Periodic Reporting for period 2 - ORION PROJECT (A FIRST STEP TOWARDS AVIATION DECARBONIZATION WITH SMART LITHIUM BATTERIES)
Okres sprawozdawczy: 2022-01-01 do 2023-06-30
Lithium batteries are one of the key drivers in the transition towards carbon-free energy in the transport sector and can replace the toxic, polluting substances (such as Cadmium & Lead) that are still currently used in aviation. However, securing these technologies for the harsh and highly regulated environments of aviation and aerospace still remains a significant challenge.
In this context, LIMATECH’s ambition is to develop a European range of lithium starter batteries for the aeronautics sector. LIMATECH has succeeded in meeting the challenge of securing lithium batteries for aviation by developing protective electronics. This “Battery Management System” in protected by several patents and is highly anticipated by major players within the aeronautics sector.
The aim of the ORION project is to accelerate the launch of a first range of 24V lithium starter batteries, that will enable LIMATECH to address the largest share of the aeronautics battery market. The project activities involve finalizing and obtaining certifications for two of the batteries in the 24V range: the 24V-15Ah (WP1) and the 24V-40Ah (WP2). In parallel, project work also focuses on the commercial and industrial scale-up strategy that will enable LIMATECH to bring this innovation to market (WP3). LIMATECH’s ultimate objective is to become one of the world’s references in lithium batteries for the aeronautics industry, replacing toxic batteries and generating savings of 1 million tons of Co2 within the next 8 years.
In this context, LIMATECH’s ambition is to develop a European range of lithium starter batteries for the aeronautics sector. LIMATECH has succeeded in meeting the challenge of securing lithium batteries for aviation by developing protective electronics. This “Battery Management System” in protected by several patents and is highly anticipated by major players within the aeronautics sector.
The aim of the ORION project is to accelerate the launch of a first range of 24V lithium starter batteries, that will enable LIMATECH to address the largest share of the aeronautics battery market. The project activities involve finalizing and obtaining certifications for two of the batteries in the 24V range: the 24V-15Ah (WP1) and the 24V-40Ah (WP2). In parallel, project work also focuses on the commercial and industrial scale-up strategy that will enable LIMATECH to bring this innovation to market (WP3). LIMATECH’s ultimate objective is to become one of the world’s references in lithium batteries for the aeronautics industry, replacing toxic batteries and generating savings of 1 million tons of Co2 within the next 8 years.
During this first period, we have mainly focused on the 24V-15Ah battery (WP1) and project management and commercialization (WP3).
The first work package concerns the qualification of the battery with the smallest capacity in the range. We initially planned to develop a 24V-17,5Ah battery, but project progress showed that a 15Ah battery would enable us to reach a bigger market - including H125 and H130 helicopters built by Airbus Helicopters, one of our go-to-market partners. This slight modification does not change the development of the product as described in the project proposal. At the end of this first 12-month period, the battery is in the qualification stage and our certification request has been received by the EASA (Deliverable 1.1).
On the design side, we have been able to progress on the following modules:
- Mecanics: optimization of components and sub-assemblies (change of prototyping processes for medium series processes, selection of provisionable materials, optimization of cost prices); hardening of design and qualification of materials and mechanical linkages in accordance with environmental constraints selected with Airbus Helicopters; simplification of components; design of mechanical interfaces for better Plug&Play integration on H125/130 helicopters; etc.
- Hardware: integration of all safety functions required for ETSO C179B (global or unitary detection of under and over voltage, passive balancing, EPV detection, IPR detection, switching device, battery instrumentation, protection against under or overtemperature, temporary and permanent lockout, etc.) ; integration of user functions via HMI (ON/OFF, heater, visual communication of SOH/SOC, service and defaults); integration of electronic interface functions (communication of history, defaults, alerts and service, etc.) by discrete CAN and ARINC protocols, etc.
- Software : integration of coding infrastructure; integration of a flash memory ; integration of SOC/SOH diagnostics, defaults, alerts and service functions
On the qualification side, we have been able to perform the following tests: integration tests of security functions at different temperatures, perfomances tests (vibrations, different temperatures), sealing tests, runaway thermal containment tests and tests for the integration in aircraft electrical system. At this stage in the project, our design is compliant with ARP4754A, ARP4761, DO254 and DO178 standards. In the course of 2022, our battery will pass the critical design review (tests in real environments) with Airbus Helicopters.
Furthermore, the experience gained through developing the 15Ah size battery is being used to accelerate the development of other batteries, such as the 40Ah product that is targeted in WP2. This will be the focus of the second part of the project.
Concerning Work Package 3 (Project management & Scale-Up strategy), Limatech has implemented effective project management procedures and created a dedicated page on the company website for news regarding the H2020 project (“EIC Green New Deal”). With regards to the commercial and industrial scale-up strategy, we are focusing on helicopters as an early adopter market and then targeting other aircraft that need 24V-15Ah batteries. The next objective is to design a battery with a bigger capacity (40 to 45Ah) to target commercial and business aviation. A “make-or buy analysis” has been carried out to specify the production that will remain in-house (composition of the battery module and compliance tests) and outsourced to certified European suppliers (electronic board assembly, mechanical components and mechanical integration). Finally, progress on our IP strategy has seen 4 patents in our portfolio accepted by the French INPI and we are preparing an international extension for three of them through a PCT request. We have ordered a comprehensive data analysis based on patents and publications to target all necessary countries (USA, Canada, Mexico, Brazil, Europe, China, Japan, India, Russia, South Africa and Australia).
