nasa emu batt program progress cflora

7/28/2019 NASA EMU Batt Program Progress CFlora

1/30

000074.A.PresentationTemplate

ProprietaryInformation

ABSLSpaceProducts2009

Prepared by CraigFlora ProgramManager 11/17/2009Approved by

CraigFlora,JeremyNeubauer,JakeDembeck,and

ChrisPearson,ABSL

The NASA EMU Battery Program andProgress


2/30




EMU Program & Progress 2

Agenda Background

Design development

Manufacturing development

Testing accomplishments

On-going and near term plans
http://upload.wikimedia.org/wikipedia/commons/9/9c/Astronaut-EVA_edit.jpg


3/30





Astronautlife-supportduringEVAispresentlyprovidedbySilver-Zincbatteries

NASAwishestoreplacethesebatterieswithLi-Ion

batteriesforimprovedperformanceandsimplified

handlinglogistics

TominimizechangestotheExtravehicularMobilityUnit(EMU)program,mechanicalinterfacetothe

batteryhousingisunchanged

JSCidentifiedtwoCOTS18650Li-Ioncellstobe

evaluatedwithalaterdownselectfollowingcell

screeningandengineeringunittesting

Background


4/30





Aftercompetitiveprocurement,ABSLplacedunderinitialcontractto

perform: Screeningofapproximately6000cellsofeachcandidatecelltype

JNcellsscreenedatABSLsUSfacility,LVcellsatABSLsUKfacility

PerformpreliminaryanddetaildesignofbatterybrickthatwillbeassembledintoNASAprovidedbatteryhousing

Fabricateandacceptancetest12bricks,6ofeachcelltype

Fabricate8batteryassemblies,calledLLBs Performengineeringunittestingwith6LLBs

Qualificationtypeenvironmentaltestingwith2LLBs

Abuse/safetytestingwith2LLBs

100cyclemissionsimulationtestingwith2LLBs

FollowingsuccessfulCDR,contractoptionplacedwithABSLtofabricate35flightbricksandperformqualificationtestingwith2LLBs

Note:thiswasthefirstmajorhardwarecontractatABSLsColoradofacility,buthavenowdemonstratedsimilarcapabilityasABSLsUKfacilitywithmultipleflightbatteriesdeliveredforvariouscustomers

Background Cont.


5/30

000074.A.PresentationTemplateProprietaryInformation



Goaltomaximizecapacitywithinexistinghousinggeometry

andvoltagerangeof16.0to20.6volts Minimumacceptablecapacity:26.6Ah

Optimizationwasa16p5stopologywithmeshedcellmatrix NotusingABSLtraditionalapproachbecauseNASAwillbeusing

customchargerwithintegratedbankbalancingifrequired

TypicalABSLdesignfeaturesandEMUspecifics Cellselectrically&mechanicallyscreenedforanydefectsorout-

of-familycharacteristics

Cellsarebondedintocounterboredcaptureplates Redundantcellweldsusingcommonbuspads Robustelectricalinsulation

ForadditionalsafetyagainstFOD,isolationbarrierplacedbetweencellbanks

Aluminumsidepanelsforthermaldissipationandmountingtobatteryhousing

Design Development


6/30




Brick Design

Capture plates

Double layer of Kapton

Cell bank with 16cells in parallel

Common bus padswith weld tabs

Main commoner link andbrick terminal pads


7/30




Inparallelwithdesigndevelopment,assemblyprocessesdeveloped

Weldschedules

ModifiedfromheritagescheduleforSonyHCcells

After100sofweldsthatwereachievingconsistenthighpullstrengths,thoughtwe

weresuccessful,butcross-sectionsrevealedadditionalrefinementneeded

Agreedtouseexistingweldscheduleforengineeringunitswhilefurtherweld

schedulerefinementperformed

Additionalweldscheduledevelopmentwassuccessfulandweldscheduleisnow

fullyqualifiedforflighthardware

NASAcertifications

ManufacturingandInspectionPersonnelwereNASAcertifiedforapplicationand

inspectionofsoldering,conformalcoating,andcrimping

Detailedassemblytravelersandsupportingmanufacturingdocumentationreleased

Manufacturing Development


8/30




Welding per 60010A WI(Macgregor M2 welder with Multitest 2.5X Pull Tester)


