Results for “THERMAL BATTERY” — Page 12

NASA NTRS2019

BioBot: Innovative Offloading of Astronauts for More Effective Exploration

The BioBot concept consists of a robotic rover which is capable of traversing the same terrain as a spacesuited human. It carries the primary life support system for the astronaut, including consumables, atmosphere revitalization systems (e.g., CO2 scrubbing, humidity and temperature management, ventilation fan), power system (e.g., battery, power management and distribution),and thermal control system (e.g., water sublimator, cooling water pump), along with umbilical lines to connect to the supported astronaut. Although not technically part of life support, it would be logical for the BioBot to also provide long-range communications, video monitoring, tool and sample transport, and other functions to enable and enhance EVA productivity in planetary surface exploration.The design reference scenario for this concept is that astronauts involved in future lunar or Mars exploration will be on the surface for weeks or months rather than days, and will be involved in regular EVA operations. It is not unreasonable to think of geologists spending several days inEVA exploration each week over a prolonged mission duration, with far more ambitious operational objectives than were typical of Apollo. In this scenario, each astronaut will be accompanied by a "BioBot", which will transport their life support system and consumables, an extended umbilical and umbilical reel, and robotic systems capable of controlling the position and motion of the umbilical. The astronaut will be connected to the robot via the umbilical, carrying only a small emergency open-loop life support system similar to those contained in every PLSS. The robotic mobility base will be designed to be capable of traveling anywhere the astronaut can walk, and will also be useful as a transport for the EVA tools, science instrumentation, and collected samples. In addition, the BioBot can potentially carry the astronaut on traverses as well. Such a system will also be a significant enhancement to public engagement in these future exploration missions, as the robotic vehicles can also support high-resolution cameras and high bandwidth communications gear to providehigh-definition video coverage of each crew throughout each EVA sortie.

Akin, David L.↗

NASA NTRSDate not supplied

Experimental Demonstration and Characterization of a Ceramic Sintered Wick Heat Pipe Evaporator

As electrified aircraft propulsion (EAP) matures and power electronics, electric machines, and batteries achieve higher power density, the thermal management of these devices becomes ever more critical. In this paper, a heat pipe made from a dielectric ceramic material is proposed, which enables its use in the thermal management of a high frequency filter inductor for an EAP power electronics application. The manufacturing process for the sintered powder wick was developed and its performance characterized. The heat pipe is further experimentally demonstrated via an open evaporator test and shown to behave analogous to a constant conductance heat pipe.

Thermal Management↗

NASA NTRSDate not supplied

Experimental Demonstration and Characterization of a Ceramic Sintered Wick Heat Pipe Evaporator

As electrified aircraft propulsion (EAP) matures and power electronics, electric machines, and batteries achieve higher power density, the thermal management of these devices becomes ever more critical. In this paper, a heat pipe made from a dielectric ceramic material is proposed, which enables its use in the thermal management of a high frequency filter inductor for an EAP power electronics application. The manufacturing process for the sintered powder wick was developed and its performance characterized. The heat pipe is further experimentally demonstrated via an open evaporator test and shown to behave analogous to a constant conductance heat pipe.

Thermal management↗

NASA NTRS2012

Loop Heat Pipe with Thermal Control Valve as a Variable Thermal Link

Future lunar landers and rovers will require variable thermal links that allow for heat rejection during the lunar daytime and passively prevent heat rejection during the lunar night. During the lunar day, the thermal management system must reject the waste heat from the electronics and batteries to maintain them below the maximum acceptable temperature. During the lunar night, the heat rejection system must either be shut down or significant amounts of guard heat must be added to keep the electronics and batteries above the minimum acceptable temperature. Since guard heater power is unfavorable because it adds to system size and complexity, a variable thermal link is preferred to limit heat removal from the electronics and batteries during the long lunar night. Conventional loop heat pipes (LHPs) can provide the required variable thermal conductance, but they still consume electrical power to shut down the heat transfer. This innovation adds a thermal control valve (TCV) and a bypass line to a conventional LHP that proportionally allows vapor to flow back into the compensation chamber of the LHP. The addition of this valve can achieve completely passive thermal control of the LHP, eliminating the need for guard heaters and complex controls.

