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Find NASA NTRS and DOE OSTI reports about batteries and energy storage. Search electrode materials, lithium-ion batteries and storage systems in indexed report metadata.

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All sources NASA NTRS DOE OSTI

NASA NTRS2004

Reconditioning of Batteries on the International Space Station

Primary source of electric power for the International Space Station (ISS) is the photovoltaic module (PVM). At assembly complete stage, the ISS will be served by 4 PVMs. Each PVM contains two independent power channels such that one failure will result in loss of only one power channel. During early stages of assembly, the ISS is served by only one PVM designated as P6. Solar arrays are used to convert solar flux into electrical power. Nickel hydrogen batteries are used to store electrical power for use during periods when the solar input is not adequate to support channel loads. Batteries are operated per established procedures that ensure that they are maintained within specified temperature limits, charge current is controlled to conform to a specified charge profile, and battery voltages are maintained within specified limits. Both power channels on the PVM P6 have been operating flawlessly since December 2000 with 100 percent power availability. All components, including batteries, are monitored regularly to ensure that they are operating within specified limits and to trend their wear out and age effects. The paper briefly describes the battery trend data. Batteries have started to show some effects of aging and a battery reconditioning procedure is being evaluated at this time. Reconditioning is expected to reduce cell voltage divergence and provide data that can be used to update the state of charge (SOC) computation in the software to account for battery age. During reconditioning, each battery, one at a time, will be discharged per a specified procedure and then returned to a full state of charge. The paper describes the reconditioning procedure and the expected benefits. The reconditioning procedures have been thoroughly coordinated by all affected technical teams and approved by all required boards. The reconditioning is tentatively scheduled for September 2004.

Hajela, Gyan↗

NASA NTRS2004

Battery Resistance Analysis of ISS Power System

The computer package, SPACE (Systems Power Analysis for Capability Evaluation) was created by the members of LT-9D to perform power analysis and modeling of the electrical power system on the International Space Station (ISS). Written in FORTRAN, SPACE comprises thousands of lines of code and has been used profficiently in analyzing missions to the ISS. LT-9D has also used its expertise recently to investigate the batteries onboard the Hubble telescope. During the summer of 2004, I worked with the members of LT-9D, under the care of Dave McKissock. Solar energy will power the ISS through eight solar arrays when the ISS is completed, although only two arrays are currently connected. During the majority of the periods of sunlight, the solar arrays provide enough energy for the ISS. However, rechargeable Nickel-Hydrogen batteries are used during eclipse periods or at other times when the solar arrays cannot be used (at docking for example, when the arrays are turned so that they will not be damaged by the Shuttle). Thirty-eight battery cells are connected in series, which make up an ORU (Orbital Replacement Unit). An ISS "battery" is composed of two ORUs. a great deal of time into finding the best way to represent them in SPACE. During my internship, I investigated the resistance of the ISS batteries. SPACE constructs plots of battery charge and discharge voltages vs. time using a constant current. To accommodate for a time-varying current, the voltages are adjusted using the formula, DeltaV = DeltaI * Cell Resistance. To enhance our model of the battery resistance, my research concentrated on several topics: investigating the resistance of a qualification unit battery (using data gathered by LORAL), comparing the resistance of the qualification unit to SPACE, looking at the internal resistance and wiring resistance, and examining the impact of possible recommended changes to SPACE. The ISS batteries have been found to be very difficult to model, and LT-9D has dedicated

Newstadt, Gregory E.↗

NASA NTRS1999

Lithium-Ion Polymer Rechargeable Battery Developed for Aerospace and Military Applications

A recently completed 3 -year project funded by the Defense Advanced Research Projects Agency (DARPA) under the Technology Reinvestment Program has resulted in the development and scaleup of new lithium-ion polymer battery technology for military and aerospace applications. The contractors for this cost-shared project were Lockheed Martin Missiles & Space and Ultralife Batteries, Inc. The NASA Lewis Research Center provided contract management and technical oversight. The final products of the project were a portable 15-volt (V), 10-ampere-hour (A-hr) military radio battery and a 30-V, 50-A-hr marine/aerospace battery. Lewis will test the 50-A-hr battery. The new lithium-ion polymer battery technology offers a threefold or fourfold reduction in mass and volume, relative to today s commonly used nickel-cadmium, nickel-hydrogen, and nickel-metal hydride batteries. This is of special importance for orbiting satellites. It has been determined for a particular commercial communications satellite that the replacement of 1 kg of battery mass with 1 kg of transponder mass could increase the annual revenue flow by $100 000! Since this lithium-ion polymer technology offers battery mass reductions on the order of hundreds of kilograms for some satellites, the potential revenue increases are impressive.