9/30




Cells Installed Into Lower CapturePlate with Insulating Block Dividers


10/30




Post Welding

4 welds per cell anode or cathode


11/30




Final Brick Assembly

Side panels

Kapton insulating wrap


12/30




Eachbrickundergoespostfabricationacceptancetesting

Visualinspection Massmeasurement Electricalisolation Dimensionsandhousingfitcheck Functionalperformance(OCV,9Apulseat30%SOC)

4vacuumcyclesand3day+35Cvacuumdwell 5thermalcycles(-14Cto+45C) Individualbankcapacitymeasurements

1st cycle:19.2A(C/2)chargeto4.2Vwith9.6A(C/4)dischargeto3.0V

2nd cycle:5Achargeto4.12Vwith3.8Adischargeto3.2V(missionconditions)

Repeatfunctional,mass,andvisualexam Nomechanicalorperformanceissueswithanybricks Bankcapacities34.8Ahto35.3AhforJNcellsand31.0Ahto31.3Ah

forLVcellsundermissionconditions

Brick Acceptance Test


13/30




Bricks Acceptance Testing

Vacuumcycling andheatedvacuum dwell

Ambientpressurethermalcycling

Bank capacity testingwith Maccor 4000 cycler


14/30




Followingsuccessfulcompletionofbrickacceptancetesting,4bricks

ofeachcelltypewereintegratedintoNASAsGFEhousingkits

Housingkitincludesmechanicalhousing,PCBboardwithbanklevelPTCs,in-linefuse,thermistor,andwiringintotwoconnectors

LLB Assembly


15/30




LLB AssemblyWithbrickupside

down,housinginsertedoverthetop

andsecuredwith

fastenersintoside

panels

PCBalignedandfastenedto

brickterminalswithfasteners

intocaptureplates

Lidinstalledandfastenedto

housing

Completed

assemblyis

weighed,QA

inspectedand

boughtoff


16/30




OneLLBofeachcelltypeexercisedthroughextensive

environmentalcampaign

Environmental Tests

(10C, 22C, 32C) (15 cycles) (24 cycles -25C to 54C)

(acceptance - clamp)(qual - clamp)(qualin fixture)

Qual, bench (10C, 22C, 32C) (21 day stand, DPA)

BothLLBsurvivedwithnomechanicalissues,noevidenceofvibration

orshockinduceddegradations,andonlymild(


17/30




Pre/Post Performance006703 0002 (JN) 006803 0001 (LV)

Temp.

Pre

(Ah)

Post

(Ah)

Delta

(Ah)

Delta

(%)

Pre

(Ah)

Post

(Ah)

Delta

(Ah)

Delta

(%)10C 34.04 33.59 -0.45 -1.3% 30.43 29.95 -0.48 -1.6%

22C 34.30 33.86 -0.44 -1.3% 30.47 30.06 -0.41 -1.3%

32C 34.49 34.13 -0.36 -1.0% 30.54 30.26 -0.28 -0.9%

PN, SN When Completed

OCV

(V)

CCV

(V)

AC Imp*

(m) Result6803, 0001 Pre Vibe 18.878 17.841 24.6 Pass

Post Vibe 1 18.881 17.821 N/A Pass



Post Shock 18.830 17.779 23 Pass

6703, 0002 Pre Vibe 18.834 17.781 31.4 Pass




Post Shock 18.771 17.718 30.06 Pass

*at brick terminals

Vibration Testing Functional Checks

DPAfoundallfastenersstillattorquevalues,nosignsofabrasion,orotherdiscrepancies


18/30





Capacity vs Temperature

Temp.

