian University of Science and Technology
N-7491 Trondheim, Norway
Tel. 47 73 59 7119, Fax 47 73 59 7117
E-mail: [email protected]
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7/16/2015
Generating Power from EPAM (Electroactive Polymer
Artificial Muscle)
ACTUATOR
E
EAP
W
ENERGY
(ELECTRICAL)
MECHANICAL WORK
GENERATOR OR SENSOR
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Traditional Renewable Energy

Photovoltaic power generation
 Wind power generation
 Wave power generation
 Biomass power generation
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Problems for Traditional
Renewable Energy Generation






Complex mechanical devices
Big place to install devices
Difficult maintenance
High cost
Long time to make them be main energy
production
……
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New Renewable Energy






A new power generation method
Ecological and practical energy
EPAM method
Generating energy by the movement of any
objects
Large-scale power generation (wind, Wave)
Small-scale power generation (human movement)
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What is an Electroactive Polymer
Artificial Muscle?

EAP converts electrical energy to
mechanical work and vice versa.
ACTUATOR
E
EAP
W
MECHANICAL WORK
ENERGY
(ELECTRICAL)
GENERATOR OR SENSOR
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Many Types of EPAMs
Dielectric
elastomers are
particularly
promising
Dielectric Elastomer
a.k.a.
Electroelastomers
Electrostrictive Polymer
Conducting Polymers
IPMC
“Artificial
Muscle”
Thermal and Others
Gels
Nanotubes
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Advantages of EPAM

Lighter – low density, high performance,
multifunctional polymers (Polymers are 1/8 the density of
common materials used in engines and generators)

Cheaper – inexpensive materials, fewer parts, no
precision machining

Quieter – high energy density and compliance of
polymers allows quiet primarily sub-acoustic operation
with few moving parts

Softer – rubbery materials are impedance matched to
large motions (e.g. human motion, engines)

Versatile – polymers are scale-invariant; systems can
be made in variety of form factors (conformal, elongated,
etc.)
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Dielectric Elastomers: Principle of Operation

Dielectric elastomers are a type of
EAP that uses an electric field across
a rubbery dielectric with compliant
electrodes
Polymer film
Voltage off
Compliant electrodes (on
top and bottom surfaces)
V

Variable capacitor generator– energy
generated as nearly incompressible
polymer layers increase in area and
decrease in thickness when stretched
+Vout
(high)
+
_
+
_
Voltage on
BASIC FUNCTIONAL ELEMENT
Compliant Electrodes (2)
+
_
+
_
+Vin (low)
+
_
Dielectric Elastomer
EAP STRETCHED
Energy = ½ Qo2 (1/Cf - 1/Ci)
C = er eo x film area/film
thickness
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+Vout
(high)
9
+
+
+
+
+
_
_
_
_
_
EAP RELAXED
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+Vin (low)
Many Possible EAP Transducer Configurations
V
DIAPHRAGM
EXTENDER
Active
Electrode Area
V
V
STACK
V
V
V1
BIMORPH
ROLL
TUBE
V2
V
UNIMORPH
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Polymer Dielectric Elastomer Materials
Several elastomers work well

Acrylic and silicone are most
promising and have shown
exceptional energy density


Acrylic has greater energy
density but also greater
damping and electrical
leakage
Silicone has exceptional
temperature range
(–60 to 260 C)
.45
Specific Energy Density [J/g]

Latest Acrylic
Energy Density Tests
.40
.35
.30
.25
.20
.15
.10
End of 1999
Acrylic Tests
.05Verification
0
of
HS3 Silicone
Phenomena
12/98
Initial Acrylic
Tests
2186 Silicone
6/99
12/99
Demonstrated Specific
Energy Density
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Time
Power Conversion and Management

