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.     

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.     

Tests of a full-sized mechanically rechargeable zinc-air battery inan electric vehicle

A mechanically rechargeable zinc-air battery that has high power density and fast refueling capability is described. The battery is built from modules of 32 or 44 cells connected in series, and the modules can be arranged in any combination of series and parallel connections, and in practical quantity, according to the requirements of the vehicle, motor, and controller. The results of laboratory and in-vehicle tests of a zinc-air battery consisting of two 32-cell modules connected in series, with nominal voltage of 75 V and nominal capacity of 216 Ah, are presented     

Continuing challenges in lithium battery development

In these days of emphasizing standardization, Acquisition Reform, Non-Developed Items (NDI) and Commercial-Off-The-Shelf (COTS) technologies, we are facing new challenges associated with these trends. Program managers are pressured to use a standard or COTS battery, while simultaneously, the new systems being developed have increasingly complex and demanding power requirements. Hardware must be developed with shorter schedules, and policies of Acquisition Reform limit the amount of control the government has over the development of a given item. In this paper, we review battery development efforts that have resulted in unexpected problems. Relevant data from both current and past test programs are presented. Recommendations are provided concerning how to best avoid duplication of effort, while ensuring that the final product will have the best chances of succeeding     

Jump starting 42V PowerNet vehicles

The introduction of a 36V battery along side of the 12V battery will enhance starting reliability, but it also creates new risks and, therefore, a strategy for jump start is needed. This paper discusses the issues that must be addressed with respect to charging and jump starting the batteries in the 42V/14V dual voltage systems     

Considerations regarding the comparison of traction batteries

S.E.A. has been developing, since 1983, the zinc-flow-battery to be ready for mass production. In 1993 the Boston based Power Cell Corporation (PCC) acquired S.E.A. and the new company intends to erect a facility to produce 150.000 kWh at the end of 1994. Since 1985 zinc-flow-batteries are used to power electric-vehicles in capacities between 5 kWh and 45 kWh at voltages between 48 V and 216 V. A 22.5 kWh/96 V battery assembled in a Fiat-Panda is shown, which achieves 260 km per charge at 50 km/h constant. This Panda participated in several rallies. A purpose designed 15 kWh/144 V battery for the Hotzenblitz-EV is also shown, which demonstrates the design-flexibility of the battery. The battery is mounted from underneath the car body between the four wheels and does not consume valuable space in the front or rear of the car. This position is a significant contribution to the safety of passengers. Mass production for this EV is foreseen in 1995. About 50,000 kms of testing experience partially in direct comparison with originally assembled lead acid batteries showed results with zinc-flow-battery equipped EVs, which were significant better than was expected. Referring to about the same battery weight a two- to threefold range was experienced with the zinc-flow-system independent of the driving cycle and independent of the battery capacity compared     

Power sources and portable computers

The safety aspects of the nickel-metal-hydride and high-capacity nickel-cadmium batteries used in Apple Computer's current notebook computers are discussed. No problems are anticipated with nickel-cadmium packs, which have an excellent record for safety because the cell design parameters are well understood and there is ample safety margin under abusive conditions. At its early stage of development, the nickel-metal-hydride cell is not as electrochemically robust as the nickel-cadmium, and it does not have as wide an operational temperature range. The possible hydrogen release from nickel-metal-hydride batteries on charging at low temperatures can also be a potential explosion hazard. Nickel-metal-hydride is considered less environmentally harmful than nickel-cadmium and has escaped legislated recycling requirements     

Industrial battery technologies and markets

Industrial battery market segments generally fall into two major categories--traction batteries, also called motive power batteries; and stationary batteries, also referred to as standby power batteries. The major industrial battery subcategories are discussed. Industrial trucks and rail and mine vehicles represent two major subcategories of motive power batteries. Industrial trucks include forklifts, automated guided vehicles (AGVs), various types of towing vehicles, floor cleaning equipment and so forth. Battery-powered rail and mine vehicles are used in mines where gas is present that could be ignited by spark ignition engines. Locomotive starting batteries and railcar emergency power batteries are also included in the second subcategory. The distinction is beginning to blur between valve-regulated industrial batteries and golf cart or marine batteries. Both industrial and SLI(starting/lighting/ignition)-derivative batteries are competing for markets in the future. The future trends in industrial battery production in Japan, USA and Europe are discussed     

Selective buck-boost equalizer for series battery packs

To maximize the capacity and reliability of a series connected battery pack, a new selective equalizer developed from the earlier ramp equalizer is proposed. A set of bipolar junction transistors (BJTs) controlled by a microcontroller is used to route equalization current to the lowest voltage batteries. Since only the lowest voltage batteries are connected to the equalizer, the need for uniform transformer leakage inductance is avoided, and a lower power level can be used since no excess current flows to the other batteries. An equalization experiment has shown that a 37 W selective equalizer had a slightly better effect on a 24-battery pack than a 63 W ramp equalizer     