Hartenstine, John↗

NASA NTRS1993

Pump and Flow Control Subassembly of Thermal Control Subsystem for Photovoltaic Power Module

The pump and flow control subassembly (PFCS) is an orbital replacement unit (ORU) on the Space Station Freedom photovoltaic power module (PVM). The PFCS pumps liquid ammonia at a constant rate of approximately 1170 kg/hr while providing temperature control by flow regulation between the radiator and the bypass loop. Also, housed within the ORU is an accumulator to compensate for fluid volumetric changes as well as the electronics and firmware for monitoring and control of the photovoltaic thermal control system (PVTCS). Major electronic functions include signal conditioning, data interfacing and motor control. This paper will provide a description of each major component within the PFCS along with performance test data. In addition, this paper will discuss the flow control algorithm and describe how the nickel hydrogen batteries and associated power electronics will be thermally controlled through regulation of coolant flow to the radiator.

Motil, Brian↗

NASA NTRS1988

Space Station battery system design and development

The Space Station Electric Power System will rely on nickel-hydrogen batteries in its photovoltaic power subsystem for energy storage to support eclipse and contingency operations. These 81-Ah batteries will be designed for a 5-year life capability and are configured as orbital replaceable units (ORUs), permitting replacement of worn-out batteries over the anticipated 30-year Station life. This paper describes the baseline design and the development plans for the battery assemblies, the battery ORUs and the battery system. Key elements reviewed are the cells, mechanical and thermal design of the assembly, the ORU approach and interfaces, and the electrical design of the battery system. The anticipated operational approach is discussed, covering expected performance as well as the processor-controlled charge management and discharge load allocation techniques. Development plans cover verification of materials, cells, assemblies and ORUs, as well as system-level test and analyses.

Haas, R. J.↗

NASA NTRSDate not supplied

Predicting Maximum Temperatures of a Li-ion Battery on a Simulated Flight Profile using a Model-based Prognostics

One of the challenges in using Li-ion packs in aeronautics is their safety, and thermal runaway (TR) is a major concern. The current engineering solutions to prevent a Li-ion pack from a catastrophic TR require additional mass and volume to isolate cells. The excess mass could be reduced by improving detection and, thus, preventing a TR event. One of the possible early warning indicators of a TR is crossing a threshold temperature. We have developed an approach, based on the Unscented Kalman Filter (UKF), to predict the likelihood of reaching the threshold temperature for simulated flight profiles. The current battery prognostics algorithms for aerospace predict state-of-charge (SOC) and end-of-life (EOL) [1]. We extended this two-level algorithm to predict the maximum temperature during discharge. The amount of heat generated in a cell depends on factors such as cell chemistry, cell packaging, total cycles, operating temperature, and abuse history [2]. Our semi-empirical thermal model depends on three phenomenological parameters which account for those factors. In addition, a two-parameter reduced-order model is developed to predict the temperature rise for short bursts of “random-walk” (RW) discharge current sequence, which simulates a flight's current-loading profile. The performance of these models on different datasets and types of current loading will be presented. To predict the maximal temperatures for future cycles we must estimate the evolution of thermal parameters as the batteries age. It is found that the parameters of the 3-parametric thermal model cannot be estimated only from the RW data. To address the issue, we will present two alternative approaches: i) expanding the datasets to include discharge profiles beyond RWs; ii) model reduction to a two-parametric model. The two approaches will be illustrated by an application to the cycling data from a commercial LG 18650 cell. References: 1. M. Daigle, C.S. Kulkarni, End-of-discharge and End-of-life Prediction in Lithium-ion Batteries with Electrochemistry-based Aging Models, in: AIAA Infotech @ Aerospace, American Institute of Aeronautics and Astronautics, San Diego, California, USA, 2016. 2. M. Börner, et. al, Correlation of aging and thermal stability of commercial 18650-type lithium ion batteries, Journal of Power Sources. 342 (2017) 382–392.