The first work package concerns the qualification of the battery with the smallest capacity in the range. We initially planned to develop a 24V-17,5Ah battery, but project progress showed that a 15Ah battery would enable us to reach a bigger market - including H125 and H130 helicopters built by Airbus Helicopters, one of our go-to-market partners. This slight modification does not change the development of the product as described in the project proposal. At the end of this first 12-month period, the battery is in the qualification stage and our certification request has been received by the EASA (Deliverable 1.1).
On the design side, we have been able to progress on the following modules:
- Mecanics: optimization of components and sub-assemblies (change of prototyping processes for medium series processes, selection of provisionable materials, optimization of cost prices); hardening of design and qualification of materials and mechanical linkages in accordance with environmental constraints selected with Airbus Helicopters; simplification of components; design of mechanical interfaces for better Plug&Play integration on H125/130 helicopters; etc.
- Hardware: integration of all safety functions required for ETSO C179B (global or unitary detection of under and over voltage, passive balancing, EPV detection, IPR detection, switching device, battery instrumentation, protection against under or overtemperature, temporary and permanent lockout, etc.) ; integration of user functions via HMI (ON/OFF, heater, visual communication of SOH/SOC, service and defaults); integration of electronic interface functions (communication of history, defaults, alerts and service, etc.) by discrete CAN and ARINC protocols, etc.
- Software : integration of coding infrastructure; integration of a flash memory ; integration of SOC/SOH diagnostics, defaults, alerts and service functions
On the qualification side, we have been able to perform the following tests: integration tests of security functions at different temperatures, perfomances tests (vibrations, different temperatures), sealing tests, runaway thermal containment tests and tests for the integration in aircraft electrical system. At this stage in the project, our design is compliant with ARP4754A, ARP4761, DO254 and DO178 standards. In the course of 2022, our battery will pass the critical design review (tests in real environments) with Airbus Helicopters.
Furthermore, the experience gained through developing the 15Ah size battery is being used to accelerate the development of other batteries, such as the 40Ah product that is targeted in WP2. This will be the focus of the second part of the project.
Concerning Work Package 3 (Project management & Scale-Up strategy), Limatech has implemented effective project management procedures and created a dedicated page on the company website for news regarding the H2020 project (“EIC Green New Deal”). With regards to the commercial and industrial scale-up strategy, we are focusing on helicopters as an early adopter market and then targeting other aircraft that need 24V-15Ah batteries. The next objective is to design a battery with a bigger capacity (40 to 45Ah) to target commercial and business aviation. A “make-or buy analysis” has been carried out to specify the production that will remain in-house (composition of the battery module and compliance tests) and outsourced to certified European suppliers (electronic board assembly, mechanical components and mechanical integration). Finally, progress on our IP strategy has seen 4 patents in our portfolio accepted by the French INPI and we are preparing an international extension for three of them through a PCT request. We have ordered a comprehensive data analysis based on patents and publications to target all necessary countries (USA, Canada, Mexico, Brazil, Europe, China, Japan, India, Russia, South Africa and Australia).
The major technological challenge inherent to LIMATECH’s activity is making lithium batteries safe and reliable enough to be used in the aviation industry. The ORION project is making it possible to progress even further beyond the current state of the art, by putting LIMATECH’s lithium batteries to the test in a “real” environment (as part of the aviation certification process) and by optimizing the production tool.
Thanks to the ORION project, the approval of these certifications will enable LIMATECH to join the highly exclusive club of 6 producers of aeronautical-certified batteries in the world. At present, only one other industry player (USA) has proven capable of developing lithium batteries for the aviation sector.
Finally, the ORION project’s focus on certifying and preparing for the market-roll out of LIMATECH’s batteries reinforces the wider societal and environmental implications of the project. This includes replacing toxic substances in batteries (which are currently only available to the aviation sector through a derogation, due to the current lack of suitable alternative) with a safe and more efficient lithium alternative. LIMATECH’s light-weight lithium batteries will also make it possible to reduce by three times the amount of kerosene required to power an aircraft. Based on the sales volume of Limatech batteries from 2023 to 2028 and the kerosene savings they generate, it can be estimated that Limatech will save the aviation industry 1 million tons of CO2 just 5 years after commercialization. Ultimately, LIMATECH will be a key player in driving the transition to hybrid and electrically powered aircraft.
Thanks to the ORION project, the approval of these certifications will enable LIMATECH to join the highly exclusive club of 6 producers of aeronautical-certified batteries in the world. At present, only one other industry player (USA) has proven capable of developing lithium batteries for the aviation sector.
Finally, the ORION project’s focus on certifying and preparing for the market-roll out of LIMATECH’s batteries reinforces the wider societal and environmental implications of the project. This includes replacing toxic substances in batteries (which are currently only available to the aviation sector through a derogation, due to the current lack of suitable alternative) with a safe and more efficient lithium alternative. LIMATECH’s light-weight lithium batteries will also make it possible to reduce by three times the amount of kerosene required to power an aircraft. Based on the sales volume of Limatech batteries from 2023 to 2028 and the kerosene savings they generate, it can be estimated that Limatech will save the aviation industry 1 million tons of CO2 just 5 years after commercialization. Ultimately, LIMATECH will be a key player in driving the transition to hybrid and electrically powered aircraft.