Hagedorn, orman H.↗

NASA NTRS2005

Technical Consultation of the Hubble Space Telescope (HST) Nickel Hydrogen (NiH2) Battery Charge Capacity Prediction

The purpose of the GSFC position paper is to identify critical HST milestone dates for continued science studies followed by the attachment of a re-entry module or a robotic servicing mission. The paper examines the viability of the HST with respect to the NiH2 continued battery charge capacity. In the course of the assessment, it was recognized that the HST battery thermal control system has an average heat dissipation limitation of 30 W per bay per orbit cycle. This thermal constraint will continue to govern options for battery capacity maintenance. In addition, the HST usage represents the longest exposure ofNiH2 batteries to Low Earth Orbit (LEO) at the current level of Depth of Discharge (DOD). Finally, the current battery life is at the limit predicted by the manufacturer, Eaglepicher. Therefore, given these factors, the potential exists that the HST battery capacities could radically degrade at any point. Given this caveat on any life extrapolations, the conservative model proposed in the GSFC position paper was viewed by the NESC as having several technical assumptions such as limited utilization of flight battery capacity data, the susceptibility of the proposed prediction method to large variations when supplemented with additional information, and the failure to qualitatively or quantitatively assess life prediction sensitivities. The NESC conducted an independent evaluation of the supporting information and assumptions to generate the predictions for battery capacity loss and practicality of on-orbit battery conditioning.

Gentz, Steven J.↗

NASA NTRS2004

Use of COTS Batteries on ISS and Shuttle

This presentation focuses on COTS Battery testing for energy content, toxicity, hazards, failures modes and controls for different battery chemistries. It also discusses the current program requirements, challenges with COTS Batteries in manned vehicle COTS methodology, JSC test details, and gives a list of incidents from consumer protection safety commissions. The Battery test process involved testing new batteries for engineering certification, qualification of batteries, flight acceptance, cell and battery, environment, performance and abuse. Their conclusions and recommendations were that: high risk is undertaken with the use of COTS batteries, hazard control verification is required to allow the use of these batteries on manned space flights, failures during use cannot be understood if different scenarios of failure are not tested on the ground, and that testing is performed on small sample numbers due to restrictions on cost and time. They recommend testing of large sample size to gain more confidence in the operation of the hazard controls.

Jeevarajan, Judith A.↗

NASA NTRS2006

Hubble Space Telescope 2004 Battery Update

Battery cell wear out mechanisms and signatures are examined and compared to orbital data from the six on-orbit Hubble Space Telescope (HST) batteries, and the Flight Spare Battery (FSB) Test Bed at Marshall Space Flight Center (MSFC), which is instrumented with individual cell voltage monitoring. The on-orbit HST batteries were manufactured on an expedited basis after the Challenger Shuttle Disaster in 1986. The original design called for the HST to be powered by six 50 Ah Nickel Cadmium batteries, which would have required a shuttle mission every 5 years for battery replacement. The decision to use NiH2 instead has resulted in a longer life battery set which was launched with HST in April 1990, with a design life of 7 years that has now exceeded 14+ years of orbital cycling. This chart details the specifics of the original HST NiH2 cell design. The HST replacement batteries for Service Mission 4, originally scheduled for Spring 2005, are currently in cold storage at NASA Goddard Space Flight Center (GSFC). The SM4 battery cells utilize slurry process electrodes having 80% porosity.

