Reference brochure ION-LINE safety storage cabinets for practical storing and charging of lithium-ion batteries
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3 With support from: The Stauferklinikum – Ostalb Clinic, Mutlangen, Healthcare Hexadrone, Saint Ferréol d‘Auroure, Aviation Planet Monic, Saint-Priest-en-Jarez, Trade PHI 4 TECHNOLOGY SL, Noblejas, Science & research University of Sheffield, Science & research see you RENT GmbH, Berlin, Media Volunteer Fire Department, Greifswald, Public service bravobike GmbH, Munich, E-Mobility Beic Parcio Cymru Ltd., Abercanaid, E-Mobility
4 Maximilian Weil, ION-LINE Product Manager at asecos ››› ION-LINE safety storage cabinets: More safety for storing and charging lithium-ion batteries.
5 ION-LINE safety storage cabinets in practice Table of contents 1 2 Lithium-ion batteries 1.1 Lithium-ion batteries – safe storage and charging . . . . . . . . . . . . ....... Page 6–7 1.2 Didyouknow...? . . . . . . . . . . . . . . . . . . . . . . . ............. Page 8–9 Practical variants 2.1 Medical & healthcare – Stauferklinikum, Ostalb Clinic . . . . . . . . . . ....... Page 12–13 2.2 Aviation – Hexadrone . . . . . . . . . . . . . . . . . . . . . . ............ Page 16–19 2.3 Trade–PlanetMonic . . . . . . . . . . . . . . . . . . . . . . ............ Page 22–23 2.4 Science & research – PHI 4 TECHNOLOGY SL . . . . . . . . . . . . . ........ Page 26–27 2.5 Science & research – University of Sheffield . . . . . . . . . . . . . . ........ Page 28–29 2.6 Media–seeyouRENTGmbH............................. Page 32–35 2.7 Public service – Greifswald Volunteer Fire Department . . . . . . . . . . ...... Page 37–39 2.8 E-Mobility–bravobikeGmbH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 42–43 2.9 E-Mobility–BeicParcioCymruLtd.. . . . . . . . . . . . . . . . . . . . . . . . . . Page 44–45
6 Virtually no other technological trend has been as unstoppable in recent years as the development of ever more powerful lithium-based (Li) energy storage options. Whether in electric cars, electric bikes, cordless screwdrivers or cell phones – the metal lithium is used in many single-use and rechargeable batteries. These super-efficient power stores have a high energy density and are very effective. Without the undesirable memory effect that impacts other battery types, they are particularly suitable for small devices. At the same time, they do pose a fire risk when damaged. Due to their high energy density, they represent fire loads that could potentially cause significant damage. The potential hazard grows when batteries are charged without monitoring, for instance outside of work hours. Today, few work areas can function without lithium batteries. asecos has partnered with ION-LINE safety storage cabinets to develop fully customised solutions with excellent operating convenience and a practical safety concept for storing and charging batteries. In this brochure, you will read about how and where lithium-ion safety storage cabinets are used, and will learn more about intelligent ways to integrate them into your everyday work. LITHIUM-ION BATTERIES – SAFE STORAGE AND CHARGING
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8 DID YOU KNOW…? … the Nobel prize in Chemistry was awarded in 2019 for the development of lithium-ion batteries? … 70 % of the world's lithium supply is found in brines in South America, where it is mined? … Lithium is the lightest metal on Earth? … the world’s smallest lithium-ion battery is thinner than a single hair? You should also know that... … lithium is highly reactive. Damaged batteries can pose a f ire hazard … external heat or energy sources can heat up lithium batteries, thereby causing thermal over load and fires. … a Li-ion battery reacts negatively to deep discharge or overload … the service life and hazardous potential of a battery is dependent on its use and storage conditions and because of this … … only charge with the original charger … store batteries in a dry and cool place … protect batteries against mechanical damage … do not store and charge batteries near fire loads … never cover batteries during the charging process … do not leave batteries unsupervised while charging For more facts about lithium-ion batteries and an overview of all of our safety storage cabinet models, please see page 46.
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10 MEDICINE & HEALTHCARE
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12 Today, single-use and rechargeable lithium batteries are the first choice for advanced medical equipment. They offer the highest specific energy and energy density of any battery type. Single-use and rechargeable lithium-ion batteries were first used in pacemakers in the 1960s; today all kinds of medical devices are being powered by these batteries, including automatic external defibrillators, infusion pumps and bone growth stimulators. Lithium batteries are used in the Stauferklinikum in Schwäbisch Gmünd to operate surgical saws. These are used in accident and spinal surgery, specifically to treat broken bones, in spinal operations, and in hip and knee operations. The Stauferklinikum is a member of the Ostalb Clinic Network which, alongside the locations St. Anna-Virngrund Clinic Ellwangen and the Ostalb Clinic in Aalen, comprise around 1,000 beds and 3,000 employees, and treat over 50,000 inpatient cases each year. Speciality medical disciplines at the Stauferklinikum cover a broad and highly specialised spectrum of care. The best available treatment is delivered quickly to patients through interdisciplinary collaboration between departments. Highly specialised diagnostics and treatment, in particular thanks to a wide range of surgical services, ensure great patient care in the Schwäbisch Gmünd area and beyond. The clinic’s medical care is complemented by a wide range of treatments and nursing services. Battery-powered surgical instruments in every day use Battery-powered surgical instruments are used every day, so they must be ready to deliver 100% performance any time, in particular for emergency operations. This can only be ensured through safe storage and safe charging of the instruments. Because of this, the Stauferklinikum chose to install two type 90 (90 minute fire protection) safety storage cabinets for charging and storing lithium-ion batteries and rechargeable batteries from asecos, the leading manufacturer of safety storage cabinets in accordance with European standard EN 14470-1 / -2. “Guaranteed fire protection, in particular, was the decisive reason for choosing asecos safety storage cabinets. That is why we specifically decided to purchase two cabinets as well. Now, half of the batteries are stored in each cabinet at all times. This means battery availability and charging capacity are always ensured, even in case of an emergency. If there is a fire, rescue Ostalb Clinic – Reference Stauferklinikum | Germany OPERATING ROOM SAWS AND DRILLS – LI-ION BATTERIES IN THE HEALTHCARE SECTOR “Especially guaranteeing fire protection...”
