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.     

International Space Station power storage upgrade planned

As the Earth-orbit International Space Station (ISS) grows, it needs more power which is generated by solar panels. For periods in which the planet Earth occults sunlight, energy is stored in the biggest set of batteries ever flown in space. Reliability of power is important in a space station because a failure requires costly launch of replacement components. Even greater importance results when astronauts work in the station. A power failure that causes the astronauts to perish would be a very serious event. The first battery-containing "integrated equipment module" was launched November 30, 2000 and installed on port 6 of the International Space Station. Two more modules will be launched by the United States; to be launched in 2004 is the European Space Agency's "attached COLUMBUS APM laboratory," which will have its own power system. Unexpected battery-related events occurred in the integrated equipment module during its first year-and-a-half in orbit. The problems and their solutions were described in papers presented at the 37/sup th/ Intersociety Energy Conversion Engineering Conference. Since the International Space Station carries more battery cells than any other spacecraft, the in-flight performance data from its battery assembly can be useful to engineers who design power supplies for other spacecraft. We, therefore, summarize the battery development process, the adopted design, and an unexpected in-flight battery degradation and its correction.     

Hubble Space Telescope solar array change-out, mission anomaliesand returned flight hardware

During the successful First Servicing Mission on the Hubble Space Telescope the two solar arrays were replaced with new and improved solar arrays. An electrical short and four solar array mechanical system anomalies occurred: (1) the upper outer bistem on the +V2 wing had developed kinks and then failed to retract; (2) additional friction between the solar array latch fitting and the aft latch berthing microswitch guard probably caused the failure of the primary deployment mechanism to deploy the solar array wings; (3) the secondary deployment mechanism retract limit microswitch activation is believed to be a result of the dynamic motion of the wings during the retraction event. Successful retraction took place after five attempts; and (4) additional torques induced during extra vehicular activity, flight support system and orbiter activities caused the wings to move from the latching destination. The physical appearance and durability of the materials on the solar array and the physical position of hardware indicators were investigated at Kennedy Space Center after the flight servicing mission. Evidence of micrometeoroid damage and the darkened silicone coatings were apparent. Isolation and continuity tests confirmed the location of shorts which occurred during the First Servicing Mission     

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     

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     

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     

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     

Life cycle testing of a sealed 24-V, 42-Ah nickel-cadmium aircraftbattery

Extensive research has been conducted in the design and manufacture of very long life sealed maintenance free nickel-cadmium aircraft batteries. This study presents data on a 100% depth of discharge (DOD) life test performed on a nominal capacity 42-Ah battery. The purpose of this study is to validate design concepts, determine the life characteristics of the newly designed sealed Ni-Cd batteries, and develop baseline information on failure rates and mechanisms. The data from this experiment can be used to compare depth of discharge versus battery life with similar tests such as the lower DOD experiments performed on spacecraft batteries. This information is important in the ongoing development of long life batteries and in developing failure models for life prediction     

Spacecraft energy storage systems

Flywheel Energy Storage Systems represent an exciting alternative to traditional battery storage systems used to power satellites during periods of eclipse. The increasing demand for reliable communication and data access is driving explosive growth in the number of satellite systems being developed as well as their performance requirements. Power-on orbit is the key to this performance, and batteries are becoming increasingly unattractive as an energy storage media. Flywheel systems offer very attractive characteristics for both energy storage, in terms of energy density and the number of charge/discharge cycles, and the important side benefit of spacecraft attitude control     

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     

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     

Dynamic modeling and beating phenomenon analysis of space robots with continuum manipulators

Space robotics has been used extensively in complex space missions. Rigid-manipulator space robots may suffer from rigid-body collisions with targets. This collision is likely to cause damage to the space robot and the target. To overcome such a problem, a novel Continuum-Manipulator Space Robot (CMSR) for performing on-orbit servicing missions is proposed in this paper. Compared with rigid-manipulator space robots, CMSRs are able to perform compliant operations and avoid rigid-body collisions with a target. The CMSR consists of two kinds of flexible components, including solar arrays and continuum manipulators. The elastic vibrations of these flexible components disturb the position and attitude of CMSRs. The beating phenomenon introduced by the energy transfer among these flexible components can cause damage to solar arrays. The complicated dynamic coupling poses enormous challenges in dynamic modeling and vibration analysis. The dynamic model for CMSRs is derived and the mechanism of the beating phenomenon is analyzed in this paper. Simulation results show that an obvious beating phenomenon occurs and the amplitude of the solar arrays increases significantly when the natural frequencies of two kinds of flexible components are close. A method is provided to avoid the beating phenomenon.     

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     

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     

POWOW: power without wires: a SEP concept for space exploration

Electric propulsion has emerged as a cost-effective solution to a wide range of satellite applications. Deep Space 1 successfully demonstrated electric propulsion as the primary propulsion source for a satellite. The POWOW concept is a solar-electric propelled spacecraft capable of significant cargo and short trip times for traveling to Mars. It would enter aerosynchronous orbit and from there, beam power to surface installations via lasers. The concept has been developed with industrial partner expertise in high efficiency solar cells, advanced concentrator modules, innovative arrays, and high power electric propulsion systems. The latest version of the spacecraft, the technologies used, and trip times to Mars are presented. The POWOW spacecraft is a general purpose solar electric propulsion system that uses new technologies that are directly applicable to commercial and government spacecraft with power levels ranging from a LEO power level of 4 kW up to GEO spacecraft about 1 MW. The system is modular, expandable, and amenable to learning curve cost projection methods     

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)     

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,     

Conversations with Rep. Ken Calvert. Interview by Frank Sietzen Jr

Rep. Calvert, chair of the House aeronautics and space subcommittee of the Science Committee, answers questions related to priorities for space in the current congressional session: the Vision for Space Exploration, development of the Crew Exploration Vehicle (CEV) and other heavy-lift launch vehicles, entrepreneurial alliances in the space transportation industry, the U.S. aerospace industry, space tourism, entrepreneurs and NASA, U.S. aeronautics research, a service mission to the Hubble Space Telescope, and priority military space programs.     

World Space Congress: a vision quest

The World Space Congress (WSC) in October, 2002, brought together luminaries, aerospace engineers, students, and scientists to discuss strategies for reviving the world's space agency. WSC lectures and plenary sessions focused on future research in space. Among topics discussed are the use of the Hubble Space Telescope to scan for habitable planets and obtain data about the beginning of the universe, new weather satellites, planetary protection from comets or asteroids, exploration and establishment of colonies on the Moon and Mars, medical advances, the role of space exploration in the world economy.     

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