EUSO BALLOONBattery Power Pack

(PWP)RIKEN/UAH

Héctor Prieto, Katsuhiko Tsuno, Marco Casolino

Maintain constant power of 225 W for the phone booth and during the time required for the mission, in this case 12 and 24 hours of flight.

Zero levels of overloading the circuit due to problems with the battery

Zero levels of overheating in the circuit due to problems with the battery

Mission Objectives with success criteria

Battery Pack technical specifications

Phone Booth 24h Phone Booth 12hAltitude 40km 40kmPressure 3mBar 3mBar

Power 225W/192.72Ah, 28V 225W/96.42Ah, 28V

Operation Duty

24h 12h

Operating Temperature

Range within -40˚C/+70˚C Range within -40˚C/+70˚C

Size (500.4x300.24x170)mm (225W)

(500.4x150.12x170)mm (225W)

Mass 27.14kg 14.4kg

Battery Pack design description

Objectives  PWP shall provide the primary power in 12 hours and 24 hours flight as

well as rising operation. PWP shall provide the average power of 225W to the Phone Booth PWP shall provide enough transient current generated at instrument

booting. PWP shall be protected from the instrument overload by the fuse, circuit

breaker or current limiter.

Battery Pack design description

Description

At the moment we assume a battery system providing 28V; since the highest voltage is 28V (and HV is produced internally).

The battery pack will be attached to the gondola and provide power to the LV board and the HK board. Relays (commanded by CNES) will control the power ON/OFF.

Battery Pack connection diagramPhone Booth/12 and 24hrs

Battery Pack Phone Booth/12hrs

ComponentBattery Component Selected: Saft G62/1.2 Specification: Li-SO2/28V/34.5Ah Capacity = (Watts required/Volts required)*(Time Hours)Battery SelectionCapacity @ 24hours = (225W/28)*(24h)=96.42Ah•3 of 10 Cell Series Saft G62/1.2 = 103.5Ah

Battery Pack Mechanical Architecture Phone Booth/12hrs

Battery Pack Phone Booth/24hrs

ComponentBattery Component Selected: Saft G62/1.2 Specification: Li-SO2/28V/34.5Ah Capacity = (Watts required/Volts required)*(Time Hours)Battery SelectionCapacity @ 24hours = (225W/28)*(24h)=192.72Ah•6of 10 Cell Series Saft G62/1.2 = 207Ah

Battery Pack Mechanical Architecture Phone Booth/24hrs

Battery Pack Mechanical Architecture Phone Booth/24hrs

Battery Pack Weldering

Saft G62/1.2 nickel strips weldering conditions

Saft batteries typical discharge characteristics

Saft G62/1.2 typical discharge characteristics

Mass Estimation

Upperside and Under side

Front Face and Back

Face

150.12mm

Battery BoxPhone Booth/12hrs

500.4 mm

150.12 mm

170 mm

Lateral

500.4 mm

170 mm

Mass Calculations

Density = Aluminum Box = 2.69g/cm3 = 0.00269g/mm3

Thickness = 3mm

Lateral Sides Volume = LSV= 500.4mm*170mm*3mm*2*0.00269g/mm3 = 1373g

Upper and Under Side Volume = USV = 500.4mm*150.12mm*3mm*2*0.00269g/mm3 = 1212.43g

Front and Back Face Volume = FBV= 170mm*150.12mm*3mm*2*0.00269g/mm3 = 412g

Total Case Mass = LSV + USV + FBV = 1373 + 1212.43+412 = 3kg

TOTAL MASS INCLUDING CELLS AND CASE = (30Cells*300g) + (Case Mass = 3kg) = 12kg+20% of margin = 14.4kg