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Power available from dielectric elastomer EAPs is at a high voltage (e.g., 2
kV)
For most applications we would like to charge batteries at a low voltage (3–48
volts)
Some applications can use high voltage directly (e.g. night vision optics, inboot actuators)
High-voltage is not all bad: low current can allow for thinner, lighter wires
and simpler connectors
Battery or capacitor energy storage is needed to smooth output
Voltage
Step-Up
Polymer
Device
Voltage
Step-Down
Battery
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Output
Multifunctionality
Dielectric elastomers can combine several functions
ACTUATOR or
GENERATOR
SENSOR
STRUCTURE: Support,
Transmission, Spring, Damper
» Simpler
» Lighter
» Higher Performance
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Artificial Muscle: Dielectric
Elastomer Actuation
Dielectric elastomers have already shown
unique capabilities in a variety of actuator
applications
Artificial Muscle Roll
Bending Rolls
Mirror Shape Control
Insect-inspired Robot
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Snake Robot Segment
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Applications of EPAM
Many power generation applications can benefit from the advantages of EAPs
Engine Generators
Shoe and other
Human-Powered Generators
Parasitic Energy Harvesting
Wave & Tidal Power
Pumps and valves for fuel management
Wind Power
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Harvesting Human Movement
Several possibilities that do not excessively burden the wearer:
Heel Strike and Shoe Flexure 2–20w
Backpack Suspension and Padding
0.5–5w
Limb Swing 0.2–3w
Chest or Torso Expansion
From Breathing or
Routine Movement
Hand or Leg Cranked Generator for Emergency
0.1–1w
Back-up (Short-term) 10–100w
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Enabling a Heel-strike
Generator

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Energy from the heel strike is “free” - it would otherwise be dissipated
as heat
Energy converted per step with reasonable heel compression can be up
to 5 J
Power generated (both feet) during walking is 1W to 10 W
The amount of electrostrictive polymers needed to convert 5 J is less
than 50 g or 50 cc.
Electromagnetic or piezoelectric devices would weigh more than 10
times this weight
Conventional technology (“direct
drive”; including piezoelectrics)
EAP-based design
Relative Mass, Size, or
Cost for boots with
equivalent performance
and functionality
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Heel-strike Generator



Developed a heel-strike generator
to capture free energy while
walking
Demonstrated up to 0.8 J per heel
strike
Developed multi-layer polymer
fabrication techniques
 Demonstrated 15 layer device
+Vout
+ Dielectric Elastomer (EAP)
+
+
_
_
_
+ _
_ +
+V
in
Base
+Vout
Compliant Electrodes (2)
EXPANDED
+ +
+
+Vin
_ __
_
+
+
_
CONTRACTED
Heel-Strike generators are
expected to produce 1W of power
under normal walking conditions
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Applications of a Heel-strike Generator

Boot generator can assist the dismounted soldier in several distinct ways
 Power source or battery recharger to reduce battery weight for a mission
 Smart Shoes, Multifunctional Footwear - simplify logistics by reducing
the number of separate batteries or devices required
 power an instrument that should logically be located in a boot for
best operation:
 personal navigation system, medical status monitor,
foot warmer
 power a device that could be located in a boot for weight
or space savings
 Friendly ID beacon, comm link, magnetometer,
chem/bio detector, special battery or capacitor for
high-voltage device such as night vision scope
 Dynamic Footwear - Actuation or Adaptability for enhanced
performance
 reduced injury
OFW Concept
 improved comfort
Source: Natick
 more efficient load carrying
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Can EPAMs overcome limitations of Small
Portable Power Sources?



MAVs, Land
Current small fuel-burning
engines/generators:
Robots &
Vehicles
 Noisy
need efficient
 Inefficient (typically 5-7%)
and quiet
 Require special fuel mixtures
Electrical +
 Not inherently hybrids or
Mechanical
multifunctional - Need separate
Power
components for both mechanical and
electrical energy production
Batteries:
 Electric only
Future Soldier Systems need
 Low energy density (heavy)
efficient and quiet Electrical +
 Slow to recharge, hard to dispose
Mechanical Power
Fuel cells:
 Electric only
 Limited to certain types of fuel and
cannot run on dirty fuel
 Require additional components
and warm-up time
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Specific Example:
Mentor Micro Air Vehicle

