Life expectancy of a 24-V, 15-Ah sealed lead-acid aircraft battery

This paper presents the results of cycle life testing F24-V, 15-Ah sealed lead-acid batteries intended for use the B-1B aircraft. Test samples were procured from two different manufacturers and subjected to cycle testing at 33% and 100% depth-of-discharge (DOD). The cycle life at 33% DOD ranged from 500 to 750 cycles. The cycle life at 100% DOD ranged from 160 to 260 cycles     

Bipolar nickel-metal hydride batteries for aerospace applications

Electro Energy Inc. (EEI) is developing high power, long life, bipolar nickel-metal hydride batteries for aerospace applications. Bipolar nickel-metal hydride designs allow for high energy and high power designs with a 25 percent reduction in both weight and volume as compared to prismatic and/or cylindrical Ni-MH designs. Utilizing a sealed wafer cell design EEI has demonstrated a 1.2 kW/kg power capability. Prototype designs have achieved 70 Wh/kg. Designs studies show 80 Wh/kg are achievable with EEI's state-of-the-art technology. The sealed wafer cell is the building block for EEI's high power and high voltage bipolar batteries making the assembly easy and significantly lower in cost. Satellite and aircraft batteries are being developed which provide high power and long life. Sealed cells now show excellent rate capability and life. Cells tested in a low earth orbit (LEO) cycle have reached 9000 cycles and continue on test. High power, bipolar battery designs are ideal in applications where using conventional aerospace battery technology would require excessive capacity; weight and volume, thereby reducing usable payload on the vehicle     

Development of a long cycle life sealed nickel-zinc battery forhigh energy-density applications

Nickel-zinc battery technology is being developed for commercial applications requiring high energy density and high power capability. Development cells have demonstrated the ability to deliver over 60 Watt-hours per kilogram at the one hour rate. Cycle life has been improved to more than 600 cycles at 80% depth of discharge by using a patented, reduced solubility zinc electrode and an improved sealed cell design. More than 8000 charge/discharge cycles at 10% depth-of-discharge have been completed. Large quantities of sealed prismatic cells have been manufactured, including a 140 cell, 220 V battery for a hybrid electric vehicle (HEV)     

Hubble performance on-orbit

A summary of the Hubble Space Telescope (HST) nickel-hydrogen (NiH/sub 2/) battery performance from launch to the present. Over the life of HST vehicle configuration, charge system degradation and failures, together with thermal design limitations, have had a significant effect on the capacity of HST batteries. Changes made to the charge system configuration to protect against power system failures and to maintain battery thermal stability resulted in undercharging of the batteries. This undercharging resulted in decreased usable battery capacity as well as battery cell voltage/capacity divergence. This cell divergence was made evident during on-orbit battery capacity measurements by a relatively shallow slope of the discharge curve following the discharge knee. Early efforts to improve battery performance have been successful. On-orbit capacity measurement data indicates increases in the usable battery capacity of all six batteries as well as improvements in the battery cell voltage/capacity divergence. Additional measures have been implemented to improve battery performance, however, failures within the HST Power Control Unit (PCU) have prevented verification of battery status.     

Hubble Space Telescope at twelve years of age

The Hubble Space Telescope was deployed from the Space Shuttle Discovery into a 380-mile high Earth orbit on April 25, 1990. It subsequently made outstanding astronomical discoveries with its 8-foot (2.4-meter) telescope and other scientific instruments. Critical to the successful observations was continuous availability of power from its solar arrays during sunlit periods, and from nickel-hydrogen batteries when the satellite was in the Earth's shadow. The adopted nickel-hydrogen batteries were carefully selected and tested to confirm their depth-of-discharge and operating temperature that delivered the longest life in charge/discharge cycling service. These batteries had a design life of 7 years. At 12 years after launch the Hubble batteries have delivered more charge/discharge cycles than any other batteries in low-Earth orbit. However, the Hubble batteries have been subjected to many unexpected stresses, and peculiar reductions in battery capacity have been observed. Battery replacement requires a costly trip to the Hubble Space Telescope by astronauts, so the remaining useful life of the batteries must be predicted. Already in four servicing missions, astronauts have replaced or modified optics, solar arrays, a power control unit, and various science packages. A fifth servicing mission is scheduled in 2004. This paper discusses battery charging hardware and software controls, history of battery events in Hubble, cell performance model and spare battery tests, and capacity walkdown.     

