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     

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     

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     

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     

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     

Artificial hearts, batteries, and electric vehicles

New battery applications ranged from an implanted battery that powers an artificial heart, to powering a seismic sensor behind an oil-well drilling bit as it grinds through rock looking for oil-bearing structure. These applications require high reliability that justifies the cost of thorough qualification testing, production control, acceptance testing of every cell, and tracking every cell by its serial number through its lifetime. Electric vehicle developments ranged from electric scooters for commuting to work in Europe to electric cars connected to the electric grid when not being driven. Availability of their battery energy for carrying load peaks is so valuable that the electric utility being supported could offer to replace the vehicles batteries whenever they wear out, with no cost to the car owner.     

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     

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.     

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     

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     

Electric vehicles (EVs): `a look behind the scenes'

The author addresses and summarizes some of the broader issues relating to electric vehicles including legislation, regulation, funding, infrastructure, niche markets, safety, and the near-term need for lead-acid batteries. The impact of low emission requirements is examined. The principle hazards associated with lead-acid batteries and the attendant liability issues are identified. Federal safety requirements are discussed in some detail     

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     

Hybrid power sources for Land Warrior scenario

Hybrid systems utilizing a zinc-air battery or a Proton Exchange Membrane Fuel Cell (PEMFC) as the high energy density component coupled with a rechargeable battery (lead-acid or nickel-metal hydride) or electrochemical capacitor (EC) bank as the high power density component were tested under a high-pulse application load, Land Warrior (LW). The hybrid power sources successfully operated the LW cyclic load beyond the capabilities of the specific single chemistry systems studied. The zinc-air battery hybrids allowed approximately triple the operation time of PEMFC hybrids. The best performing hybrid system was the zinc-air battery/lead-acid battery. It provided the greatest operating voltage and longest operating time     

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     

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.     

PowerCore combining structure and batteries for increased energy toweight ratio

Much of the mass of a battery is comprised of nonreactive materials. In an NiH₂ battery, this includes the pressure vessel and 50% of the positive electrode. PowerCore reconfigures the battery materials to serve as a structural sandwich panel. The effective specific energy of the new device can exceed 100 Wh/kg. PowerCore is intended to handle power demands of low Earth orbiting communications satellites such as IRIDIUM. This paper describes the concept and development progress     

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)     

Charging the new batteries-IC controllers track new technologies

Demands for portability have fueled significant developments in new battery technology. These developments have resulted in many more options in selecting the battery type for use in a particular project, but since most applications today are opting for rechargeable battery systems, the availability of battery charging solutions can become an equally important criteria in the selection process. Complicating this process are the demands for fast-but safe-charging with charge algorithms easily implemented with low-cost hardware. With the higher levels of complexity attendant with these more demanding algorithms, solutions have come primarily from the integrated circuit industry and the purpose of this paper is to provide a few examples of the latest efforts in this arena, specifically as addressed to lead-acid, nickel metal-hydride, and lithium-ion technologies     

Advanced lithium ion battery charger

A lithium ion battery charger has been developed for four and eight cell batteries or multiples thereof. This charger has the advantage over those using commercial lithium ion charging chips in that the individual cells are allowed to be taper charged at their upper charging voltage rather than be cutoff when all cells of the string have reached the upper charging voltage limit. Since 30-60% of the capacity of lithium ion cells may be restored during the taper charge, this charger has a distinct benefit of fully charging lithium ion batteries by restoring all of the available capacity to all of its cells     

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