Thermal runaway↗

NASA NTRS1989

Nickel cadmium battery performance modelling

The development of a model to predict cell/battery behavior given databases of temperature is described. The model accommodates batteries of various structural as well as thermal designs. Cell internal design modifications can be accommodated as long as the databases reflect the cell's performance characteristics. Operational parameters can be varied to simulate any number of charge or discharge methods under any orbital regime. The flexibility of the model stems from the broad scope of input variables and allows the prediction of battery performance under simulated mission or test conditions.

Clark, K.↗

NASA NTRS1985

Bipolar nickel-hydrogen battery design

The initial design for the NASA-Lewis advanced nickel-hydrogen battery is discussed. Fabrication of two 10-cell boilerplate battery stacks will soon begin. The test batteries will undergo characterization testing and low Earth orbit life cycling. The design effectively deals with waste heat generated in the cell stack. Stack temperatures and temperature gradients are maintained to acceptable limits by utilizing the bipolar conduction plate as a heat path to the active cooling fluid panel external to the edge of the cell stack. The thermal design and mechanical design of the battery stack together maintain a materials balance within the cell. An electrolyte seal on each cell frame prohibits electrolyte bridging. An oxygen recombination site and electrolyte reservoir/separator design does not allow oxygen to leave the cell in which it was generated.

Koehler, C. W.↗

NASA NTRS1973

Mariner Mars 1971 battery design, test, and flight performance

The design, integration, fabrication, test results, and flight performance of the battery system for the Mariner Mars spacecraft launched in May 1971 are presented. The battery consists of 26 20-Ah hermetically sealed nickel-cadmium cells housed in a machined magnesium chassis. The battery package weighs 29.5 kg and is unique in that the chassis also serves as part of the spacecraft structure. Active thermal control is accomplished by louvers mounted to the battery baseplate. Battery charge is accomplished by C/10 and C/30 constant current chargers. The switch from the high-rate to low-rate charge is automatic, based on terminal voltage. Additional control is possible by ground command or onboard computer. The performance data from the flight battery is compared to the data from various battery tests in the laboratory. Flight battery data was predictable based on ground test data.

Bogner, R. S.↗

NASA NTRS1972

Power subsystem performance prediction /PSPP/ computer program.

A computer program which simulates the operation of the Viking Orbiter Power Subsystem has been developed. The program simulates the characteristics and interactions of a solar array, battery, battery charge controls, zener diodes, power conditioning equipment, and the battery spacecraft and zener diode-spacecraft thermal interfaces. This program has been used to examine the operation of the Orbiter power subsystem during critical phases of the Viking mission - from launch, through midcourse maneuvers, Mars orbital insertion, orbital trims, Lander separation, solar occultations and unattended operation - until the end of the mission. A typical computer run for the first 24 hours after launch is presented which shows the variations in solar array, zener diode, battery charger, batteries and user load characteristics during this period.

Weiner, H.↗

NASA NTRS1987

Low cost Get-Away-Special (GAS) furnace

A simple and inexpensive Space Shuttle experimental apparatus to conduct microgravity melting and solidification is presented. A GAS space furnace was initially developed as a student design project at the USAF Academy and further refined at NASA Lewis. The experiment package consists of a melting chamber, battery power system, temperature data recording systems, and electronic controller. The melting chamber is a thin-walled tube wrapped by heating resistance wire. Thermocouples are used to record the specimen thermal history. Power is supplied by 2-V batteries wired to produce 360 W. The mV output of the thermocouples is amplified, cold-junction compensated, and converted to a frequency which is then recorded on an off-the-shelf cassette tape recorder. A backup data recording system which digitizes the amplified signal and records the data on EEPROMs has also been included. This experimental device demonstrates that basic science research can be kept simple and inexpensive.