Effect of KOH concentration on LEO cycle life of IPVnickel-hydrogen flight cell-update II

For update I see Energy and Environment: A Continuing Partnership, vol.3, American Nuclear Society (1991). An update of validation test results confirming the breakthrough in the low-Earth-orbit (LEO) cycle life of nickel-hydrogen cells containing 26% KOH electrolyte is presented. The results are part of an investigation of the effect of KOH concentration on life cycle. The cycle life of boiler plate cells was about 40000 LEO cycles compared to 3500 cycles for cells containing 31% KOH. The cycle regime was a stressful accelerated LEO, which consisted of a 27.5 min charge followed by a 17.5 min discharge (2×normal rate). The depth-of-discharge (DOD) was 80%. The cell temperature was maintained at 23°C. Results for six 48-Ah recirculation design IPV nickel-hydrogen flight battery cells currently being evaluated to validate the above findings are reported. Three of the cells contain 26% KOH (test cells), and three contain 31% KOH (control cells). They are undergoing real-time LEO cycle life testing. The 31% KOH cells failed at cycles 3729, 4165, and 11355. One of the 26% KOH cells failed at cycle 15314. The other two 26% KOH cells have been cycled for over 16600 cycles without failure     

A nickel/hydrogen battery for PV systems

The nickel-hydrogen battery, developed in the early nineteen-seventies as an energy-storage subsystem for commercial communication satellites, is discussed. The advantages offered by nickel-hydrogen batteries, including long life, low maintenance and high reliability, make it very attractive for terrestrial applications such as stand-alone photovoltaic systems. The major drawback to the wider use of the nickel-hydrogen battery is its high initial cost. A 7-kWh battery has been on test since January 1988 using a flat-plate photovoltaic array for charging. The cell, battery design and test methods are briefly described, and the results of cycling and solar tests are presented. It is concluded that the battery is well suited for remote solar applications     

A microcontroller-based intelligent battery system

State-of-charge indication for a secondary battery is becoming increasingly important for battery-operated electronics. Consumers are demanding fast charging times, increased battery lifetime, and fuel gauge capabilities. All of these demands require that the state of charge within a battery be known. One of the simplest methods employed to determine state of charge is to monitor the voltage of the battery. However, this method alone is not a good indicator of battery energy, since both NiMH and NiCd batteries have voltage-versus-energy curves that are essentially flat. This paper presents a more effective method of determining the state of charge in secondary cell batteries. A NiMH battery is used as our test vehicle, since it is one of the more difficult batteries to determine state of charge. This method monitors the battery's temperature, voltage, and discharge/charge rate. A microcontroller then manipulates the information, using look-up tables to determine the state of charge. Also, by modifying the look-up tables, this technique can be employed in many other battery technologies and is not limited to NiMH     

Performance characteristics of lithium-ion cells for NASA's Mars2001 Lander application

NASA requires lightweight rechargeable batteries for future missions to Mars and the outer planets that are capable of operating over a wide range of temperatures, with high specific energy and energy densities. Due to the attractive performance characteristics, lithium-ion batteries have been identified as the battery chemistry of choice for a number of future applications, including Mars rovers and landers. The Mars 2001 Lander (Mars Surveyor Program MSP 01) will be one of the first missions which will utilize lithium-ion technology. This application will require two lithium-ion batteries, each being 28 V (eight cells), 25 Ah and 8 kg. In addition to the requirement of being able to supply at least 200 cycles and 90 days of operation on the surface of Mars, the battery must be capable of operation (both charge and discharge) at temperatures as low as -20°C. To assess the viability of lithium-ion cells for these applications, a number of performance characterization tests have been performed, including: assessing the room temperature cycle life, low temperature cycle life (-20°C), rate capability as a function of temperature, pulse capability, self-discharge and storage characteristics, as well as mission profile capability. This paper describes the Mars 2001 Lander mission battery requirements and contains results of the cell testing conducted to-date in support of the mission,     