13 personnel also have 90 minutes to safely transport the cabinets out of the operating room” says Andreas Franzmann, Head of Corporate Communication for the clinic association. Maximum safety with high mobility asecos developed the ION-LINE type 90 cabinet series to offer the necessary protection for storing and charging highly flammable and highly reactive lithium-ion batteries. The cabinets make it possible to safely store new or used batteries and rechargeable batteries in mid-tier power classes (according to VdS 3103: 2019-06 (03)) either passively or actively. Active storage means that batteries can not only be stored, but also connected to the socket strips inside the cabinet for protected charging. The type 90 lithium-ion safety storage cabinet from asecos guarantees two levels of protection. If a fire occurs outside the cabinet, the batteries inside are protected against overheating for one and a half hours, and thereby prevented from becoming unstable or exploding. This time is essential for initiating rescue measures or evacuations. This 90 minute fire resistance also applies from the inside out for this specific cabinet design for storage and charging. There is a risk of explosions in particular during the battery charging process. When a safety storage cabinet is used, the batteries are safely protected inside the cabinet. Battery fires are also dangerous for rescue personnel, as they release carcinogenic hydrocarbons, hydrofluoric acids or heavy metal deposits; there is also a risk of the batteries bursting and of flying parts. Optimal safety relies on the interplay of both people and technology. This starts with comprehensive advising to select and equip safety products. The more precisely these products are tailored to prevailing circumstances and work processes, the more effective they are. The Stauferklinikum’s safety concept, which has now been expanded, also covers evacuations and has been coordinated with the responsible fire department. One important part of the concept is the clearance underneath the lithium-ion cabinets The lithium-ion safety storage cabinets were set up near the door and at ground level in the clinic. In case of an emergency, rapid and safe evacuation is ensured. The safety storage cabinets also have a fire-proof pipe opening. The clinic has installed a fire detector inside each cabinet, which is part of the fire detector system. With this approach, the safety storage cabinets are connected to a permanently staffed fire alarm centre which can react as quickly as possible if smoke is detected. If there is no internal fire detector system in the building, relay or remote control modules offer the ability to forward the alarm. “Our experience with the cabinets has been entirely positive, even after just a few weeks of use. Our employees are absolutely satisfied with their finishing, handling and design” says Andreas Franzmann. An experienced and confident user like the Stauferklinikum is a valuable partner in helping ensure the technology can perform its full protective and preventative function as part of an overall safety concept. Project summary Company: Stauferklinikum – Ostalb Clinic Location: Mutlangen, Germany Industry: Healthcare Application: Battery-operated surgical devices 1 For storage of flammable liquids. 2 For storage of pressurised gas cylinders.