Upperside and Under side

Front Face and Back

Face

300.24 mm

Battery BoxPhone Booth/24hrs

500.4 mm

300.24 mm

170 mm

Lateral

500.4 mm

170 mm

Mass Calculations

Density = Aluminum Box = 2.69g/cm3 = 0.00269g/mm3

Thickness = 3mm

Lateral Sides Volume = LSV= 500.4mm*170mm*3mm*2*0.00269g/mm3 = 1373g

Upper and Under Side Volume = USV = 500.4mm*300.24mm*3mm*2*0.00269g/mm3 = 2423g

Front and Back Face Volume = FBV= 170mm*300.24mm*3mm*2*0.00269g/mm3 = 824g

Total Case Mass = LSV + USV + FBV = 1373 + 2423 +824 = 4.62kg

TOTAL MASS INCLUDING CELLS AND CASE = (60Cells*300g) + (Case Mass = 4.62kg) = 22.62kg+20% of margin = 27.14kg

Battery PWP Location

Battery Protection and Support

•FireThe Battery pack will have thermal fuse overheating protector which will protect the PWP against fire risk•ExplosionThe box itself will be a protection against explosion due to the batteries will be confined there•BreakingThis mechanical issue shall be discused with the mechanical engineers in charged of the EUSO-Balloon mechanical StructureMechanical SupportECAL-Riken will provide the mechanical structure, which will be made of aluminum to avoid risk of explosion and fire propagation.(TBD)

Battery Cells, Connectors and Cables

•Cells

•Connectors

•Cables

Option I: In case of 225W /12hrs power consumption it will be necessary 30 cells of Saft G62/1.2Option II: In case of 225W /24hrs power consumption it will be necessary 60 cells of Saft G62/1.2

The Connectors we are going to use are 9 pins D-Sub connectors for all interfaces and subsystems.

The Cables we are going to use are THERMAX MIL-DTL-22759/91,92 for all interfaces and subsystems.

Battery Voltage Regulator , Fuses

•Relays (TBD)

•Switches (TBD)

•Thermal Fuse

The thermal Fuse we are going to use is Klixon C Series and MIL-PRF-23419 Space Coast IC

•Electrical Fuse

The thermal Fuse we propose to use is Klixon PN 6752-12-25, Military type MS24571-25

Why using 225W ?

Total: 96.4W+20% of security Margin = 103.68W Backup = 80W(183.68)+20% of security Margin = 221W

“This version should be discussed”

Interface Power Consumption in W

EUSO BALLOON PWP

Power Consumption in W

IR Camera PWP

IR Camera N/A 22High Voltage Power Supply 1.0

PDMB (FPGA) 7.2 PDMB-EC-ASIC 10.0

TOTAL PDM 18.2 LVPS DP1 2.1 LVPS DP2 5.0

Housekeeping 6.0 LVPS-PDM 3.4

CPU 15.0 CCB 5.0

Data Storage 10.0 GPS 1.5 CLK 4.0

LVPS-HK 1.2

TOTAL DP 53.2 Additional Spare 15.0

Heaters TBC

Total 86.4 22

Battery Pack Budget Phone Booth /225W @12 and 24hrs

Equipment Specification Model Quantity Price/Unit Total Pack

BatteryOption 3

Li-SO2/28V/34.5Ah Saft G62/1.2 30 75.5€ TBD

SwitchV: 28V; worse scenario 20VW =225WCurrent = 12.5A; Steady Current=225/20=11.25A*2PWP in parallel = 22.5ATemp = -400C /+700C

APEM-M350010 TBC

Thermal FuseV: 28 VW: 225W Steady Current = 225W/20V+Security range = 11.25A+50% security range= 17A.Temp = -400C /+700C

Thermal Fuse Klixon C Series

10 TBD

Electrical FuseV: 28 V; worse scenario =20VW: 225W Steady Current = 225W/20V = 11.25ATemp = -400C /+700C

MIL-PRF-23419Space Coast IC

50 TBC

CableV: 20VW =225WCurrent = 11.25ATemp = -400C /+700C.AWG= 14

THERMAX MIL-DTL-22759/91,92

30m 230$

THANK YOU!!!