Turner, Glon D.↗

NASA NTRSDate not supplied

Material Property Estimation in Thin Battery Components Using Guided Wave Measurement, Experimental Dispersion Curve Extraction and Finite Element Modeling

At NASA, we are investigating nondestructive evaluation (NDE) and structural health monitoring (SHM) techniques to detect precursors of thermal runaway failure in lithium metal based lithium ion batteries (LIB). The approach is centered on computational simulation models to guide inspection and aid in interpretation of results. Since lithium metal LIBs have combinations of solid and fluid-filled porous materials, obtaining accurate material properties is both challenging and critical for successful simulation of battery inspection. To this end, we investigated a multi-verification approach for material characterization of thin battery components. First, a laser Doppler vibrometer (LDV) was used to measure guided wave fields in thin (microns-thick) battery components subject to broadband excitation. The time-space wavefield data was converted to frequency-wave number data to extract guided wave dispersion curves. A data visualization and post processing graphics user interface (GUI) was developed at NASA to aid the data exploration and analysis. Due to the thinness of the samples, low frequency-thickness-product plate wave approximations allowed for the calculation of closed-form solutions for material elastic property estimation. These approximations were then verified by calculating the Lamb wave solutions using the previously obtained material properties. Finally, the estimated elastic material properties were implemented in a COMSOL simulation model, and dispersion curves were extracted from simulation results. The dispersion curves and derived material properties were then compared to the analysis results from the experimental data. These comparisons informed on the accuracy of the measured material properties and helped demonstrate the accuracy of the finite element analysis (FEA) computational models. This assessment will prove vital when we start simulating more complex multi-layer components and poroelastic media. This paper gives a brief background of the problem space, outlines the workflow for data analysis and verification, shows results from the workflow, and gives an overview of future plans for simulation of lithium metal LIB inspection.

Peter Juarez↗

NASA NTRS1994

Thermal control system for Space Station Freedom photovoltaic power module

The electric power for Space Station Freedom (SSF) is generated by the solar arrays of the photovoltaic power modules (PVM's) and conditioned, controlled, and distributed by a power management and distribution system. The PVM's are located outboard of the alpha gimbals of SSF. A single-phase thermal control system is being developed to provide thermal control of PVM electrical equipment and energy storage batteries. This system uses ammonia as the coolant and a direct-flow deployable radiator. The description and development status of the PVM thermal control system is presented.

Hacha, Thomas H.↗

NASA NTRS2007

Thermal Characterization Study of Lithium-Ion Cells

The primary challenge in designing a full scale lithium-ion (Li-ion) battery system is safety under both normal operating as well as abusive conditions. The normal conditions involve expected charge/discharge cycles and it is known that heat evolves in batteries during those cycles. This is a major concern in the design for high power applications and careful thermal management is necessary to alleviate this concern. An emerging thermal measurement technology, such as the electrochemical calorimetric of batteries, will aid in the development of advanced, safe battery system. To support this technology, several "commercial-off-the-shelf" (COTS) Li-ion cells with different chemistries and designs are being evaluated for different cycling regimes at a given operating temperature. The Accelerated Rate Calorimeter (ARC)-Arbin cycler setup is used to measure the temperature, voltage, and current of the cells at different charge/discharge rates. Initial results demonstrated good cell cyclability. During the cycle testing, the cell exhibited an endothermic cooling in the initial part of the charge cycle. The discharge portion of the cycle is exothermic during the entire discharge period. The presence of an endothermic reaction indicates a significant entropy effect during the beginning of charge cycle. Further studies will be performed to understand the thermal characteristics of the Li-ion cells at the different operating conditions. The effects on the thermal response on cell aging and states-of-charge will also be identified.

Britton, Doris L.↗

NASA NTRS1992

Thermal control system for Space Station Freedom photovoltaic power module

The electric power for Space Station Freedom (SSF) is generated by the solar arrays of the photovoltaic power modules (PVM's) and conditioned, controlled, and distributed by a power management and distribution system. The PVM's are located outboard of the alpha gimbals of SSF. A single-phase thermal control system is being developed to provide thermal control of PVM electrical equipment and energy storage batteries. This system uses ammonia as the coolant and a direct-flow deployable radiator. This paper presents the description and development status of the PVM thermal control system.

