October 02, 2019 by Sam Holland
A supercapacitor, also known as a double-layer/ultracapacitor, differs from the ordinary capacitor due to its different characteristics such as energy density, materials used, cost, and so on.
Typically a single supercapacitor can store 10 to 100 times more energy than a standard electrolytic capacitor. Even though individual supercapacitors can have very high capacitance, their maximum voltage ratings are low. That’s why the need for supercapacitor modules has increased considerably; they can provide higher voltage ratings than individual capacitors.
These double-layered capacitors don’t use the conventional solid dielectric materials like an ordinary capacitor. Instead, they are based on a carbon technology which creates a large surface area even though space between layers is extremely small. Moreover, these ultracapacitors can be charged and discharged continuously for thousands of cycles without facing any kind of energy loss. Therefore, the usage of supercapacitor modules will not only help to save energy but also reduce noise to provide a more stable electrical system.
Eaton, a power management company that has been providing energy-efficient solutions for more than 100 years, has developed XLR Energy Storage Supercapacitor modules (48V and 51V), which are specially designed for high-power energy storage. The company claims that its supercapacitors are maintenance-free and have a lifetime of up to 20 years.
XLR Supercapacitor module. Image Courtesy of Eaton.
XLR Energy Storage Supercapacitor modules are comprised of individual XL60 supercapacitor cells that provide low ESR for high power density. They can operate reliably even in extreme or harsh environments (-40 °C to +65 °C). These modules can undergo millions of charge/discharge cycles and can operate at a maximum working voltage of 48.6V. They can be easily mounted and include integrated cell voltage management circuitry, an overvoltage alarm, and temperature output. XLR Supercapacitor modules have an IP65 environmental rating for high dust areas and water jet washable.
The XLR-48 is comprised of 18 individual 2.70 V XL60 supercapacitor cells while the XLR-51 is comprised of 18 individual 2.85 V XL60 supercapacitor cells which provide higher power density.
Eaton XLR Energy Storage Supercapacitor modules don’t contain any harmful substances which can affect the environment. Since they are RoHS compliant, these modules are considered as non-hazardous storage.
Eaton’s supercapacitor modules can be used in a wide range of industrial, automotive, and other kinds of applications as given below:
Hybrid and electric vehicles
Forklifts
UPS systems
Trolleys, cranes, and electric carts
Robotics
Trains, trucks and other automobiles
Subways
Marine systems
Typically, supercapacitor modules are used in all the above applications to provide one or more of the following functions:
Power boost and backup
Power stabilization and smoothing
Regenerative braking and energy capture
Energy storage
Many warehouses use pallet shuttles, park lifts, and other kinds of equipment to improve the shipping speed of products. Usually, Li-ion batteries are used as the primary power source in them. Since the batteries need to be replaced frequently, it leads to a high maintenance cost. Moreover, these batteries are not environment-friendly, as they contain hazardous materials that need to be disposed of right away after replacement.
Eaton Supercapacitor modules can be used as an alternative for batteries, as they can be fully charged within seconds or minutes. They can also efficiently deliver their entire charge quickly depending on demand. Therefore, Eaton XLR Energy Storage Supercapacitor modules are ideal for modern warehouses to help them run not only consistently and reliably but also to significantly reduce their maintenance costs.