(C)

LLB

6703 0002

LLB

6803 0001

10 34.043 30.429

22 34.305 30.475

32 34.491 30.538

LLB with J N cells

LLB with LV cells


19/30





Vibration/Shock Testing

LLB in clamped restraint for locker storageAcceptance level: 7.43grmsQualification level: 9.89grms

LLB in GFE fixture for shuttle stowageQualification level: 6.48grms


20/30





OneLLBofeachcelltypeisundergoingamissionsimulationtest

thatcombinesthermal,vacuum,andelectrochemicalcyclingto

reproduceEVAconditions

Chargeat5Ato20.5Vinambientpressure

Dischargeat3.8Awhileinvacuumstartingfrom+32C

Chargeat5Ato20.5Vinambientpressure

Dischargeat3.8Awhileinvacuumstartingfrom+14C

Repeatfortotalof100cycles

Toexpeditetestduration,fulldischargesonlyrequiredevery10cycles

TestingbeingperformedinABSLsUKfacility

Currentlyaroundcycle80,expecttocompletetestinlateDecember

Noissuessofar,justaverylongtest startedlastJune

Mission Simulation Testing


21/30





Test Set-Up

Heating/cooling plate

Interface plate


22/30




EMU Program & Progress 22 Smoothgracefulcapacityfadeobservedsofar

Mission Simulation Results


23/30





OneLLBofeachcelltypeunderwentsafety/abusetesting

Over-chargeWithbanksbalanced,chargeLLBat1.55Ato21.9Vfor48hrs(cell

banksat4.38Vonaverage)

With1bankchargedto4.2Vandremaining4banksat3V,LLB

chargedat1.55Ato21.9V

Over-discharge Onebankresistivelydischargedto0Vthencontinueddischargein

reversebydischargingremainingbanksthatwerefullycharged

resultsinapproximately100%SOCreversal

Short-circuit

63m shortcircuitwith1bank PTCun-activatedcase

6.5m shortcircuitacross1bank PTCactivatedcase

Allsafety/abusetestsresultedinbenigndegradation

Safety/Abuse Testing


24/30





LLB Overcharge

CIDs activating

Charging suspended due to reaching max charge voltage


25/30





Bank4wasdrivenintoreverseapproximately100%SOC

Noanomalousresultswerewitnessed.

LLB Over Discharge


26/30





LLB Short Circuit Testing

61A in-rush current measured

Maximum temperature: 63.96C

Throughout test, no smoke or venting observed


27/30






PTCactivation

Current


28/30






Maximumtemperature:102.3C,measuredontopofshortedbank

Throughouttest,nosmokeorventingobserved


29/30





NASAhasnowdown-selectedtoJNcell

FollowingreviewofengineeringbrickandLLBtestdataatCDR,authorizedABSLtoproceedwithOption2ofEMUcontract Produce35flightbricks

Fabricate3LLBswithGFEhousingkits

ConductLLBacceptancetesting

Performformalqualificationtestingwith2LLBs

Flightbricksarenowinfullproductionwith8brickscompleteand4morein-work

Productionrateiscurrentlyfourbricksevery2weeks

Acceptancetestrateisfourbricksevery4weeks

PreparingforLLBfabricationinearlyDecemberfollowingbyacceptancetestingandthenqualificationtesting

Anticipatenear-termcontractwithHamilton-SundstrandforfabricatingandacceptancetestingadditionalLLBsforflightdelivery

4LLBsscheduledtolaunchJuly29aboardshuttleDiscoverytosupportISSEVAs

Present and Near Term Activity


30/30



ThankstoSamRussellandEricDarcy,NASAJohnson

SpaceCenter,fortheirexcellentcontractsupportand

technicalguidance

Acknowledgement

nasa emu batt program progress cflora

Documents