DARPA TTO project for a MAV capable of
operation in cluttered environments
Vehicle Specifications:
Total Weight (Wet):
Engine
Fuel & Tank
Batteries for electronics
and servos
Power required (hover):
550 g
140 g
75g
30g
Performance:
Hover Duration
(50g fuel)
Payload Capacity:
98 W
Superfly 2.5
“World’s First Hovering Ornithopter”
University of Toronto Institute
for Aerospace Studies with SRI
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8 min.
30 to 70g
Palm-Power Program

Specific Needs can be seen in
Palm Power Program Goals:
 Convert chemical energy of common fuels to mechanical
/ electrical energy for needs
 20 Watt average power level at 12 Volts DC
 Typical Missions :
 Three-hour MAV reconnaissance mission - 1000
Wh/kg
 Three-day Land Warrior mission - 2000 Wh/kg
 Ten-day special operations reconnaissance mission 3000 Wh/kg
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An All-polymer Engine: The Answer?

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Light: Uses lightweight electroactive polymers instead of metallic
piston/cylinders + electromagnetic generator
Can operate sub-acoustically or with quieter external combustion cycles
Unlike fuel cells and many small engines, can run efficiently on dirty
logistics fuels
Low cost and rugged – eliminates parts and bearings
Can be made in a wide variety of shapes and sizes
Electromagnetic
Generator
Dielectric elastomer
Crankshaft
Conditioning
Electronics
Piston
Cylinder
Electrical
Output
Conventional Generator System
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Conditioning
Electronics
Electrical
Output
Comparable Polymer Engine
System
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High Efficiency?

Polymer engines can potentially be
much higher efficiency than IC or other
conventional engines:
 Lower thermal conductivity of
P
polymer walls
 No sliding surface friction
 No leakage of expanding fluid
 Can exploit resonance
 Opportunity to use novel or
optimally tuned thermodynamic
cycles
 Expansion pressure controlled
electronically; ability to draw
power at virtually any point in
cycle
 Low inertia
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1
Practical Cycles
Only Approximate
Ideal Cycle
4
2
3
Stirling Cycle
V
20% or more?
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Hybrid Power



Many DoD applications (e.g. robotics, MAVs) require both
mechanical and electrical power
Polymer engine with mechanical and electrical output can
eliminates entire transducer steps
 Fuel cells: chemical  electrical  mechanical
 IC Engine + generator + motor: chemical  mechanical 
electrical  mechanical
 Polymer engine: chemical  mechanical + electrical
Hybrid polymer engine saves parts, weight and is more efficient
Combustion inside EAP
roll causes linear 23%
expansion that could be
used for both electrical
and mechanical output
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By the Numbers

Polymer engines promise better overall performance than existing
electrical and mechanical power sources
Efficiency
(%)
Power
density
(W/g)
IC engine
6
Fuel Cell
Approach
Output
Noisy
2
Mechanical
only
Very
30
0.1
Electrical only
No
Electric Motor
20-80
1
Mechanical
only
Somewhat
Electrical
generator
70-80
1
Electrical only
Somewhat
Polymer
engine
20
4
Electrical +
Mechanical
No
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Can it be done?:Polymer Engine First Steps



Successful demonstration of
polymer engines operating with high
temperature combustion gases
(>1000 ºC) for over 3 hrs at 3 Hz
 High temperature operation
allows for high thermodynamic
efficiency
 Micro-pitting observed, coatings
could prevent pitting
 Energy density already similar
to batteries (500 Whr/g)
Multiple fuels demonstrated
(butane, propane, hydrogen)
External combustion cycle also
demonstrated
DARPA/ARO program aimed at
addressing the key technical challenge –
Can a polymer “cylinder” survive
combustion?
Air
Air
Combustion
Combustion
chamber
chamber
Propane
Propane
Valve
Flow rate
controllers
27
Spark
Spark
system
system &&
generator
generator
electronics
electronics
Roll-based
Diaphragm-based
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Flame
arrester
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Other Power Applications of EPAMs

