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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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New procedure for recharging nickel/cadmium batteries is fast and eliminates overcharging. Method charges "dead" cells using increments rather than continuous, constant current. Time required for procedure is approximately 18 hours and correspondingly reduced overcharging reduces generation of heat. Further advantage is cells are more electrochemically active than after 48 hours charging by old method.
A 50-ampere hour nickel cadmium cell test pack was operated in a power profile simulating the orbit of the Earth Radiation Budget Satellite (ERBS). The objective was to determine the ability of the temperature compensated voltage limit (V sub T) charge control system to maintain energy balance in the half sine wave-type current profile expected of this mission. The four-cell pack (50 E) was tested at the Naval Weapons Support Center (NWSC) at Crane, Indiana. The ERBS evaluation test consisted of two distinct operating sequences, each having a specific purpose. The first phase was a parametric test involving the effect of V sub T level, temperature, and Beta angle on the charge/discharge (C/D) ratio, an indicator of the amount of overcharge. The second phase of testing made use of the C/D ratio limit to augment the V sub T charge limit control. When the C/D limit was reached, the current was switched from the taper mode to a C/67 (0.75 A) trickle charge. The use of an ampere hour integrator limiting the overcharge to a C/67 rate provided a fine tuning of the charge control technique which eliminated the sensitivity problems noted in the initial operating sequence.
Circuitry, power handling, and operational characteristics and anomalies of the Electrical Power System (EPS) of the Solar Maximum Mission are discussed. The EPS is designed as a standard unit to be a candidate for use on future space missions. Blown, improperly derated fuses in the Attitude Control System and the Signal Conditioning Assembly have led to switching to magnetrons for solar angle, with a loss of accuracy, and a loss of one-half of telemetry data, respectively. In addition, reasons for an 11-14% degradation of solar array output are uncertain due to the loss of precise attitude control. Current surges to peak at 76.5 A (down from 94.5 A) at sunrise, stays for four to five minutes, then resumes nominal output for the remainder of the 61-68 daytime period. Eclipse varies between 28 and 35 minutes, with corresponding depth of discharge of 14%. The batteries charge at 20 A, and although an overcharge mode has been continuously sensed, operation has been normal and temperature sensors have not indicated overcharge; cell failure has also not been sensed. The system has a two year design life and a desired life of four years.
The promise of very high specific energy and power was not yet achieved for practical battery systems. Some recent approaches are discussed for new approaches to achieving high performance for lithium/DeS2 cells and sodium/metal chloride cells. The main problems for the development of successful LiAl/FeS2 cells were the instability of the FeS2 electrode, which has resulted in rapidly declining capacity, the lack of an internal mechanism for accommodating overcharge of a cell, thus requiring the use of external charge control on each individual cell, and the lack of a suitable current collector for the positive electrode other than expensive molybdenum sheet material. Much progress was made in solving the first two problems. Reduction of the operating temperatures to 400 C by a change in electrolyte composition has increased the expected life to 1000 cycles. Also, a lithium shuttle mechanism was demonstrated for selected electrode compositions that permits sufficient overcharge tolerance to adjust for the normally expected cell-to-cell deviation in coulombic efficiency. Sodium/sulfur batteries and sodium/metal chloride batteries have demonstrated good reliability and long cycle life. For applications where very high power is desired, new electrolyte coinfigurations would be required. Design work was carried out for the sodium/metal chloride battery that demonstrates the feasibility of achieving high specific energy and high power for large battery cells having thin-walled high-surface area electrolytes.
A study has been made of charge and discharge voltage changes with cycling of Ni/H2 cells containing electrolytes of various KOH concentrations. A study has also been made of electrochemical behavior of the nickel electrodes from the cycled Ni/H2 cells as a function of overcharge amounts. Discharge voltages depressed gradually with cycling for cells having high KOH concentrations (31 to 36 percent), but the voltages increased for those having low KOH concentrations (21 to 26 percent). To determine if there was a crystallographic change of the active material due to cycling, electrochemical behavior of nickel electrodes was studied in an electrolyte flooded cell containing either 31 or 26 percent KOH electrolyte as a function of the amount of overcharge. The changes in discharge voltage appear to indicate crystal structure changes of active material from gamma-phase to beta-phase in low KOH concentrations, and vice versa in high KOH concentration.
The nickel-hydrogen secondary battery has many desirable features which make it attractive for satellite power systems. It can provide a significant improvement over the energy density of present spacecraft nickel-cadnium batteries, combined with longer life, tolerance to overcharge and possibility of state-of-charge indication. However, to realize these advantages, accurate thermal modeling of nickel-hydrogen cells is required in order to properly design the battery pack so that it operates within a specified temperature range during the operation. Maintenance of a low operating temperature and a uniform temperature profile within the cell will yield better reliability, improved cycle life and better charge/discharge efficiencies. This research has the objective of developing and testing a thermal model which can be used to characterize battery operation. Primarily, temperature distribution with the heat generation rates as a function of position and time will be evaluated for a Ni-H2 cell in the three operating modes: (1) charge cycle, (2) discharge cycle, and (3) overcharge condition, if applicable. Variables to be examined include charging current, discharge rates, state of charge, pressure and temperature. Once the thermal model has been developed, this resulting model will predict the actual operating temperature and temperature gradient for the specific cell geometry to be used.
