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     

Aerospace and military battery applications

This paper gives a review of the papers presented at the IEEE 17th Annual Battery Conference on Applications and Advances, Long Beach, CA, USA, 2002. The topics covered are: Li batteries for satellites, capacity fade of Li-ion cells cycled at different temperatures, Ni-H/sub 2/ battery lifetime, batteries for Mars-exploring vehicles, Li-ion cell performance enhancement at low temperatures, navy service batteries, and US Army man portable applications and mobile power challenges.     

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     

Making batteries last longer [for electric vehicles]

The early 1900's era of electric cars ended because the batteries didn't last long enough, and a new gasoline-engine-powered car cost less than a replacement battery. Long-life batteries are the key to achieving a low life-cycle cost for the electric vehicles that will help solve the air-pollution problem in our cities. New ways of making batteries last longer are discussed     

Global avionics in the future

The following topics are discussed: new batteries for old airplanes; new charge controls for lengthening battery life; fast methods for batteries charging; AC conductance measurement based battery testing; pulse power; bipolar lead-acid batteries vs supercapacitors; Ni electrode cells for spacecraft; worn-out battery disposal; recycling technology; vehicle batteries cost; high energy content batteries; and energy storage for electric utilities     

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     

Flywheel technology: past, present, and 21st century projections

This paper describes the present status of flywheel energy storage technology, or mechanical batteries, and discusses realistic future projections that are possible based on stronger composite materials and advancing technology. The origins and use of flywheel technology for mechanical energy storage began several hundred years ago and was developed throughout the Industrial Revolution. One of the first “modern” dissertations on the theoretical stress limitations of rotational disks (isotropic only) is the seminal work by A. Stodola whose first translation to English was made in 1917. The next big milestones were during the 1960s and 1970s when NASA sponsored programs proposed energy storage flywheels as possible primary sources for space missions. However, it was not until the 1980's when microelectronics, magnetic bearing systems and high power density motor-generators became enabling technologies. The next decade proved that a mechanical battery could surpass chemical batteries for many applications     

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     

Segmented battery charger for high energy 28 V lithium ion battery

Since they were first introduced in the early 1990s, lithium ion batteries have enjoyed unprecedented growth and success in the consumer marketplace. Combining excellent performance with affordability, they have become the product of choice for portable computers and cellular phones. Building on the same energy and life cycle attributes, which marked their consumer market success, but adding new high power storage capability, lithium ion technology is now poised to play a similar role in the transportation, military, and space sectors. With major program in various aspects of electric and hybrid electric vehicles, Saft has developed a family of battery products that address the power and energy storage where lightweight, long life, and excellent energy or power storage capabilities are needed. Significant progress in the packaging and control of high power, yet compact, batteries has been accomplished for a variety of vehicle applications. This paper discusses the charger and balancing strategies of one of this family of products     

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     

Advanced materials for next generation NiMH portable, HEV and EVbatteries

While Ovonic NiMH batteries are already in high volume commercial production for portable applications, advances in materials technology have enabled performance improvements in specific energy (100 Wh/kg), specific power (600-1000 W/kg), high temperature operation, charge retention, and voltage stability. Concurrent with technology advances, Ovonic NiMH batteries have established performance and commercial milestones in electric vehicles, hybrid electric vehicles, as well as scooter, motorcycle and bicycle applications. As important as these advances, significant manufacturing cost reductions have also occurred which allow continued growth of NiMH technology. In this paper, advances in performance, applications and cost reduction are discussed with particular emphasis on the improved proprietary metal hydride and nickel hydroxide materials that make such advances possible     

Battery configurations for multi-megawatt pulse power

The capability of lead-acid batteries for supplying very high power for a short time is explored. The application of such a battery for accelerating a hypersonic plane is used to illustrate the requirements. A technique for analyzing batteries and controlling voltage for pulse loads is described. Evaluation of lead-acid batteries in production and voltage regulation by switching batteries in and out are covered. Alternatives to batteries, including superconducting magnetic energy storage, are discussed     

Nuclear Power Systems for Spacecraft

A review and comparison of the weights, sizes, and costs of nuclear and non-nuclear spacecraft power systems is presented and discussed. Nuclear power systems include the range below 10 kW, with an electrical output to weight ratio of 0.5 to 1.0 pounds per watt. Comparisons show that primary batteries are lighter for short-duration missions of a few hours; fuel cells are lighter for durations of one to two months; and solar-cell/secondary battery combinations are to be preferred when sunlight is adequate.     

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.     

Perspective on ultracapacitors for electric vehicles

Recent advances in performance of chemical double layer capacitors (DLC) with aqueous and non-aqueous electrolytes have made it possible to seriously consider them for commercialization. Non-aqueous (organic) carbon based laboratory monopolar devices have recently met key U.S. Department of Energy (DoE) mid-term specifications (> 5 WNkg, >500 W/kg and >100,000 life cycles) for load-leveling electric vehicles batteries. All DLC technologies currently under development by DoE are discussed. Each technology has distinct advantages and none are clear winners at this time. A study has been completed by the General Electric Company on the interface electronics needed to best utilize the energy of capacitors for load-leveling batteries. System costs are presented based on this study, several battery technologies, and capacitor projections     

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     

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     

Hybrid power source for manportable applications

In this paper, we present the results of work with a hybrid power system made of a fuel cell and rechargeable battery with pulse power capability. This hybrid power source successfully ran pulse power load based on the power profile of the present and future manportable military electronics and communications equipment. The hybrid consisted of a 35 W proton exchange membrane fuel cell (PEMFC) stack in parallel with a Li-ion battery. In this work, two cyclic load scenarios were utilized. Each consisted of a baseline load for 9 minutes followed by a higher pulse load for 1 minute. One test profile consisted of 20 W (baseline)/40 W (pulse) load, whereas, the second was 25 W/50 W. Under both scenarios, the hybrid provided significant enhancements in performance over the individual components tested separately. These results are discussed and analyzed. Also discussed are possible future implications of such technology and approach.     

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.     

Market mature 1998 hybrid electric vehicles

Beginning in 1990, the major automotive passenger vehicle manufacturers once again re-evaluated the potential of the battery powered electric vehicle (EV). This intensive effort to reduce the battery EV to commercial practice focused attention on the key issue of limited vehicle range, resulting from the low energy density and high mass characteristics of batteries, in comparison to the high energy density of liquid hydrocarbon (HC) fuels. Consequently, by 1995, vehicle manufacturers turned their attention to hybrid electric vehicles (HEV). This redirection of EV effort was highlighted finally in 1997, at the 57th Frankfurt Motor Show, the Audi Duo parallel type hybrid was released for the domestic market as a 1998 model vehicle. Also at the 1997 32nd Tokyo Motor Show, Toyota Hybrid System (THS) Prius was released for the domestic market as a production 1998 model vehicle. This paper presents a comparative analysis of the key features of these two 1998 model year production hybrid systems. Among the conclusions, two issues are evident: one, the major manufacturers have turned to the hybrid concept in their search for solutions to the key EV issues of limited range; and, heating/air conditioning; and two, the focus is now on introducing hybrid EV for test marketing domestically