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16 Nowadays, almost everyone is familiar with these tiny aircraft: from hobby users taking fascinating aerial images, to professional equipment for companies or airborne operations in the military sector. Drones are highly popular, and continuously developing. As the technological possibilities expand, more and more new applications are found for unmanned aviation, and drones are being used in even more areas. French company Hexadrone specialises in developing drones for use in civil and military applications. Hexadrone was borne from the passion of its founder, Alexandre Labesse, for mechanical systems, photography, and building model aeroplanes. Since it was founded in 2014, the company has grown steadily: after initially offering flight services, it now also trains telepilots, sells its own drones, and above all assembles and designs custom drone solutions. Tundra, a fully modular and intelligent drone, is considered the company's flagship product. The drone can change its flying characteristics by exchanging arms, thereby adapting to its environment. Flying support Drones like the Tundra are used, for example, when searching for avalanche victims. The search for a buried victim is a true challenge for rescue personnel. In addition to the winter conditions, low temperatures and deep snow, rescue personnel reaction time is a key factor when searching for avalanche victims. Using drones for such critical tasks exposes search and rescue personnel to fewer risks, shortens search and intervention times, and helps locate victims more precisely. However, military uses represent another application for these kinds of drones. Here as well, in contrast to planes or helicopters, drones can support ground troops for hours or even days, delivering ongoing information about the surrounding area and transmitting data to deployed soldiers in real time. Especially for such applications, it is important that the drones not only work safely, but also that they are optimised for long flying and working times and high payloads. High-performance batteries like lithium-ion batteries are used to do so; an optimal power supply not only keeps drones in the air longer, but the batteries are also extremely lightweight. However, such powerful batteries also bring risks. High fire risk during charging There is a high risk of fires, in particular when charging lithium batteries. If a defective lithium battery is connected to a charger, it may no longer be able to correctly convert the energy being fed into it. The energy generates warmth, and if this warmth turns into heat, it may cause a fire. Defects in the battery can be caused by a variety of factors. These include mechanical damage to the lithium battery (falls, impacts, crushing) or improper Hexadrone SAS | France DRONES CONQUER THE AIR
17 storage (thermal loads, the effects of moisture, deep discharge). However, there is a potential risk even when charging undamaged lithium batteries. The battery could be overloaded, for example, due to an excessive charge voltage or charging time with defective or non-original chargers. Exposure to significant external heat can also be dangerous. In short: when charging lithium batteries, there are many sources of faults for the user. If a lithium-ion battery does cause a fire, ION-LINE models offer a multi-stage warning and fire suppression system for improved safety. Preventative action To ensure Hexadrone can offer the best possible protection for its employees, Alexandre Labesse has focused on safely storing his drones, and in particular their lithium-ion batteries. “Our insurer’s requirements related to fire and explosion risks have caused us to think more carefully about the issue of safe storage for lithium-ion batteries. We quickly recognised how important and necessary it is to protect our equipment and avoid major destructive events. In addition, we want to have just one storage area for batteries. In the past, we stored lithium-ion batteries in simple shelving units and carried out charging and discharge processes directly at work stations in the workshop. Because of this, Hexadrone was looking for a fire-safe solution that makes it possible to store and charge lithium-ion batteries safely.” Safety storage cabinets from asecos meet these requirements, and allow for active storage of lithium-ion batteries. Battery packs can be charged directly in the safety storage cabinet with the help of the right charger. Integrated in the daily work process Mr Labesse remembers: “Before we purchased the cabinet, lithium-ion batteries
18 were stored on shelves, and charging and discharge processes were carried out at work stations in the workshop. Today, the safety storage cabinet is a fixed part of our work organisation, and we use it multiple times a day”. Hexadrone set up the ION-LINE cabinet directly in the central work area, the workshop. Lithium-ion batteries are stored and charged there, to be used for customer drones and for the company's test drones. “The safety storage cabinet is simple to operate and meets our expectations in terms of volume and ergonomics. Before and after each flight, we go to the cabinet to get charged batteries and recharge empty batteries” reports Alexandre Labesse. Depending on the activity, Hexadrone stores around 20 6S batteries (22.2V), of different types, Li-ion, Li-po and Li-po semi-solid in the ION-LINE to power its different drone types. “Before we purchased the cabinet, lithium-ion batteries were stored on shelves...”
19 Project summary Company: HEXADRONE Location: Saint Ferréol d‘Auroure, France Industry: Aviation Application: Storing and charging drone batteries
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22 Cashless payment methods are becoming more and more popular. Whether contactless card payments or direct payments with a smartphone – digital is key, with no cash needed!” The advantages are clear: cashless payments are faster and more hygienic, without the need to carry around a heavy wallet full of change. For shops and restaurants, offering customers the option of cashless payment is becoming more and more important. An electronic payment terminal is essential for these kinds of businesses. An electronic payment terminal, like a debit or credit card reader, makes it possible to exchange funds electronically between a purchaser and seller without having to exchange a physical cheque or cash. The purchaser simply needs to hold their card or cell phone up to the reader, wait briefly for a beep, and the transaction is complete! A typical payment terminal consists of a card insert, a magnetic strip reader, a chip card reader, and an NFC (Near Field Communication) reader for contactless payments. The payment is then transmitted from the purchaser to the seller via an interface for authorising the transaction. To ensure a payment terminal does not suddenly go out during a transaction in a business, or need recharging each time a customer pays with a debit or credit card, payment terminals need energy storage solutions that offer high power, rapid charging and long operating times. Lithium-ion batteries meet all of these requirements. Using lithium-ion batteries in payment terminals, for instance, allows up to 300 transactions to be carried out easily. In addition, lithium-ion batteries also offer a higher energy density than other types of batteries. This means that they can store more energy in a smaller, lighter package. This is particularly important for mobile payment terminals which need to be lightweight and portable so that dealers and sellers can easily hand them to the customer. Trust in quality French company Planet Monetic, headquartered in Sophia Antipolis near Nice, is a leader in the European payment terminal market. The company was founded in 2003 by its current CEO Sébastien Beraud, and offers a wide range of payment terminals for different industries, such as retail, restaurants, hotels and the leisure sector. Planet Monetic uses lithium-ion batteries for its products, and has opted for safe battery storage and controlled charging with an asecos safety storage cabinet due to the large number of batteries the company keeps stored on site. “We were aware of the risks associated with storing and charging lithium-ion batteries. Because of this, we want a safe and certified solution for our company that allows us to store the batteries in a single cabinet that can be isolated in case of a fire”. As a pioneer in terms of safety, asecos understands the potential hazard posed by lithium-ion batteries, and has developed ION-LINE safety storage cabinets as a solution for safe battery storage and charging. “Another company recommended asecos products to us. We then decided to put our trust in asecos and chose an ION-LINE model”, Sébastien explains. Planet Monetic employees need to go to the safety storage cabinet more than three times a day, for instance to remove or insert batteries, so the position of the cabinet in the work area played an important role. “The safety storage cabinet was positioned directly adjacent to the work area, at a central location where all employees could easily access it. We set it up at some distance from other flammable products”. Multi-stage warning and f ire suppression system Lithium-ion batteries pose a particularly high risk when the batteries are charged without supervision, for example outside of work hours (such as at night). Because of this, the cabinet model in use at Planet Monic is equipped with a multi-stage warning and fire suppression system and smoke detection. When a temperature increase is detected, visual and acoustic warning signals sound. The warning light changes Planet Monetic | France NO CASH? NO PROBLEM! “The safety storage cabinet was positioned directly adjacent to the work area...”
