enhanced thermal battery development for electronic...

An advanced weapon and space systems company

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ATK OS Power Sources CenterATK OS Power Sources CenterATK ThiokolATK Thiokol

49th Annual NDIA Fuze ConferenceSeattle, WA

5-7 April 2005

Enhanced Thermal Battery Development for Electronic Fuzing using 6-Sigma Tools

Authors:John Bostwick ATK OS Power Sources CenterPaul Schisselbauer ATK OS Power Sources CenterEldon Bott ATK Thiokol


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Presentation Outline

Thermal Battery

• Introduction

• Decision To Enter Thermal Market

• Known Technical Challenges

• Selection of G3190A1 Configuration

• Phase I: Design/Develop Battery

• Phase II: Define Production Process

• Qualification/Low-Rate Production

• Next Application?


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Introduction• Certain battery systems are

ideally suited to military applications.

• Cold Operating Temp. (-45F)

• Long Shelf Life (>20 years)

• Lithium Oxyhalide Batteries are best suited to applications that require extended life.

• Lithium/Thionyl Chloride

• Lithium/Sulfuryl Chloride

• Lithium/Sulfur Dioxide

• Thermal Batteries are best suited to applications that require high power.

• Lithium Silicon/Iron Disulfide

• Lithium Silicon/Cobalt Disulfide

1

10

100

1000

10000

1 10 100 1000

Specific Energy (Wh/Kg)

Spec

ific

Pow

er (W

/Kg)

1.0 h

0.10 h

0.01 h

100 h1000 h

10 h

Thermal Batteries

Lithium Oxyhalide Batteries

Ragone Plot Comparing Thermal Batteries to Lithium Oxyhalide Batteries.

(Approximate data - plot for illustration purposes only)


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Market Entry• ATK customers have expressed concern about limited source of

supply for thermal batteries

• ATK has in-house expertise to develop and manufacture thermal batteries – kicked off “Enterprise Initiative” in 2004

• Leverage ATK Thiokol’s rocket motor technology and manufacturing processes to achieve battery improvements.

• Material Properties

• Powder Processing Techniques

• Thermal Insulation, etc.

• Leverage Power Sources Center design, development and high-volume manufacturing capabilities


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Technical Challenges

• Understanding the science of thermals well enough to engineer

• Thermals are notoriously difficult to manufacture

• Powder formulation and processing

• Electrode pellet forming

• Cell Stack Assembly

• Historically, introducing automation to this inherently labor-intensive assembly process has been problematic


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Test Configuration Selection

• Objective: demonstrate thermal capability to support improvement evaluations, i.e baseline a test configuration to use as a benchmark.

G3190A1 Thermal Battery

• Primary Reserve Thermal Battery• Chemistry : Lithium Silicon / Iron Disulfide• Initiation: Electric Igniter• Output: +22 to +32 vdc @ 350 ma • Rise time < 0.5 sec.• Operating Life : ≥ 200 sec.• Op. Temp. : -54°C to +105 °C• Size: 1.5 in. dia. x 2.38 in. length• Weight: 210 grams• Shelf Life: 10 year req.


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• G3190A1 Battery has common size/power requirements for multiple applications, such as:

DSU-33 Proximity Sensor PGMM

• Many applications could benefit from an alternate, U.S.-based supplier of thermal batteries:


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• Disciplined process used to achieve successful demonstration• Voice of customer

• Concepts and trade study

• Detailed design narrowed down

• Preliminary testing done to verify design steps

• Demonstration test conducted

• Initial efforts started late-2004, with demo achieved mid-February

• Go-forward schedule:

Phase I: Design/Develop

Q1’05 Q2’05 Q3’05 Q4’05 Q1’06Demo

Phase 2

Prod. Ramp-upQualify

Development for other applications will begin in late CY05

Prod. Ramp-upNext Application


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Cross Sectional View of Demo Battery

Terminal Pins (4X)

Case

Thermal Insulation Wrap

Insulation

Anode Tabbed Collector (-)

Cathode Tabbed Collector (+)

Active Components – (15) Cells, series connection

Terminal Plate

Potting Insulation

Shim

Igniter

Igniter Lead Wires (2X)

Glass to Metal Seal (4X)

Laser Weld


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Phase I: Design/Develop• Voice of Customer

• Communicated future need for increased power

• Requirements documentation received and phone interviews conducted

• Customer helped critique the project charter

• Concepts and trade study

• Gov’t labs provided “lessons learned” from previous efforts

• Process Map developed to focus development


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Phase I: Design/Develop (continued)

• Detailed design narrowed down

• Design-For-Manufacturing-and Assembly (DFMA)

• Bench-marked critical parameters

• Characterization of powders

• Preliminary testing done to verify design steps

• Pellet level tests; 3-5 cell level testing; modifications to test fixture

• Initial optimization of powder formulation and thermal insulation

• Demonstration test results – completion of Phase I


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339113D003279129TBDemo_2

308184TBDemo_1

Run Time (s)Rise Time (ms)Serial No.

Performance Summary

Success on first test!Success on first test!


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Phase II: Manufacturing Process

• With successful demo, ATK is now proceeding with Phase II:

• Refine design

• Optimize powder formulation

• Build additional prototypes

• Develop production tooling and facility requirements

• Identify BOM and perform make/buy decisions

• Outline production process

• Confirm UPC estimates

• Similar to the demo phase, ATK will utilize 6-Sigma tools for manufacturing process development


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Six-Sigma tools drive process development

• Refine battery design – based on feedback from “Voice of the Customer” and DFMA lessons

• Optimize powder formulations –use Design of Experiments (DOE) to characterize variables

Anode Pellet

• Build additional prototypes – collect data and understand key characteristics for Quality Function Deployment (QFD)

Leverage ATK Thiokol material science expertise on thermal batteries.Leverage ATK Thiokol material science expertise on thermal batteries.


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• Develop tooling/facility – design around requirement for Statistical Process Control (SPC) data collection

• Identify BOM and make/buy decisions –use vendors with like-minded approach to design/assembly; require SPC data

• Outline Production Process – utilize Poke-Yoke method to reduce potential for defects; prepare operating procedures

• Confirm UPC estimates – use value-stream-mapping and other Lean initiatives

Leverage Center’s success with Six-Sigma tools on thermal productionLeverage Center’s success with Six-Sigma tools on thermal production


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Qualification/Low-Rate Production

• G3190A1 Qualification requirements

• 38 batteries tested in accordance with DRW 9331230, Rev C

• Operating Environments – High and Low temperature

• Non-Operating – Thermal shock, temperature humidity, shock, vibration, 100% inspection (leak, electrical, dimensional, visual)

• Tentative date for Qualification testing is September 2005

• Initial production will begin in October

• Ramp-up within four months to approximately 2,500 units/month


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Next Application?

• Seeking applications with design/development need in fall 2005

• Best-fit application will have potential for follow-on production, commonality with other ATK applications, new program preferred, or opportunity for second source on existing program


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Acknowledgements• Technical support and guidance for this development project were

provided by several U.S. Government organizations.

• Specifically, the authors would like to thank:

• U.S. Army Research Laboratory, Electro-Chemistry Branch, Adelphi, Maryland

• Naval Surface Warfare Center-Carderock Division, West Bethesda, Maryland

• Sandia National Laboratories, Albuquerque, New Mexico

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