Battery management considerations for multichemistry systems

The performance advantage of Li-ion batteries versus NiCd and NiMH technology has created a worldwide demand for Li-ion cells that is much greater than current manufacturing capacity. This is keeping prices high and supplies scarce-a situation expected to continue for at least several more years. Multichemistry chargers, while challenging to design, keep price-performance points flexible and guard against interruptions in supply. This paper surveys the design issues in implementing chargers that handle NiCd, NiMH, or Li-ion cells interchangeably     

Remaining useful life prediction of aircraft lithium-ion batteries based on F-distribution particle filter and kernel smoothing algorithm

As an emergency and auxiliary power source for aircraft, lithium (Li)-ion batteries are important components of aerospace power systems. The Remaining Useful Life (RUL) prediction of Li-ion batteries is a key technology to ensure the reliable operation of aviation power systems. Particle Filter (PF) is an effective method to predict the RUL of Li-ion batteries because of its uncertainty representation and management ability. However, there are problems that particle weights cannot be updated in the prediction stage and particles degradation. To settle these issues, an innovative technique of F-distribution PF and Kernel Smoothing (FPFKS) algorithm is proposed. In the prediction stage, the weights of the particles are dynamically updated by the F kernel instead of being fixed all the time. Meanwhile, a first-order independent Markov capacity degradation model is established. Moreover, the kernel smoothing algorithm is integrated into PF, so that the variance of the parameters of capacity degradation model keeps invariant. Experiments based on NASA battery data sets show that FPFKS can be excellently applied to RUL prediction of Li-ion batteries.     

Advanced lithium ion solid polymer electrolyte battery development

Lockheed Martin Missiles & Space (LMMS), Ultralife Batteries, Inc. (UBI), Eagle Picher Technologies, LLC (EPT), Sandia National Laboratories (SNL) and Rentech, Inc. (RTI) are developing lithium ion solid polymer electrolyte (Li-ion SPE) batteries. Under a new Advanced Technology Program (ATP), this team will develop new high-energy density cells and batteries for space and portable electronics applications. These new batteries will utilize new high-energy density anode and cathode active materials developed by SNL and RTI. UBI will incorporate these new materials into an optimized Li-ion SPE electrode laminate. EPT will develop batteries for aerospace applications based on this electrode laminate technology while LMMS will design the battery charge management controller and provide system expertise     

Prismatic lithium-ion batteries

Lithium-ion (Li-ion) batteries have demonstrated the ability to fulfill the energy storage needs of many new technologies. The most significant drawbacks of currently available technologies, such as LiCoO ₂ based Li-ion cells, is their high cost and significant environmental hazards. Li-ion cells which use a lithium manganese oxide (LiMn₂O₄) spinel based cathode material should be much less costly and safer than LiCoO₂ based cells. Performance data from prismatic design cells which use a LiMn₂O₄ based cathode material is presented and shown to meet many military performance criteria. The most significant drawback of this technology is the short cycle life     

航空锂电池适航审定规章解读及符合性方法研究

锂离子电池作为动力电池有着优异的性能,在民航行业上有广阔的应用前景。但行业对其技术特征 和安全风险的认识还不充分,现行的规章条款缺乏足够的安全要求,国外局方针对锂离子电池颁发了专用条 件,但回顾相关事故可以发现,锂离子电池的验证和审查环节还不完善,相关条款更新修正的步伐也同锂电池 的发展现状和技术水平不相适应。以航空锂电池事故为例,分析航空锂离子电池作为动力电池的安全性风险, 从对现有规章条款和专用条件的解读出发,借鉴不同行业近年来积累的锂电池验证和使用经验,针对航空动力 锂电池的适航符合性方法提出一些改进方案,可作为现有锂电池适航符合性方法的有益补充,为自主建立健全 适航验证规范体系做出探索。     

Aerospace lithium solid polymer batteries

Lockheed Martin Missiles and Space and Ultralife Batteries, Inc. are developing batteries for spacecraft and launchers based on Li-ion solid-polymer-electrolyte cell technology. These cells utilize a carbon anode, a manganese dioxide cathode and a solid polymer electrolyte. Electrode and electrolyte layers are thin and flexible. The electrode assembly is easily fabricated into thin, flat prismatic shapes using ordinary lamination techniques and is hermetically sealed in thin foil packaging. Cells ranging in capacity from 4 Ah to 50 Ah have been designed and are in development testing. The packaged cells have specific energies in excess of 100 Wh/kg. Prototype 30 volt batteries have also been designed and are being assembled and tested along with the critical battery cell charge management controllers needed to recharge all cells to full capacity while preventing overvoltage damage. The major results of this development effort are reviewed and the key issues for advancing this technology to flight qualification demonstrations are discussed     

Lithium-ion battery software safety protection

Production Li-ion batteries include hardware and software safety protection. The hardware protection includes PTC (positive temperature coefficient) thermistor switch, electrical circuit disconnect and rupture vent. The software protection involves a charging algorithm (charging to ultimate voltage), which is used with internal electrical circuitry (cell voltage control and equalization circuit). This paper discusses a specific charging algorithm and additional software protection features associated with hard, soft and chemical shunt recognition     

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,     

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     

A maximum power transfer battery charger for electric vehicles

A battery charger is described that uses an on-line microcontroller to maximize its output power. This is done by always operating at either the maximum allowable input current or the thermal limit imposed by the charger itself. In this case the thermal limit is determined by the junction temperatures of the two main insulated gate bipolar transistors (IGBTs). Since direct measurement of these temperatures is impractical, they must be calculated by a computer algorithm that uses various on-line measurements. Experimental results for an 8 kW charger indicate a reduction in the bulk charging time of about 26% when used with a set of NiFe batteries.     