Nickel-Cadmium Batteries as Capacitive Filters for Pulsed Loads

This investigation consisted of several tests of specially fabricated nickel-cadmium batteries having circular disk-type electrodes. These batteries were evaluated as filter elements between a constant current power supply and a 5 Hz pulsed load demanding approximately twice the power supply current during the load on a portion of the cycle. Short tests lasting 104 cycles were conducted at up to a 21 C rate and an equivalent energy density of over 40 J/Ib. In addition, two batteries were subjected to 10h dischar cycles, one at a 6.5 C rate and the other at a 13 C rate. Assuming an electrode-to-battery weight ratio of 0.5, these tests represent an energy density of about 7 and 14 J/Ib, respectively. Energy density, efficiency, capacitance, average voltage, and available capacity were tracked during these tests. After 10y capacity degradation was negligible for one battery and about 20 percent for the other. Cadmium electrode failure may be the factor limiting lifetime at extremely low depth of discharge cycling. The output was examined and a simple equivalent circuit was proposed.     

The Analysis of Voltage-Limited Battery Charging Systems

This paper discusses the techniques and problem areas associated with the charging of sealed secondary batteries for spacecraft, and the operating characteristics of the modified voltage-limited charging system. An approach is described for the characterization of battery parameters. The method of selection of a suitable voltage-temperature limit, with regard to battery parameters and system performance requirements, is described. A 4 ampere-hour battery system is analyzed, and its capability is defined parametrically.     

Field evaluation of Honda's EV PLUS battery packs

The EV PLUS demonstration program provides an opportunity to evaluate battery life while gaining expertise in managing Ni-MH battery technology under real-world conditions. Since individual customers use the vehicles, Honda developed a battery service and evaluation system convenient to customers, yet not burdensome to dealer service. This paper discusses the method of detection of low battery capacity, the technique used to convey this information to users, the bench evaluation system of returned batteries, and explains how the analysis is utilized to enhance the EV PLUS' battery control strategy.     

The Hy-StorTM battery

The Hy-Stor^TM Battery is a rechargeable battery being developed for electric vehicles and other large battery applications. The battery combines the high energy storage capability of metal hydride alloys with the high cycle life and discharge rate capabilities of nickel-hydrogen cells. It is a hybrid battery concept that offers potential performance, economic and safety advantages over other large battery technologies. Very recent developments indicate that much smaller batteries can also be produced to meet the needs of the portable computer and other portable electronic device markets. Initial tests demonstrated the ability of a metal hydride storage system to achieve high cycle life when absorbing hydrogen that was saturated with battery electrolyte solution and then passed through a purifier. Based on positive test results, a patent for the Hy-Stor battery was applied for and granted     

Safety testing of lithium ion batteries for navy devices

Lithium ion battery technology is being introduced into power supplies used by our armed forces for a variety of applications. In many cases, the same cells and design parameters that support commercial battery packs are being used in military battery packs. This approach is expected to result in a major decrease in the total life cycle cost of the equipment these batteries support. On June 13, 1991, NAVSEA issued INST9310.1B1, which states that all lithium battery powered equipment must undergo safety evaluation and approval prior to fleet use. This safety program governs a process whereby approvals are issued for lithium batteries to be used in specific equipment on ground facilities, surface combatants, air combatants, and/or submarines. The Naval Ordnance Safety and Security Activity (NOSSA) manages the program. The chief technical advisors are Code 644 at NSWC Carderock Division and Code 609A at NSWC Crane Division. This paper describes three battery designs that incorporate lithium ion technology, and the results of battery safety tests conducted in accordance with navy requirements.     

Rotorcraft flight endurance estimation based on a new battery discharge model

To avoid the numerical complexities of the battery discharge law of electric-powered rotorcrafts,this study uses the Kriging method to model the discharge characteristics of Li-Po batteries under standard conditions.A linear current compensation term and an ambient temperature compensation term based on radial basis functions are then applied to the trained Kriging model,leading to the complete discharged capacity-terminal voltage model.Using an orthogonal experimental design and a sequential method,the coefficients of the current and ambient temperature compensation terms are determined through robust optimization.An endurance calculation model for electric-powered rotorcrafts is then established,based on the battery discharge model,through numerical integration.Laboratory tests show that the maximum relative error of the proposed discharged capacity-terminal voltage model at detection points is 0.0086,and that of the rotorcraft endurance calculation model is 0.0195,thus verifying their accuracy.A flight test further demonstrates the applicability of the proposed endurance model to general electric-powered rotorcrafts.     

