Freudenberg e-Power Systems

XALT Energy is a true leader in cell technology. Our lithium-ion cell technology combines lithium-ion chemistry, low-impedance cell design and world class manufacturing systems to give customers an unprecedented cost/performance advantage over any other technology. Our automation processes deliver cell quality and consistency that is unlike any other in the world. Our precision automated stacking of electrodes gives your cells consistent cell performance and vastly improved lifetime.

We offer NMC/Graphite chemistries to cover a wide range of applications. Each can be made into 2 sizes and a variety of different thicknesses. In addition, each has designs for the power to energy ratio needed.

Nickel Manganese Cobalt – Graphite (NMC-G)

XALT Energy Nickel Manganese Cobalt cathode cells with Graphite anodes (NMC/G) offer a great balance of power and energy with high reliability, safety with lower total cost of ownership.

Features

• Great reliability, consistent high quality and robust technology
• Proven chemistry since 1998
• Pouch style cell
• Larger surface area allows for better heat dissipation

The XPAND Module (XMOD) is FBPS's Energy’s ultra-high-density lithium-ion battery building block for highly integrated Energy Storage Systems (ESS) based on XALT Energy’s world-class lithium-ion cells. XMOD was developed for use in high-voltage, high-capacity multi-module arrays housed in large enclosures to achieve an overall reduction in system mass, volume and cost. XMOD is designed for use in heavy duty transportation vehicles like commercial trucks and buses, as well as rail.

Saving System Cost, Weight and Space

XMOD modules have the same core construction as the exceptionally durable XPAND battery packs, designed to be placed in your enclosure. The XMOD design is optimized for large systems where the integrator installs the modules in a suitable protective enclosure. Eliminating individual pack enclosures saves system weight and allows modules to be packaged very close to each other, resulting in higher energy storage capacity in the available space. Furthermore, with the module arrays enclosed in a protective enclosure, high voltage connections can be made directly to the XMOD terminals, thereby eliminating the need for costly HV connectors and cables.

Upgradeable, Ultra-Long Lifecycle

The XMOD module is designed to accommodate cells in XALT’s 225mm family without the need for retooling, anticipating a wide variety of application voltage, power and energy. This means as XALT’s cell technologies advance or modules become available for re-purposing, the XMOD can be replaced while all external interfaces remain the same.

Advanced Thermal Management

XMOD’s advanced active liquid cooling system maintains ideal cell temperatures throughout the module and responds quickly to increases in power demand and changes in ambient (environmental) temperatures. Efficient direct liquid cooling prolongs cell life under the most demanding cycle profiles, while maintaining reducing packaging volume.

The BMS is the “brains” of the XPAND system providing the monitoring, balancing and safety functionality for the system.

The main job of the BMS is to maintain the lithium-ion cells within their safe operating range regardless of the demands being placed on them. This means the ability to accurately predict operating situations that have the potential for creating over-voltage or under-voltage conditions, as well as high or low temperature conditions – then reacting quickly and safely to prevent those conditions from occurring.

• Proven, AEC qualified components
• Sealed enclosure (IP67/IP69)
• Modular & flexible design – components are interchangable and auto-addressing
• Scalable 4-360 series cell groups
• Supports single cell and parallel cell groupings

• Power, SOC, and SOH prediction
• Thermal system control and interface
• Charger control interface
• CAN 2.0A, CAN 2.0B, J1939 application
• Robust 2-wire communication with 1250VDC isolation working voltage

• Passive balancing up to 5W / Cell
• High Voltage Interlock Loop (HVIL) monitoring of each battery string and the application
• Redundant contactor control features to ensure safe operation
• Supports ASIL D voltage measurement and ASIL C current measurement
• Compatible with all Li chemistries

Advantages:

Ideal for energy storage applications where high performance and high reliability are key to successful integration:

• Commercial bus & transportation
• Medium and heavy duty trucks
• ISO and sub-ISO marine
• High performance / high voltage apps
• Industrial equipment
• Light rail

Features:

• Multi-string management – for large scale systems of parallel battery strings
• Battery system performance algorithms (SOC, SOHc,SOHr, power available, optimal charging)
• High voltage interlock loop monitoring and control
• Isolation resistance measurement
• Battery usage recorder
• Functional safety features protected by SafeRTOS
• Telematics – data collection

Battery Controls

Battery Disconnect Unit/String Control Unit (BDU/SCU)

The BDU manages individual strings of series-connected XMP subpacks through its on-board String Controller Unit (SCU), pre-charge circuit, current sensor, and contactors. For large XPAND systems of multiple parallel-connected strings, BDUs are connected in parallel.

• Compatible with 12V or 24V systems
• Isolated high voltage measurements up to 1250 VDC
• Current sensing capability -500A to +500A standard; up to ± 1200A optional
• Redundant dual contactor controls ensure safe operation
• Self-addressing provides simple installation and service
• IP69 compliant (with connectors mated)

Master Control Unit (MCU)

The MCU manages multiple parallel strings (up to 24) while providing a single and simple interface to the application controller.