Hollandsworth, Roger↗

NASA NTRS2009

Modular Battery Charge Controller

A new approach to masterless, distributed, digital-charge control for batteries requiring charge control has been developed and implemented. This approach is required in battery chemistries that need cell-level charge control for safety and is characterized by the use of one controller per cell, resulting in redundant sensors for critical components, such as voltage, temperature, and current. The charge controllers in a given battery interact in a masterless fashion for the purpose of cell balancing, charge control, and state-of-charge estimation. This makes the battery system invariably fault-tolerant. The solution to the single-fault failure, due to the use of a single charge controller (CC), was solved by implementing one CC per cell and linking them via an isolated communication bus [e.g., controller area network (CAN)] in a masterless fashion so that the failure of one or more CCs will not impact the remaining functional CCs. Each micro-controller-based CC digitizes the cell voltage (V(sub cell)), two cell temperatures, and the voltage across the switch (V); the latter variable is used in conjunction with V(sub cell) to estimate the bypass current for a given bypass resistor. Furthermore, CC1 digitizes the battery current (I1) and battery voltage (V(sub batt) and CC5 digitizes a second battery current (I2). As a result, redundant readings are taken for temperature, battery current, and battery voltage through the summation of the individual cell voltages given that each CC knows the voltage of the other cells. For the purpose of cell balancing, each CC periodically and independently transmits its cell voltage and stores the received cell voltage of the other cells in an array. The position in the array depends on the identifier (ID) of the transmitting CC. After eight cell voltage receptions, the array is checked to see if one or more cells did not transmit. If one or more transmissions are missing, the missing cell(s) is (are) eliminated from cell-balancing calculations. The cell-balancing algorithm is based on the error between the cell s voltage and the other cells and is categorized into four zones of operation. The algorithm is executed every second and, if cell balancing is activated, the error variable is set to a negative low value. The largest error between the cell and the other cells is found and the zone of operation determined. If the error is zero or negative, then the cell is at the lowest voltage and no balancing action is needed. If the error is less than a predetermined negative value, a Cell Bad Flag is set. If the error is positive, then cell balancing is needed, but a hysteretic zone is added to prevent the bypass circuit from triggering repeatedly near zero error. This approach keeps the cells within a predetermined voltage range.

Button, Robert↗

NASA NTRS2011

Exploring the Model Design Space for Battery Health Management

Battery Health Management (BHM) is a core enabling technology for the success and widespread adoption of the emerging electric vehicles of today. Although battery chemistries have been studied in detail in literature, an accurate run-time battery life prediction algorithm has eluded us. Current reliability-based techniques are insufficient to manage the use of such batteries when they are an active power source with frequently varying loads in uncertain environments. The amount of usable charge of a battery for a given discharge profile is not only dependent on the starting state-of-charge (SOC), but also other factors like battery health and the discharge or load profile imposed. This paper presents a Particle Filter (PF) based BHM framework with plug-and-play modules for battery models and uncertainty management. The batteries are modeled at three different levels of granularity with associated uncertainty distributions, encoding the basic electrochemical processes of a Lithium-polymer battery. The effects of different choices in the model design space are explored in the context of prediction performance in an electric unmanned aerial vehicle (UAV) application with emulated flight profiles.

Saha, Bhaskar↗

NASA NTRS2017

Crewed Space Vehicle Battery Safety Requirements Revision D

The Crewed Space Vehicle Battery Safety Requirements document has been prepared for use by designers of battery-powered vehicles, portable equipment, and experiments intended for crewed spaceflight. The purpose of the requirements document is to provide battery designers with information on design provisions to be incorporated in and around the battery and on the verification to be undertaken to demonstrate a safe battery is provided. The term "safe battery" means that the battery is safe for ground personnel and crew members to handle and use; safe to be used in the enclosed environment of a crewed space vehicle; and safe to be mounted or used in unpressurized spaces adjacent to habitable areas. Battery design review, approval, and certification is required before the batteries can be used for ground operations and be certified for flight.

Russell, Samuel↗

NASA NTRS2018

Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Battery Assessment

In 2013, the Boeing Company model 787-8 Dreamliner commercial aircraft experienced three catastrophic lithium (Li) battery failures. The cause of each failure resulted in a single-cell thermal runaway (TR) condition, which propagated to adjacent battery cells. Two of the failures involved rechargeable lithium-ion (Li-Ion) batteries, and the third event involved a nonrechargeable lithium-manganese dioxide (Li-MnO2) battery. In response to these Li battery failures, the NASA Engineering and Safety Center (NESC) approved a technical assessment of the International Space Station Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Li non-rechargeable battery. This assessment was conducted to evaluate the SAFER Li nonrechargeable battery safety design features against Boeing 787 Dreamliner Li battery failure lessons learned. Specifically, this investigation focused on assessing the severity of a SAFER battery TR hazard conditions.