23 from green to red, and an alarm is triggered with a long interval between tones. In addition, the alarm can be forwarded to the building control system via a potential-free switching contact, so that authorised persons are informed immediately. This type of alarm means there is no immediate danger, so the situation can be reviewed promptly by qualified internal personnel to initiate further measures. Reasons why the signal is triggered might include a rise in temperature during the charging process or a ventilation system failure. If the internal temperature drops again, the system returns to normal operation and the alarm goes off. The next alarm stage is triggered when smoke begins to develop, once the smoke detector reacts. The warning light remains red, the alarm triggers a medium tone interval, and the alarm is forwarded to the building control system. If the smoke detector does not detect any further smoke development inside the cabinet, then the system can be returned to normal operation by unplugging the mains voltage briefly. The last alarm stage is triggered when the temperature sensor inside the cabinet registers a temperature increase to over 70 °C, in addition to the smoke detector already triggered. The warning light switches from a red continuous light to a flashing light, and the alarm switches to a fast tone interval. In most cases, the combination of both indicators (heat and smoke) indicates a fire inside the cabinet – which triggers the fire suppression system integrated inside the cabinet itself. The technical ventilation also switches off as another protective measure, and the socket strips also turn off in lithium-ion safety storage cabinets with charging equipment. With these measures, all hazards and the fire in the cabinet are initially mitigated. In addition, the 90 minute fire resistance capability of the lithium-ion safety storage cabinets – from both inside and out – delivers valuable time: employees can be safely evacuated, fire department and rescue personnel can take additional protective measures after arriving on site. Project summary Company: Planet Monetic Location: Saint-Priest-en-Jarez, France Industry: Electronic payment systems Application: Battery storage and charging for payment terminals
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26 Virtually no other technological trend has been as unstoppable in recent years as the development of ever more powerful energy storage options. For around 30 years, lithium-ion single-use and rechargeable batteries have been taking over the energy storage market, and are being used in more and more products and devices. Spanish manufacturer Nanomate develops advanced materials made of nanostructures for lithium-ion batteries and supercapacitors. The goal: Improving the capability of these devices! Nanomate is a company with a strong core of research and development that offers technological solutions based on nanomaterials for a wide range of industries. The Energy business area, in particular, focuses on development, production, and marketing of nanomaterials to improve energy storage batteries. Nanomaterials, combined with active battery materials like LiFePO4, significantly improve the performance of the final devices. In addition to the battery sector, Nanomate is building a new factory in Badajoz for a supercapacitor device that promises to be one of the company's flagship projects. This will be the first supercapacitor factory in Spain, and will stand out for its modular design and initial production capacity of 600,000 units per year. White gold Lithium is considered a valuable raw material today, and is a key part of our everyday lives. This lightweight metal is essential for the rechargeable batteries commonly used in e-bikes, laptops and smartphones. In addition to its high energy density, the useful properties of the material include its long service life and large number of potential charging cycles for lithium-ion batteries. Arantxa Pinar Serrano, Head of the Research and Development Department for energy storage at Nanomate, describes the production of these batteries as follows: “First, the electrodes responsible for storing energy in the device are produced. Then, they are assembled by placing a separator between the anode and cathode to prevent physical contact between the electrodes from causing a short circuit in the device. Electrolyte is added after assembly – a fluid acting as an ion-conducting medium. This fluid ensures the reactions necessary for energy storage can occur. The device is then sealed in a highly controlled, low-reactivity atmosphere to prevent the ingress of air. Finally, we use a variety of test procedures to validate the characteristic performance parameters of these devices, such as their capacity and service life. After testing, we store the batteries in an asecos ION LINE safety storage cabinet.” Preventative action The higher the energy density of such batteries is, the higher the fire risk. To limit this risk as far as possible, Arantxa explains why the company chose to purchase a safety storage cabinet: “At Nanomate, safety is a key value in the corporate Nanomate – Phi4Tech | Spain CHARGING INTO THE FUTURE
27 culture. We are aware of the major risk associated with storing these batteries and supercapacitors over a long period of time. Because of this, we purchased a specialised cabinet as soon as possible. By storing our equipment in an asecos cabinet, we are ensuring the safety of our employees and our devices”. The biggest danger: Thermal runaway What makes batteries so dangerous are the chemical properties of their components. The electrolytic fluid inside the batteries consists of organic solvents and is therefore flammable – roughly as flammable as petrol. This factor, combined with their high energy density, makes batteries a significant fire hazard. If the temperature increases in even one cell of a battery, all neighbouring cells will heat up in a cascade. If the temperature reaches a limit range, beginning at around 60 °C, depending on the solvent, and becoming extremely critical above 100 °C, a chain reaction will occur that becomes more and more difficult to control. Within a fraction of a second, the temperature will increase up to 800 °C, the gases produced will escape the shell of the battery cell, and the battery will burn in an explosive manner. This kind of situation is unpredictable. Flames will be produced, and flammable battery material will be ejected through the air like fireworks. This endangers personnel and can trigger even more fires. A fire can spread quickly, in particular if it jumps to neighbouring batteries in a kind of domino effect. Double protection This is why proper battery storage is so important. All ION-LINE models from asecos have been developed and tested