Polymer actuators may offer advantages for
other power systems
 Valves & pumps for fuel cells
 Actuated valves for engines, air controls,
fuel pumps, etc.
Polymer diaphragms can provide large
displacements for lightweight pumps
Proof-of-principle diaphragm array pump.
Dielectric elastomer actuator for direct
control of engine valving
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Simple Sensors


Simple low-cost large-strain sensor
is a simple embodiment of a
generator
Well suited for:
 Human motion
(Plethysmography, Kinesiology)
 Computer input devices for
virtual reality applications etc.
 General purpose displacement
detector for low-cost
instrumentation and
measurement
 Low-cost position, force or
pressure sensors for actuators,
generators, etc.
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Large variety of sensors can be
based on dielectric elastomers
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Power from EPAM?



EPAMs are promising for addressing a
variety of power generation challenges
First proof-of-principle devices made and
tested
 Variety of transducer configurations
 Heel-strike generator
 Polymer engine
Improved devices are under development
 Lifetime issues are being addressed
 Electronics for power management is a
key challenge
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Human-Powered Generators



Large-strain capability of electrostrictive
polymers allows for simple and efficient
integration into generators
 efficiency is not speed dependent
 device can weigh 10x less than an
electromagnetic generator with the
same output rating
Novel generator designs with few moving
parts are possible
Similar devices can also be couple to nonhuman power sources (e.g. engines, wind
turbines)
PISTON
Linear generator
MULTILAYER STACK OF
ELECTROSTRICTIVE
POLYMER ELEMENTS
HAND CRANK
SLIDER
MULTILAYER STACK OF
ELECTROSTRICTIVE POLYMER
ELEMENTS
Rotary generator
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Lighter Generators for Engines


High energy density and large strain capability of EAPs allows
for simple, lightweight and efficient integration with
combustion engines
Novel engine/generator designs are may be a higher
risk/higher payoff alternative
MULTILAYER STACK OF ELECTROSTRICTIVE POLYMER ELEMENTS
PISTON
SLIDER
ROTARY ENGINE
MULTILAYER STACK OF ELECTROSTRICTIVE POLYMER ELEMENTS
ENGINE CRANKSHAFT
Linear generator/piston
engine combination
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Rotary generator/engine
combination
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Wave-powered generators

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

In August, 2007, the prototype of the buoy type power
generation device has been completed and the first
experiment has been done in Tampa, Florida. (SRI, EAPM
company and Hyper Drive)
Single layer, 58cmx20cm and 100μm in thickness EPAM
(40g) can generate 1.8 W electrical energy from a wave 12
cm in height which is repearted once every three seconds
(the generation energy from one wave is 5.4J). The energy
conversion effiency at this time was about 46%)
It is easy to get more energy using many layers construction.
Advantages: device is simple, no complex mechanical
devices, low cost, high efficiency and easy maintenance.
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The buoy for wave-powered generation floating off the coast
of Florida. EPAM units are mounted in the center (photo:
courtesy of Hyper Drive and SRI International).
The black portions are cylindrical EPAMs (photo:
courtesy of Hyper Drive and SRI International)
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New wave-powered generators
in North Sea

New type of wave-powered generators
 New type of tide-powered generators
 New wind-powered generators
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Idea for the wave-powered
generator
(EPAM array)
+V out
-V
+V inn
Flame
EPAM
Axis
Holes in float
Body moved related to
axis
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Challenges






Low cost, ecological and practical power
generation methods.
NTNU’s competence in the field of EPAM both in
international and national.
Research and development in actuator, sensors and
power generator
Industry applications of EPAM
New materials in EPAM
Electronic system design
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New Renewable Energy
Projects

New design
 New material
 New companies
 New applications
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Research and development
alliances







NTNU
SINTEF
NN (Norwegian Industries)
SRI (USA)
Hyper Drive (Japan)
Shanghai University (China)
etc
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Funding for pre-project







NTNU
SINTEF
Innovation Norway
NFR
Industries
EU
?
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Thanking
further!!
New revolution or
innovation?
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