Iannello, Christopher J.↗

NASA NTRSDate not supplied

Additively Manufactured Ink-based Cell Batteries for Flexible Conformational Applications

With the rise of additively manufactured electronics, the importance of thin, flexible printed batteries has increased for shape-conformal electronics. Traditionally, battery cells such as industry-standard lithium-ion batteries, have been rigid and therefore unable to conform to time-variant surfaces such as smart cards/RFID devices, disposable battery-powered skin patches, foldable electronic devices, and IoT nodes. Aligned with the effort to advance technologies on printed electronics for habitat systems and advanced manufacturing, this proof-of-concept will focus on printing a 50 mAh Zn-Ag battery implementing a DIW Technique. After prototype manufacturing, electrical and environmental testing on the flexible battery cell will be conducted to the evaluate energy and power density over 50 charge cycles under standard atmosphere conditions. The project aims to provide PCB designers, fabricators, and assemblers an integrated battery package to eliminate external batteries, external wiring and connectors, and conformational complexity. Potential end uses of the printed battery process will be within Martian and lunar habitat systems, Gateway, and surface vehicles, or aerial robots where space and geometry is a restriction.

Printed Electronics↗

DOE OSTI2021

Secondary battery management system

A method and system for managing a battery system. The method including receiving at least one measured characteristic of the battery over a pre-defined time horizon from the at least one sensor, receiving at least one estimated characteristic of the battery from a electrochemical-based battery model based on differential algebraic equations, determining a cost function of a Moving Horizon Estimation based on the at least one measured characteristic and the at least one estimated characteristic, updating the electrochemical-based battery model based on the cost function, estimating at least one state of the at least one battery cell by applying the electrochemical-based battery model, and regulating at least one of charging or discharging of the battery based on the estimation of the at least one state of the at least one battery cell.

MirTabatabaei, Anahita↗

NASA NTRS2015

Batteries at NASA - Today and Beyond

NASA uses batteries for virtually all of its space missions. Batteries can be bulky and heavy, and some chemistries are more prone to safety issues than others. To meet NASA's needs for safe, lightweight, compact and reliable batteries, scientists and engineers at NASA develop advanced battery technologies that are suitable for space applications and that can satisfy these multiple objectives. Many times, these objectives compete with one another, as the demand for more and more energy in smaller packages dictates that we use higher energy chemistries that are also more energetic by nature. NASA partners with companies and universities, like Xavier University of Louisiana, to pool our collective knowledge and discover innovative technical solutions to these challenges. This talk will discuss a little about NASA's use of batteries and why NASA seeks more advanced chemistries. A short primer on battery chemistries and their chemical reactions is included. Finally, the talk will touch on how the work under the Solid High Energy Lithium Battery (SHELiB) grant to develop solid lithium-ion conducting electrolytes and solid-state batteries can contribute to NASA's mission.

batteries↗

NASA NTRS2004

Lithium-sulfur dioxide batteries on Mars rovers

NASA's 2003 Mars Exploration Rover (MER) missions, Spirit and Opportunity, have been performing exciting surface exploration studies for the past six months. These two robotic missions were aimed at examining the presence of water and, thus, any evidence of life, and at understanding the geological conditions of Mars, These rovers have been successfully assisted by primary lithium-sulfur dioxide batteries during the critical entry, descent, and landing (EDL) maneuvers. These batteries were located on the petals of the lander, which, unlike in the Mars Pathfinder mission, was designed only to carry the rover. The selection of the lithium-sulfur dioxide battery system for this application was based on its high specific energy and high rate discharge capability, combined with low heat evolution, as dictated by this application. Lithium-sulfur dioxide batteries exhibit voltage delay, which tends to increase at low discharge temperatures, especially after extended storage at warm temperatures, In the absence of a depassivation circuit, as provided on earlier missions, e.g., Galileo, we were required to depassivate the lander primary batteries in a unique manner. The batteries were brought onto a shunt-regulated bus set at pre-selected discharge voltages, thus affecting depassivation during constant discharge voltages. Several ground tests were preformed, on cells, cell strings and battery assembly with five parallel strings, to identify optimum shunt voltages and durations of depassivation. We also examined the repassivation of lithium anodes, subsequent to depassivation. In this paper, we will describe these studies, in detail, as well as the depassivation of the lander flight batteries on both Spirit and Opportunity rover prior to the EDL sequence and their performance during landing on Mars.