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     

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     

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.     

Safety tests of lithium 9-volt batteries for Navy applications

COTS batteries are relatively inexpensive, readily accessible, and extremely versatile. These attributes allow the military to save time and money during the research and development stages. Of these COTS batteries, a 9-Volt (9 V) lithium/manganese dioxide battery is the subject of this paper. This 9 V battery has the ability to provide a low magnetic signature, which is very important to the Navy for many applications, Also, it is Underwriters Laboratories (UL) listed at the unit level; however, these UL tests cannot be directly related to the safety of these 9 V batteries when they are combined in various series and parallel configurations. Naval Surface Warfare Center (NSWC) Carderock was tasked to rate the safety of several such specialized battery packs. It was found that packs consisting of two 9 V batteries in parallel were relatively safe, experiencing no violent behavior. Battery packs with six 9 Vs in parallel vented and deformed the 9 V batteries, but no smoke or flames were noticed. A battery pack with thirty 9 V batteries, 2 in series with 15 legs, experienced venting, smoke, and flames under certain circumstances, After testing, the six and thirty 9 V packs were required to include the addition of various safety devices     

Electric-vehicle batteries

Electric vehicles that can't reach trolley wires need batteries. In the early 1900's electric cars disappeared when owners found that replacing the car's worn-out lead-acid battery costs more than a new gasoline-powered car. Most of today's electric cars are still propelled by lead-acid batteries. General Motors in their prototype Impact, for example, used starting-lighting-ignition batteries, which deliver lots of power for demonstrations, but have a life of less than 100 deep discharges. Now promising alternative technology has challenged the world-wide lead miners, refiners, and battery makers into forming a consortium that sponsors research into making better lead-acid batteries. Horizon's new bipolar battery delivered 50 watt-hours per kg (Wh/kg), compared with 20 for ordinary transport-vehicle batteries. The alternatives are delivering from 80 Wh/kg (nickel-metal hydride) up to 200 Wh/kg (zinc-bromine). A Fiat Panda traveled 260 km on a single charge of its zinc-bromine battery. A German 3.5-ton postal truck traveled 300 km with a single charge in its 650-kg (146 Wh/kg) zinc-air battery. Its top speed was 110 km per hour     

Lithium micro-battery development at the Jet Propulsion Laboratory

Recent successes in the effort to miniaturize spacecraft components using MEMS technology, integrated passive components, and low power electronics have driven the need for very low power, low profile, low mass micro-power sources for micro/nanospacecraft applications. Recent work at JPL has focused upon developing thin film/micro-batteries compatible with temperature sensitive substrates. A process to prepare crystalline LiCoO₂ films with RF sputtering and moderate (<700°C) annealing temperature has been developed. Thin film batteries with cathode films prepared with this process have specific capacities approaching the practical limit for LiCoO₂, with acceptable rate capabilities and discharge voltage profiles. Solid-state micro-scale batteries have also been fabricated with feature sizes on the order of 50 microns     

Zinc-air batteries for forward field charging

In order to realize the operational and service cost savings through the use of rechargeable batteries, the dismounted soldier is burdened with the weight, volume and/or charging logistics of the batteries. By providing the soldier with a high energy density source and a lightweight compact battery charger, the burden imposed by rechargeable batteries in the forward field can be minimized. Zinc-air batteries have the potential for meeting the energy demands of forward battlefield charging. They are attitude insensitive, have a high specific energy and are inherently inexpensive, lightweight and safe     

Portable power source needs of the future Army-batteries and fuelcells

This paper describes the US Army's future needs for silent portable power in the area of batteries and fuel cells. These needs will continue to increase as a result of the introduction of newer types of equipment, the increasing digitization of the battlefield, and future integrated Soldier Systems. Current battery programs are aimed at improved, low-cost primary batteries, and rechargeable batteries with increased energy densities. The Army fuel cell program aimed at portable systems capable of the order of 150 W is also described     

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.     

Galileo probe battery system

NASA's pair of Galileo spacecraft arrived at Jupiter on 7 December 1995. The Probe descended into the upper Jovian atmosphere, performing its planned sequence of scientific measurements of the properties of that medium for about an hour. This Probe has been the most ambitious planetary entry vehicle to date. It evolved over several years of planning and construction, its launch was postponed many times, for a variety of reasons; and it required more than 6 years of travel after launch to reach the planet. Its electrical power was provided by a primary Li-SO₂ battery, supplemented with two thermal batteries (CaCrO₄-Ca) used for firing pyrotechnic initiators during the atmospheric entry. These power sources were designed to be robust, to assure they would perform their intended function after surviving several years in space. This paper discusses the final production, qualification, and the systems testing of these batteries prior to and following launch. Their excellent performance at Jupiter confirmed their life enhancement design features