Hacha, Thomas H.↗

NASA NTRSDate not supplied

Battery Evaluation Profiles for X-57 and Future Urban Electric Aircraft

Battery energy density is one of the most critical design parameters for sizing all-electric aircraft, however it’s easily overestimated. Establishing the effective, usable energy density is confused by varying degrees of margin needed to account for structural and thermal management between different cell chemistry and pack designs. Therefore, a better methodology is needed to fairly compare emerging battery technologies for electric aircraft. Currently, there is a loss of critical information when vehicle trade studies are performed using “nominal” published cell-level performance metrics. Aircraft power demands rarely match these nominal power profiles, and aircraft designers lack the ability to accurately simulate the battery performance and temperature off-nominally unless the battery chemistry is well established. Conversely, battery suppliers have no generalized reference cases to publish more realistic performance metrics. This can lead to poor assumptions, such as aircraft studies assuming a fixed discharge efficiency of a battery, when in reality the usable energy in a pack is dependent on the power and thermal profile. Information needed to properly assess weight penalties for thermal management is also typically poorly characterized when assessing candidate batteries. This paper serves to better inform battery development, and similarly, provide aircraft designers with more realistic assumptions for applying knockdown margins in their designs. Detailed power and thermal performance estimates are provided, which provide a starting point for sizing power and thermal budgets using experimentally derived battery models. Results show that the X-57 battery-to-shaft efficiency is 77.3% for a particular optimized mission. Considering a 25% reserve on the battery capacity, this means that only roughly half of the original 55.3kWh ‘nominal’ pack energy can be converted to useful work during a mission. Further estimates on a clean-sheet VTOL optimization show an average 82.7% battery-to-shaft efficiency, using 98% peak efficiency inverters and 97.4% peak efficiency motors. Although higher battery efficiencies are possible, the resulting weight penalty negates improvement in vehicle performance. These trade-offs and resulting power profiles are provided as a starting point to better assess future battery designs.

Battery Electric Aircraft↗

NASA NTRSDate not supplied

Battery Evaluation Profiles for X-57 and Future Urban Electric Aircraft

Battery energy density is one of the most critical design parameters for sizing all-electric aircraft, however it’s easily overestimated. Establishing the effective, usable energy density is confused by varying degrees of margin needed to account for structural and thermal management between different cell chemistry and pack designs. Therefore, a better methodology is needed to fairly compare emerging battery technologies for electric aircraft. Currently, there is a loss of critical information when vehicle trade studies are performed using “nominal” published cell-level performance metrics. Aircraft power demands rarely match these nominal power profiles, and aircraft designers lack the ability to accurately simulate the battery performance and temperature off-nominally unless the battery chemistry is well established. Conversely, battery suppliers have no generalized reference cases to publish more realistic performance metrics. This can lead to poor assumptions, such as aircraft studies assuming a fixed discharge efficiency of a battery, when in reality the usable energy in a pack is dependent on the power and thermal profile. Information needed to properly assess weight penalties for thermal management is also typically poorly characterized when assessing candidate batteries. This paper serves to better inform battery development, and similarly, provide aircraft designers with more realistic assumptions for applying knockdown margins in their designs. Detailed power and thermal performance estimates are provided, which provide a starting point for sizing power and thermal budgets using experimentally derived battery models. Results show that the X-57 battery-to-shaft efficiency is 77.3% for a particular optimized mission. Considering a 25% reserve on the battery capacity, this means that only roughly half of the original 55.3kWh ‘nominal’ pack energy can be converted to useful work during a mission. Further estimates on a clean-sheet VTOL optimization show an average 82.7% battery-to-shaft efficiency, using 98% peak efficiency inverters and 97.4% peak efficiency motors. Although higher battery efficiencies are possible, the resulting weight penalty negates improvement in vehicle performance. These trade-offs and resulting power profiles are provided as a starting point to better assess future battery designs.

Battery↗