in accordance with standard EN 14470-1. Because of this, lithium-ion batteries stored in these safety storage cabinets are protected against overheating for a period of 90 minutes whether a fire develops inside or outside the cabinet. Standard EN 1363-1 governs protection of the cabinet from the inside to the outside, determining the fire resistance duration of components that could be exposed to a fire under standardised conditions. ION-LINE models from asecos have been tested and verified to handle such situations, and also offer a fire resistance capability of 90 minutes from inside to outside. If a battery inside the cabinet ignites and triggers a fire, it will remain safely inside the cabinet. Arantxa reports: “We needed a cabinet that would guarantee the necessary safety if a reaction occurs inside one of our devices. Asecos’ cabinet is made of fire-resistant materials that can withstand fire for 90 minutes if one does occur. This is enough time to act in dangerous situations. We are also very satisfied with asecos’ service. We received the cabinet in very good condition, and installation was very easy thanks to the manual”. “We needed a cabinet that would guarantee the necessary safety if a reaction occurs inside one of our devices”. Project summary Company: PHI 4 TECHNOLOGY SL Location: Noblejas, Spain Industry: Battery cell technology Application: Research and development Energy storage devices
28 Whether in your living room, at the hospital, or in your car: robots are used everywhere today – some of them large, and some quite small. There is no doubt that robotics have the potential to change the world in which we live today. Because of this, knowledge and teaching surrounding this technology is more important than ever. Students at the University of Sheffield in England are learning how to design and build these sophisticated machines with their complex algorithms. Their studies also cover the function of lithium-ion batteries, which serve as essential, advanced energy storage solutions for robots. Robots of all kinds, whether they are designed to walk, roll, or drive, require energy to perform their tasks and achieve sufficient autonomy. In industrial environments, for example, robots are exposed to a wide variety of different loads. This spectrum ranges from hot, moist or dusty production sites to challenging outdoor applications like bomb disposal. Robots designed for entertainment or learning purposes, or for everyday use, have an easier time as they are typically used in clean and heated buildings. Because of this, the energy storage systems they use need to withstand not only various external influences, but also impacts such as shocks, impacts, vibration, pressure, falls or deformation so that they do not pose a hazard for users or the environment. Lithium-ion batteries, therefore, are a good choice for robotics applications. They deliver better performance and faster recharging capability for robots not only due to their small size, which makes them easier to protect against external influences, but also due to their long operating times. Tinkering and experimentation Students at the University of Sheffield investigated and learned about exactly these kinds of correlations in their Robotics coursework. The University of Sheffield is a renowned educational institution known for taking a leading role in academic research and teaching. In addition to a broad range of degree programmes and research activities, the university focuses on innovative technologies and their applications in different areas. The university's Robotics programme allows students to deepen their technical understanding and gain practical experience in developing and controlling robots. In doing so, they learn not only the fundamentals of robotics, but also how to integrate lithium-ion batteries as an efficient energy source for robots. Aspects such as safety and proper battery management also play a key role, as lithium-ion batteries pose particular requirements for handling and storage. “Lithium-ion batteries are a part of our everyday studies, so we are aware of the dangers these batteries pose. The fact that asecos’ safety storage cabinet is fire resistant, allowing us to not only store batteries safely but to charge them as well, made our decision to purchase this asecos product a very easy one” explains James Screaton, Technical Department Manager. University of Sheffield | England MISSION POSSIBLE: LEARNING ROBOTICS
29 ION-LINE ventilation system To ensure students learn how to handle batteries correctly right from the start, they are taught about the dangers associated with using these batteries. “I would say we go to the safety storage cabinet 3 to 4 times a day to retrieve batteries and work with them during class time. After classes end, the batteries are then stored safely in the cabinet again so they are ready for the next day” reports James Screaton. At least 20 batteries need to be available at all times to ensure all students can work with the lithium-ion batteries during a course. After the course ends, these are charged simultaneously in the ION-LINE safety storage cabinet for the next day. Heat is produced during the charging process; this is dissipated from the interior of the cabinet using a plug-and-play technical extraction unit that can be mounted to corresponding ION-LINE models. This approach reliably prevents heat accumulation which could cause the batteries to heat up further – ultimately resulting in a loss of performance, premature wear, or even dangerous situations like thermal runaway or an explosion. In addition, the shelves of the ION-LINE cabinet series are perforated, ensuring proper air circulation inside the cabinet. If a fire does break out inside the cabinet, for instance due to a defective battery, the technical ventilation switches off automatically thanks to the integrated electronics and sensors, and the fire is kept inside the cabinet. Toxic substances In addition to a fire, the destruction of a lithium-ion cell poses another danger for the environment. Lithium-ion cells begin to chemically decompose at 80 °C. If the cell overheats and catches fire, toxic substances such as electrolyte and solvent vapours, as well as hydrogen chloride, are released from PVC lines. These flue gases, as well as other hazardous and polluting substances like hydrogen fluoride or caustic phosphoric acid, are released. ION-LINE safety storage cabinets are equipped with features like bottom collecting sumps for such cases, so that these liquid pollutants cannot escape the inside of the cabinet. Project summary Company: University of Sheffield Location: Sheffield, United Kingdom Industry: Education and research institution Application: Teaching material “Lithium-ion batteries are a part of our everyday studies...”