High reliability lithium rechargeable batteries for specialties

Since their development in the late 1980s, lithium rechargeable batteries have enjoyed rapid growth and wide use as a commodity battery known for its higher energy density storage and lightweight convenience. These same attributes are emerging as a strong platform in power source development for the medical and aerospace sectors with highly customized applications and narrowly defined criteria. Accordingly, this new generation of lithium rechargeables must be hermetically sealed, have long-term storage capability, and zero-fault tolerances for common causes of field failures such as electrolyte leakage or short circuits from mechanical deformation. Quallion has been developing and manufacturing highly reliable lithium rechargeable cells for medical, aerospace, and specialty applications. Summarized in this paper are some key technologies developed at Quallion for designing and manufacturing of this new class of lithium rechargeable batteries. They include: 1) leakage reliability; 2) self-extinguishing electrolyte system; 3) mechanical impact resistance; 4) deep discharge storage; and 5) high reliability manufacturing.     

9th Annual Battery Conference on Advances and Applications

The developments in batteries reported at the 8th Annual Battery Conference on Advances and Applications, are discussed. It was sponsored by the electrical engineering department of California state university, long beach, CA, with IEEE-AESS cooperation. Previous well-funded battery research had been directed toward getting low weight in spacecraft batteries, which had to be boosted into orbit with expensive rockets. Ni-H₂ batteries, even though costly, won the race. Their demonstrated life, like 30,000 charge-discharge cycles, gives an earth-orbiting satellite decades of usable life. Other types of batteries discussed are: aircraft batteries; electric vehicle batteries; Ni-Cd cells; Zn-Br batteries; industrial Pb-acid batteries; rechargeability; computer controlled charging; and small rechargeable and primary batteries     

Military qualification of a high-reliability, light-weight 24 V/30Ah aircraft battery

The United States Navy has flown Valve Regulated Lead-Acid Batteries (VRLA) for approximately 18 years. The first VRLA aircraft batteries were cylindrical cell design and evolved to a prismatic design to save weight, volume, and to increase rate capability. This paper discusses the next generation of the VRLA aircraft battery. The HORIZON composite grid VRLA design reduces weight, increases high rate performance, and is expected to increase service life. This paper discusses the weight reduction over the present 30 Ah prismatic VRLA aircraft battery design; improvements in high rate engine start performance, and present status of the development effort. Finally, the paper discusses the applications for the 30 Ah composite grid VRLA aircraft battery, and shows the future application opportunities for light-weight VRLA, both in the military and commercially     

Status of the Air Force nickel hydrogen low earth orbit life test

The US Air Force NiH₂ LEO (low earth orbit) life test consists of 200 cells undergoing real-time LEO cycling, pulse discharge testing, and storage testing. To date, three of the program's four objectives have been met: NiH₂ performance in LEO applications has been demonstrated. A significant number of cells have completed more than 20,000 cycles at 40% DOD. A database for cells of both 3.5 in. and 4.5 in. diameter has been generated. There have been no indications of any performance problems related to scaling up in terms of cell size. Initial data on the pulse discharge performance of a small number of cells has been demonstrated. Concerning the goal of achieving 20,000 cycles at 60% DOD, the data are mixed. Overall, it appears highly unlikely that cell designs such as those currently in the US Air Force test can achieve 20,000 cycles at 60%     

Electric car progress

Our global temperature's rise is caused by our atmosphere's ever-increasing content of carbon-dioxide, most of which comes from the exhaust of transportation vehicles. This has resulted in a worldwide search for alternatives to the high-powered gasoline fueled automobiles in wide use today. Replacing gasoline-powered cars with electric and hybrid-electric vehicles has become the most popular tool for reducing carbon-dioxide emissions into our atmosphere. Evaluation of electric alternatives to gasoline-engine propulsion of cars covers such topics as the efficiency, weight, and lifetime of fuel cells, and increasing the charge/discharge life of the new lightweight lithium and nickel metal-hydride batteries. A summary of the work currently being carried out on battery and hybrid vehicles is included here