Lithium-SO2 batteries↗

NASA NTRS2015

A Battery Certification Testbed for Small Satellite Missions

A battery pack consisting of standard cylindrical 18650 lithium-ion cells has been chosen for small satellite missions based on previous flight heritage and compliance with NASA battery safety requirements. However, for batteries that transit through the International Space Station (ISS), additional certification tests are required for individual cells as well as the battery packs. In this manuscript, we discuss the development of generalized testbeds for testing and certifying different types of batteries critical to small satellite missions. Test procedures developed and executed for this certification effort include: a detailed physical inspection before and after experiments; electrical cycling characterization at the cell and pack levels; battery-pack overcharge, over-discharge, external short testing; battery-pack vacuum leak and vibration testing. The overall goals of these certification procedures are to conform to requirements set forth by the agency and identify unique safety hazards. The testbeds, procedures, and experimental results are discussed for batteries chosen for small satellite missions to be launched from the ISS.

Certification↗

NASA NTRS2022

Lithium-ion Battery Strain Gauge Monitoring and Depth of Discharge Estimation

Lithium-ion battery diagnostics and prognostics rely on measurements of electrical impedance, capacity, and voltage to infer the internal state of the battery. Mechanical changes to the cell structure represent an additional measure of the battery’s state because these changes are related to the overall battery health. As lithium-ion batteries are charged and discharged, lithium ions are inserted or removed from the anode and cathode, a process called intercalation and de-intercalation. As lithium ions intercalate and de-intercalate, they can cause changes to the lattice of the electrode particles, resulting in volumetric changes. These volumetric changes cause mechanical stresses and strains on the lithium-ion battery electrodes, and subsequently, the whole cell’s thickness varies as it is charged and discharged. This paper presents a study on the use of surface-mounted strain gauges for in-situ measurement of structural changes to lithium-ion batteries, along with a characterization of the unit-to-unit differences in strain response. A neural network modeling structure is then used to predict the battery’s depth of discharge under dynamic discharge conditions.

Lithium-ion batteries, depth of discharge, strain ↗

DOE OSTI2025

Automation for Electric Vehicle Battery Pack Disassembly

Battery‐electric vehicles (EVs) are growing exponentially. The demand for these batteries is expected to increase sevenfold by 2035. The EV batteries reach their end of life when the capacity fades to 70%–80% of new, with some being removed from the primary applications with even lower levels of degradation. These batteries can be used in less demanding applications. The disassembly process is currently manual, slow, unsafe, and expensive. Automation is needed to increase the throughput. EV battery packs feature various continually changing designs and form factors, which limit the usefulness of deterministically programmed robotic solutions. The conceptual robotic disassembly of EV batteries has attracted the attention of researchers. However, while many approaches have been proposed, practical implementations are lacking. Here, we review proposed concepts for EV battery disassembly and describe the selected approach, with elements of partial solutions validated in a laboratory setting, including the selection of commercial solutions, the development of custom end effectors, and methodologies for detection, localization, and classification of fasteners. The computer vision tasks employed an overhead 2D camera to detect the type of battery pack and approximate localization of fasteners, and a 3D camera mounted on the robotic arm for precise localization (position and tilt) and classification.

Islam, Abu [Rochester Inst. of Technology, Rochest↗

NASA NTRS1990

The NASA research and technology program on batteries

The NASA research and technology program on batteries is being carried out within the Propulsion, Power and Energy Division (Code RP) of NASA's Office of Aeronautics, Exploration and Technology (OAET). The program includes development of high-performance, long-life, cost-effective primary and secondary (rechargeable) batteries. The NASA OAET battery program is being carried out at Lewis Research Center (LeRC) and the Jet Propulsion Laboratory (JPL). LeRC is focusing primarily on nickel-hydrogen batteries (both individual pressure vessel or IPV and bipolar). LeRC is also involved in a planned flight experiment to test a sodium-sulfur battery design. JPL is focusing primarily on lithium rechargeable batteries, having successfully transferred its lithium primary battery technology to the U.S. Air Force for use on the Centaur upper stage. Both LeRC and JPL are studying advanced battery concepts that offer even higher specific energies. The long-term goal is to achieve 100 Wh/kg.

Bennett, Gary L.↗