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32 See you RENT GmbH | Germany From cinema to social media clips – videos are a part of our everyday lives. Whether on the big screen or on a smartphone, videos allow viewers to immerse themselves in another world or a new idea. What is the most essential part of the shoot? The equipment! This can vary from project to project: sometimes, you need a lot of small pieces of equipment, sometimes just a few large pieces – sometimes it needs to be mobile, and sometimes it is set up in a studio. But no matter what accessories are needed for a film project, high-performing batteries are essential. For self-powered work or as a buffer battery, for instance to ensure a camera doesn’t suddenly go out of service during the shoot. Lithium-ion batteries are a good solution for this problem. From the camera to the lens, from the boom to the LED light. Each production needs different equipment. Renting equipment, rather than buying it, is usually an economical solution – and in every case the most sustainable one. Berlin company see you RENT GmbH, which specialises in renting filming technology, already knows this very well. Since it was founded in 2009, the company has become an established, reliable partner to the film industry, offering comprehensive solutions for any technical requirement. The 13-person team supports not only major motion pictures, but also small, independent projects with deep expertise and plenty of passion Back to basics Thanks to services like those offered by see you RENT GmbH, as well as the conversion to digital technology, film production has grown simpler in recent years. Of course, this was not always the case. Even just a few decades ago, films were recorded using cameras with power-hungry mechanisms and analogue film reels. These cameras were large, heavy, and usually louder than options available today thanks to digital sensors. Lead-gel battery technology was also not powerful enough to keep old analogue cameras and their successors running for long periods of time. This all changed at the start of the 1990s, when a Japanese electronics company developed the first commercial, rechargeable lithium-ion battery. Since one of the company's main LIGHTS, CAMERA, ACTION!
33 products at the time were video cameras, the lithium-ion batteries were initially used in these devices. The design of the battery made it possible to significantly reduce the weight of the video cameras. However, the batteries available at the time had only a low capacity and amperage, although these have changed significantly since that time. Revolutionary, yet dangerous As advanced and sustainable the development of lithium-ion batteries has been, people today are also aware of the hazards posed by these batteries. Improper handling can damage the batteries and trigger fires due to internal short circuits; these can cause significant harm not only where the batteries are stored, but throughout the building as well. Unsupervised charging of lithium-ion batteries in particular, for instance outside of work hours or overnight, is always a potential hazard. Protective electronics built into a battery should prevent overloading, but even these kinds of battery management systems (BMS) can fail, for instance if an unsuitable charge is used. Behind the scenes To ensure see you RENT GmbH's equipment is always available to customers right when they need it to start work, the batteries for these devices need to be charged up and ready for use. To ensure this, the Berlin camera rental company stores its roughly 300 lithium-ion batteries of different capacities on site and ready for use in its store.
34 To ensure the batteries do not pose a hazard and that the risk of a potential fire is prevented, the CEO and owner of see you RENT GmbH, Martin Diebel, took the forward-thinking step of purchasing a lithium-ion security storage cabinet from asecos to charge his lithium-ion batteries. “To not only protect our neighbours, but also make our storage area safer, we purchased two large safety storage cabinets for our biggest, most powerful lithium-ion batteries, as well as for smaller, weaker batteries”. During passive storage, new or used lithium-ion batteries are simply stored for a certain period of time. During active storage, such as that established at the Berlin company, battery packs can be charged or partially discharged (60-70%) inside the safety storage cabinet with the help of a charger. Today, the safety storage cabinet is an essential part of the company's everyday work: “To avoid negatively impacting our work processes, all our employees have access to the safety storage cabinet. Interestingly, the cabinet is opened around 40 times a day. This shows how important and essential it is for our company” reports Martin Diebel. “To not only protect our neighbours, but also make our storage area safer...”