Nickel-hydrogen multicell common pressure vessel batterydevelopment update

Flight qualification of the multicell common pressure vessel (CPV) nickel-hydrogen (Ni-H₂) battery is discussed. The battery has completed full flight qualification, including random vibration at 19.5 g for two minutes in each axis, electrical characterization in a thermal vacuum chamber, and mass-spectroscopy vessel leak detection. A first launch is scheduled in 1992. Several design variations, ranging from 9 Ah to 125 Ah and 12 to 32 V, have been developed and prototypes fabricated. Designs for smaller capacity, smaller diameter (6.4-8.9 cm), and higher voltage (up to 100 V) are in progress. The CPV battery offers cost and weight savings of up to 30% as compared to traditional nickel-cadmium (Ni-Cd) and individual pressure vessel (IPV) Ni-H₂ batteries. The fully qualified design provided a 50% weight savings over its Nd-Cd predecessor for the same application. Its reduced volume also provides a significant advantage over IPV technology. Resistance data show a further advantage     

COTS器件管理要求研究

通过对COTS 器件使用风险和管理现状进行说明,对国内外电子器件管理要求的分析和研究,提出 了针对COTS 器件管理的适航要求建议,期望能达成限制机载设备中COTS 器件使用的风险,提升机载设备可 靠性及民用飞机安全性的目的。     

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.     

Sensitivity of a ramp equalizer for series batteries

To realize the maximum potential of large series connected battery packs, the individual battery voltages should be maintained at fairly uniform values, i.e., the voltages should be equalized. The ramp type of electronic equalizer has proven to be very effective in performing this task since it offers the advantages of simplicity and convenience. However, to achieve maximum performance, it is necessary to understand how the circuit is affected by certain parameters. This is accomplished by defining the circuit sensitivity and using a simplified model to explain the relative effects of leakage inductance, frequency, and power level     

Fast equalization for large lithium ion batteries

Slight differences between the series connected cells in a lithium ion (Lilon) battery pack can produce imbalances in the cell voltages, and this greatly reduces the charge capacity. These batteries cannot be trickle-charged like a lead acid battery since this would slightly overcharge some cells and may cause these cells to ignite. Therefore, an electronic equalizer (EQU) should be used to balance the cell voltages individually. The targeted EQU described herein can be connected to any cell via a set of sealed relays to provide much faster equalization and higher efficiency than previous methods.     

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,     

U.S. Army battery needs-present and future

The purpose of this paper is to describe the needs of the U.S. Army for silent portable power sources, both in the near and longer term future. As a means of doing this, the programs of the Power Sources Division of the Army Research Laboratory are discussed. In carrying out these programs, the personnel of the Power Sources Division work closely with the Battery Management Office of the Army Materiel Command, which is located in the Logistics and Readiness Directorate of the Communication-Electronics Command (CECOM). We are also closely integrated with the Army Research Office, and the fuel cell personnel of the CECOM Research Development and Engineering Center (RDEC), and the battery personnel of the RDECs for the Tank and Automotive Command and the Missile Command. The six program areas discussed in which the Power Sources Division is engaged are: primary batteries, rechargeable batteries, reserve/fuze batteries, pulse batteries and capacitors, fuel cells, and thermophotovoltaic power generation     

Operational testing of valve regulated lead acid batteries incommercial aircraft

Valve regulated lead acid (VRLA) batteries provide electrical performance that is virtually identical to sintered plate nickel-cadmium battery systems. In addition, the VRLA batteries offer the user a no-maintenance battery and other enhanced features that make this a very desirable battery for aircraft applications. In field trials, where VRLA batteries were substituted for nickel-cadmium batteries, the VRLA provided the user with a high reliability turbine engine starting battery under a wide variety of climatic conditions     

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     

航空蓄电池能量均衡技术研究

航空电池组中单体电池之间会逐渐出现不一致性,会降低电池组性能和使用寿命,甚至引发安全事故。本文提出了一种基于主动均衡的航空蓄电池组能量均衡系统结构,提出了一种能量集中式双向传递的Cúk型均衡电路,设计了顶部均衡和底部均衡的均衡控制策略。开发了航空镍镉蓄电池能量均衡系统,进行了镍镉电池组能量均衡实验分析,实验结果表明新型能量均衡器具有均衡速度快、均衡电池单体可任意选择、能量双向传递的优点,通过电池组能量均衡控制能明显改善电池组内单体之间的不一致性,提高电池组容量利用率和使用寿命。     

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