Features

• Compatible with 12V or 24V systems
• Autonomously controls balancing of battery strings
• Provides autonomous addressing to individual battery strings, supporting a true modular architecture
• HV Interlock Loop (HVIL) monitoring of each battery string
• Provides collective system and diagnostic information to the application
• IP69 compliant (with connectors mated)

XALT Rack System (XRS-2)

XRS-2 with Pack and CellsThe XRS-2 is a highly configurable rack system designed to contain XPAND XMP battery system components for marine applications. The rack has been validated to pass the aggressive DNV-GL vibration specifications and resist the harshest corrosive environments, all while minimizing size and weight. It is exceptionally easy to install, service and upgrade while being modular and expandable, width and height can be optimized for any application. The XRS-2 can be populated with any of the XPAND XMP sub-packs. Specialized coatings provide extreme resistance against corrosion.

Features

• Designed for use with XPAND XMP sub-packs
• Easy to install, configure, and upgrade
• Integrated liquid cooling distribution and off-gas ventilation ducting
• Expandable to virtually no limit

Telematics

Access any of your battery systems in applications world-wide through the XBV Portal. The XBV telematics system consists of a control unit and an all-in-one antenna that allows you access to data that has been consolidated for easy viewing from virtually any electronic device that can be connected to a web-based portal. Intuitive dashboards show all critical battery system information and monitor the status of all your battery systems simultaneously on one interactive map. Data gives you the ability to provide a prognostic approach to servicing applications which reduces down-time by knowing when to schedule service and being able to respond quickly to system issues. XBV is easily integrated into new designs or existing systems and has a wide range of operating voltages. XBV allows access to historical location tracking and geofence, has diagnostic reporting capabilities and can generate reports and logs.

Features

• Multiple connectivity options (2G, 3G, 4G, WiFi)
• Easily integrated into new designs or existing systems
• Adhesive mount antenna for quick and non-intrusive installation
• Robust electrical and mechanical design
• Wide range of operating voltages
• Supports multiple CAN baud rates
• Historical location tracking and geofence capabilities
• Diagnostic reporting capabilities
• Generate reports and view logs

Advantages

• Multiple connectivity options (2G, 3G, 4G, WiFi)
• Easily integrated into new designs or existing systems
• Adhesive mount antenna for quick and non-intrusive installation
• Robust electrical and mechanical design
• Wide range of operating voltages
• Supports multiple CAN baud rates
• Historical location tracking and geofence capabilities
• Diagnostic reporting capabilities
• Generate reports and view logs

Fuel Cell Technology Products & Systems

Complete Fuel Cell Systems for Carbon-Neutral, Heavy-Duty Applications

Fuel cell technology from Freudenberg Fuel Cell e-Power Systems offers a breakthrough in clean, reliable alternate powertrain options for the transportation and other essential industries. Passenger ferries, yachts, container ships, trucks and passenger buses will all go farther, work harder and generate fewer CO2 emissions in a future that runs on fuel cell energy. When extreme power, long-term reliability, optimal total cost of ownership and sustainability are paramount, Freudenberg offers unparalleled quality solutions to keep your products moving.

Reinforced by more than 30 years of fuel cell research and development, Freudenberg’s offers technologically superior fuel cell solutions harness the company’s world-class materials, testing and engineering capabilities. The company provides heavy-duty application manufacturers with a single point of contact for all of their fuel cell needs, from functional components to complete fuel cell systems. This includes all necessary subsystems (balance-of-plant) and services such as telematics, remote monitoring, field service and cost-optimized refurbishment of stacks. Freudenberg's expertise not only covers low-temperature PEM fuel cells (LTPEM), which are commonly used in transportation, but also high-temperature PEM fuel cells (HTPEM).

Fuel Flexibility as Unique Selling Point

Every customer has unique system requirements and Freudenberg Fuel Cell e-Power Systems are manufactured to optimize system flexibility. Fuel flexibility for maritime customers, in particular, is a unique company strength. For ships with long range requirements, Freudenberg offers both classic direct hydrogen systems and systems with integrated fuel reformers. The integrated reformers enable ships to use carbon-neutral fuels with higher energy density, such as e-methanol. With this proprietary technology, Freudenberg offers its maritime customers years of reliable, carbon-neutral ocean travel that is sustained by the superior service life and flexibility of its fuel cell systems.

The Freudenberg fuel cell portfolio also offers another impressive technological solution to customers: A hybrid system that seamlessly combines the advantages of a battery and fuel cell in one power solution. These hybrid designs maximize fuel efficiency, performance and service life while lowering investment costs. Freudenberg is the only supplier on the market with the deep technological expertise required in both fuel cells and batteries systems and components to engineer and integrate these power sources into intelligent hybrid systems. It goes without saying that the company also develops an intelligent energy management solution for these systems, in accordance with ISO26262 standards.

Multiple Benefits for System Operators

Freudenberg offers the market unique in-house, value-added benefits in every hybrid solution it engineers. Whether starting with a separator and cell and finishing with a complete battery system or starting with gas diffusion layers, a membrane electrode assembly (MEA) and a stack and finishing with a fuel cell, Freudenberg systems can be modularly assembled with different performance levels depending upon the required performance profiles. For system operators, this means higher efficiency, better suitability for everyday use and cost advantages in terms of total cost of ownership.

Freudenberg Fuel Cell e-Power Systems offers complete electric power systems to customers that are environmentally friendly, provide maximum power and cost efficiency, are reliable "long-distance runners" and combine low weight and flexible installation designs. As a single source supplier of all fuel cell requirements, Freudenberg Fuel Cell e-Power Systems is ready to partner with you to power up your future success.