35 Project summary Company: see you RENT GmbH Location: Berlin, Germany Industry: Film industry Application: Storage and charging of batteries for camera technology
36 PUBLIC SERVICE
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38 Rescue work, putting out fires, and protecting the public are all part of a day's work for the Greifswald Volunteer Fire Department. Emergency personnel and specialists in the department are responsible for responding to a wide range of emergencies. Ultimately, they are tasked with reacting immediately to emergency calls and initiating rescue measures. To ensure they can do so, the fire department’s technical equipment needs to be state-of-the-art – including high-quality and reliable electric operating equipment. With around 60,000 residents and an area of approx. 51 km², Greifswald is the fourthlargest city in Mecklenburg-Vorpommern. In this university town and Hanseatic city, the Greifswald Fire Department is an essential municipal institution which ensures fire safety throughout the urban area. A committed team of volunteer fire fighters comprising over 100 members is an essential part of that protection, and supports professional fire fighters in both large deployments and in maintaining fire safety throughout Greifswald. They not only respond to fires, but also provide technical assistance to handle animal strikes or transport injured persons. Of risks and rescuers The calls fire departments respond to today are diverse – and so are the devices and equipment they need for their deployments. Because of this, the technical equipment fire departments use has changed significantly in recent years, as Norbert Stawinski, Operational Planner for professional fire fighters, reports: “More and more battery-operated devices, like radios, thermal imaging cameras, heavy cutting equipment and chainsaws, are coming on the market and therefore into rescue departments and the fire department’s equipment rooms”. The Greifswald Fire Department knows these battery-powered devices can be not only life-saving, but also hazardous: “We have definitely seen an increase in deployments due to defective lithium-ion batteries. These are usually caused by laptops, cell phones, or electric bikes”. To prevent such hazardous situations in the equipment room, the Greifswald Fire Department purchased an ION-LINE safety storage cabinet from asecos, where batteries can be not only stored, but also charged. After all, it is essential for this equipment to maintain its full capacity at all times, to be ready in case of an emergency. New challenges What makes lithium-ion batteries so dangerous is their fire behaviour, and Greifswald Volunteer Fire Department | Germany FIRE AND FLAMES “We have definitely seen an increase in deployments due to defective lithium-ion batteries”.
39 that behaviour continues to pose new challenges for fire departments. In contrast to fires caused by other common causes, fires caused by batteries generate jets of flame. In comparison to more familiar fuels, reactions caused by lithium-ion batteries are difficult to assess due to unpredictable fire behaviour, reaching an all new dimension of danger. If lithium-ion cells are overloaded or exposed to high temperatures, the layer structure of the metal oxides used collapses, resulting in thermal runaway. Exothermic reactions also release high quantities of energy, along with oxygen. High heat causes the electrolyte fluid to evaporate and form a flammable gas. If this gas ignites, the lithium-ion cell catches fire. This chain reaction is essentially impossible to stop with commonly available technologies. The fire can spread from cell to cell inside the battery. Batteries experiencing thermal runaway can cause secondary fires in plastics or cardboard. These can be suppressed with foam, CO2, powder and metal fire extinguishers, however they are very likely to be reignited by burning cells. Rapid evacuation Because of this, storing lithium-ion batteries in a specialised safety storage cabinet like asecos’ ION-LINE models ensures a high level of building safety. These cabinets cannot prevent a defective battery from catching fire, but they can protect the surrounding area and persons nearby. The safety storage cabinets offer not only 90 minutes of fire resistance from the outside to the inside, but from the inside to the outside as well. This means that, if a fire does occur inside the cabinet – for instance due to an overheating battery – the building is protected against flames and the toxic gases emitted for 90 minutes. This provides valuable time for safely evacuating employees and allowing fire department and rescue personnel to initiate further safety measures on site. The cabinet is designed with clearance underneath so that it can be effectively evacuated by the fire department. In case of danger, it can be removed quickly from the building. In addition, in case of a fire, professionals should have access to the inside of the cabinet so that they can decide whether to remove the batteries and thereby interrupt the chain reaction. These safety aspects were pivotal in the Greifswald Fire Department's decision, as Norbert Stawinski says: “asecos delivered the full package. The cabinet is very easy to handle, and it can be moved to a different setup location at any time. The entire safety storage cabinet can also be removed in case of a defective battery. The combination of storage, charging, and the safety aspects won us over!” No downtime Often, charging high-power batteries after a fire department deployment can take 2 to 6 hours, or even longer in individual cases. Factors impacting this time include the battery size, charge current, and charger availability. The best solution for avoiding downtimes are devices with exchangeable batteries. Additional batteries are needed in this case, however devices can be put back into operation in just seconds. Because of this, the Greifswald Fire Department works with multiple exchangeable batteries that are stored in the safety storage cabinet. Norbert Stawinski says: “There are between 50 and 100 batteries of different sizes and power classes at the operating site. There are multiple chargers in the safety storage cabinet itself, which can charge up to 5 batteries at the same time depending on the manufacturer. Fully charged batteries are also stored there. After training or a deployment, used batteries are exchanged for charged ones”. Project summary Company: Greifswald Fire Department Location: Greifswald, Germany Industry: Public service Application: Storage and charging of batteries for rescue equipment
40 E-MOBILITY
