Engineering topics
Publications and source records attributed to Toft, Mark R..
A description of the deep-discharge event associated with UARS on-board batteries is given along with the immediate results of this event. The failures of 2nd UARS earth sensor in respect to battery currents, state-of-charge, battery temperatures, battery differential voltages and load bus voltage vs. time are graphically represented.
Data from Standard NiCd battery cell vendors is found to be useful for identifying defective cells. A method has been developed to screen cells for flight battery use and identify prime candidate cells for life-cycle testing. Specific points from the cell vendor's data, which are related to fundamentals of NiCd cell chemistry (primarily oxygen recombination) and electrical performance (voltage and capacity), when sampled at key points, are found to be related to long-term LEO life-cycle performance.
This is a follow-up of studies of the NASA standard 50 AH cell presented at the NASA battery workshop each of the last two years. This is a dynamic study. Data trends continue to be developed and analyzed for their utility in judging NiCd performance. The trends and parameters presented here may bear relevance to many designs of conventional NiCd batteries, not just the 50 AH and 60 AH sizes.
Two lots of NASA standard 50 A.H. Ni-Cd battery cells, manufactured by Gates Aerospace Batteries and built into batteries by McDonnell Douglas, have experienced significant performance problems. The two lots were used on the Compton Gamma Ray Observatory and the Upper Atmosphere Research Satellite. Both of these satellites are Low Earth Orbital (LEO) satellites containing batteries on a parallel bus charged to NASA standard V/T curves using a NASA standard power regulator. The following preliminary conclusions were reached: (1) several plate and cell parameters have migrated within their spec limits over the years (in some cases, from one extreme to the other); (2) several parametric relationships, not generally monitored and therefore not under specification control, have also migrated over the years; (3) many of these changes appear to have taken place as a natural consequence of changes in GE/GAB materials and processes; (4) several of these factors may be 'conspiring' to aggravate known cell failure mechanisms (factors such as heavier plate, less teflon and/or less-uniform teflon, and less electrolyte) but all are still in spec (where specs exist); (5) the weight of the evidence collected to characterize the anomalies and to characterize the negative electrode itself, strongly suggests that alterations to the structure, composition, uniformity, and efficiency of the negative electrode are at the heart of the battery performance problems currently being experienced; and (6) further investigation at all levels (plate, cell, battery, and system) continues to be warranted.
The concept and design for a NASA standard Nickel-Cadmium (NiCd) battery was developed from 1975 to 1977. The cell was first manufactured in 1977-1978. A performance history of this cell design is presented in viewgraph form.