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42 There is a lot of hype surrounding electric bikes. In Germany, as well as throughout Europe, they are developing into a popular means of transportation. E-bikes offer countless advantages, not least thanks to their power-saving operation. Why not leave the car in the garage, and take a 20 kilometre trip to work on your bike – without looking for a parking spot. No matter whether you are on your way to work, in town, or on a weekend trip to the mountains – more and more cyclists are using e-bikes. Axel Donath, founder of Munich startup bravobike GmbH, is well aware of this trend. However, instead of just selling new e-bikes like most bike shops, he had a different idea: the company purchases used bicycles from both private individuals and from dealers, manufacturers, and leasing companies, refurbishes them in its workshop in Munich, and then resells them. “We receive thousands of bikes each month that undergo our refurbishment process. Around 70% of these bikes are e-bikes. After a careful inspection and restoration by our trained mechanics, the bikes are sold as high-quality used bikes in our online shop” says Kathinka Weitzel, Marketing Team Lead at bravobike GmbH. Lithium-ion batteries in the e-bikes, in particular, are inspected visually for damage upon receipt. If any fault is detected, the batteries are classified defective. This is because, typically, neither the cause of the fault nor the forces applied on the battery can be determined. In addition, batteries are read out if possible during the technical inspection and examined for warnings like error codes. Hazardous charging If a workshop uses many of these energy storage devices, like lithium-ion batteries, for electric bikes, it is aware that challenges could potentially occur in certain circumstances. Due to the high energy density of the batteries, there is a danger that they could react in an unforeseen way in certain situations, become unstable, or even cause a fire. Such fires involving lithium-ion batteries are difficult to manage, and can have serious consequences for people, an office, and the environment. The danger increases if batteries are charged without supervision, for example outside of work hours. If batteries are stored in specialised lithium-ion safety storage cabinets for passive and active storage, this danger can be prevented. bravobike GmbH stores their lithium-ion batteries in an asecos ION LINE safety storage cabinet. This safety storage cabinet offers not only 90 minutes of fire protection from the outside to the inside, but an identical resistance from the inside to the outside. Furthermore, the cabinet offers a multi-stage warning and fire suppression system, as well as integrated alarm forwarding. Rapid information The ION-LINE model used by bravobike GmbH offers three different ways to forward the alarm: the potential-free switching contact, the relay module and bravobike GmbH | Germany SUSTAINABLE MOBILITY WITH ELECTRIC BIKES
43 the remote module. The potential-free switching contact forwards the alarm to a continuously manned internal or external command office. The optional relay module offers the option of alarm differentiation; different alarm states can be transmitted to the internal or external command office, instead of a collective alarm. The remote module, also optional, allows the alarm to be forwarded via the wireless network in the form of a message/call, and is particularly well-suited for companies and facilities without a central building control system. In case of an emergency, alarms are immediately triggered to one or more defined persons. Alarm forwarding ensures that potential fires inside the safety storage cabinet are noticed immediately, any time of day or night. In case of a fire, the company has enough time to evacuate the building, assess the situation, and take necessary steps and countermeasures, like removing the cabinet from the building. Double protection Kathinka Weitzel compares the situation for storing lithium-ion batteries before and after purchasing the safety storage cabinet: “Before we purchased the cabinet, we stored auxiliary and new batteries to be installed in a bike later on a shelf, without any fire protection. Today, they are stored in the battery cabinet where they are safe”. bravobike GmbH's ION-LINE cabinet is located in the workshop area, where approx. 30 lithium-ion batteries are stored. For added safety, the cabinet is not accessible to all employees, but rather only to selected persons who use lithium-ion batteries in their everyday work. This measure also supports correct storage at all times. Project summary Company: bravobike GmbH Location: Munich, Germany Industry: Bicycles Application: Storage of e-bike batteries “Today, the batteries are stored in the battery cabinet where they are safe.“
44 Bike Park Wales | Great Britain ACTION AND ADRENALINE Tearing down the slope and building up speed, feeling the adrenaline course through your body and the thrill that goes along with it. For many mountain bike enthusiasts, tackling a track with artificial obstacles is the quintessential high speed experience on two wheels. A bike park is a track specially designed for mountain bikes with a variety of obstacles and slopes. It offers hobby riders and professionals a chance to test their skills and speed on the bike under safe conditions. For several years, e-bikes have been taking over bike parks as well, as more and more park operators are adding courses designed for electric bikes. The advantages of e-bikes in bike parks are obvious: they offer added support on steep inclines, and allow riders to go longer distances and ride faster without losing steam. This allows riders to sped more time on challenging sections and improve their skills. In particular for less experienced or older riders, e-bikes can be a good way to take on the challenges offered by the parks, and experience the thrill of downhill riding. Some bike parks have now constructed specialised courses for e-bikes to offer electric bike riders a safe and comfortable riding experience. The Bike Park Wales is one such park. Trail paradise The Bike Park Wales in Great Britain is one of Europe’s most famous, and most visited bike parks. The park encompasses over 1200 hectares, and is located in the picturesque Wales countryside, with a view of the Brecon Beacons and the Pen-y-Fan. The park offers over 40 different courses designed and maintained by professional trail builders to meet the highest standards and offer the best possible riding experience. The Bike Park Wales was opened in 2013 by its current owners, Rowan Sorrell and Martin Astley, and offers mountain bike trails for all levels from beginners to professionals, as well as specialised equipment for e-bikes and accessible courses. Currently, the bike park has seven e-bikes for customers to rent and ride on the trail sections. Powerful e-bikes Powerful and durable batteries are essential, however, for ensuring e-bikes can achieve their full capacity and offer a high range. Lithium-ion batteries are used for this purpose in most modern e-bikes. The battery serves as the power source for the e-bike, and stores electric energy. It is generally attached to the frame or luggage rack of the bike and can be removed for easy charging. However, these lithium-ion batteries also pose safety risks that are often underestimated. Due to their high energy density, they can spontaneously combust or become unstable in certain conditions, and explode if heated up. If a battery has a technical defect or malfunction, it can even catch fire.
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