The question of the best approach for battery charge control is addressed from two points of view: from the battery point-of-view; and from the spacecraft/mission point-of-view. In terms of performance, more aggressive charging can result in higher discharge voltage and capacity; however, aggressive charging usually implies more overcharge at higher rates and a concomitant higher end of charge temperature (higher stress, shorter life). In terms of life, benign charging can result in lower discharge voltage and capacity (poorer performance). Additionally, benign, or low stress charging, usually implies less overcharge at lower rates with lower end of charge temperature (lower stress, longer life). A discussion of these topics is presented in viewgraph form.
Battery management during prelaunch activities has always required special attention and careful planning. The transition from nickel-cadium to nickel-hydrogen batteries, with their high self discharge rate and lower charge efficiency, as well as longer prelaunch scenarios, has made this aspect of spacecraft battery management even more challenging. The AXAF-I Program requires high battery state of charge at launch. The use of active cooling, to ensure efficient charging, was considered and proved to be difficult and expensive. Alternative approaches were evaluated. Optimized charging, in the absence of cooling, appeared promising and was investigated. Initial testing was conducted to demonstrate the feasibility of the 'Adiabatic Charging' approach. Feasibility was demonstrated and additional testing performed to provide a quantitative, parametric data base. The assumption that the battery is in an adiabatic environment during prelaunch charging is a conservative approximation because the battery will transfer some heat to its surroundings by convective air cooling. The amount is small compared to the heat dissipated during battery overcharge. Because the battery has a large thermal mass, substantial overcharge can occur before the cells get too hot to charge efficiently. The testing presented here simulates a true adiabatic environment. Accordingly the data base may be slightly conservative. The adiabatic charge methodology used in this investigation begins with stabilizing the cell at a given starting temperature. The cell is then fully insulated on all sides. Battery temperature is carefully monitored and the charge terminated when the cell temperature reaches 85 F. Charging has been evaluated with starting temperatures from 55 to 75 F.
This paper reports on results of the tests of the Sony Lithium Ion Cells. The physical, electrochemical, and Canon Battery (BP-927) characteristics of the cells are reported. The tests given include overcharge, overdischarge, high temperature, drop tests, external short circuit, crush test, thermal tests on battery pack, overcharging and overdischarging, unbalanced configuration, heat to vent, and the vibration test. The tests are described, and the results of the tests are reviewed.
Accelerated and real-time LEO cycle-life test data will be presented for a range of commercial Li-ion and Li-polymer (gel type) cells indicating the ranges of performance that can be obtained, and the performance screening tests that must be done to assure long life. The data show large performance variability between cells, as well as a highly variable degradation signature during non-cycling periods within the life tests. High-resolution Dynamic Calorimetry data will be presented showing the complex series of reactions occurring within these Li cells as they are cycled. Data will also be presented for cells being tested using an Adaptive Charge Control Algorithm (ACCA) that continuously adapts itself to changes in cell performance, operation, or environment to both find and maintain the optimum recharge over life. The ACCA has been used to prevent all unneeded overcharge for Li cells, NiCd cells and NiH2 cells. While this is important for all these cell types, it is most critical for Li-ion cells, which are not designed with electrochemical tolerance for overcharge.
The li-ion pouch design cells exhibit similar behavior under off-nominal conditions as those in metal cans that do not have the internal safety devices. Safety should be well characterized before batteries are designed. Some of the li-ion pouch cell designs studied in this program reacted most violently to overcharge conditions at the medium rates but were tolerant to overcharge at very low rates. Some pouch cell designs have higher tolerance to vacuum exposures than some others. A comparison of the pouch material itself does not show a correlation between this tolerance and the number of layers or composition of the pouch indicating that this is a property of the electrode stack design inside the pouch. Reduced pressure (8 to 10 psi) test environments show that the extent of capacity degradation under reduced pressure environments is much less than that observed under vacuum conditions. Lithium-ion Pouch format cells are not necessarily true polymer cells.
The storage battery for the Telstar satellite must undergo frequent charge-discharge cycles; in addition, it is subject to overcharge during a substantial portion of its life. Nickel-cadmium cells were chosen as best capable of satisfactory long-time operation under these conditions. A design and selection program was undertaken to ensure that Ni-Cd cores would meet objectives imposed by battery service conditions, and the cell enclosure was designed to minimize electrolyte leakage. Selection, qualification, and life tests indicated that a storage battery using the cell design would perform satisfactorily. To date, the only failures occurring during continuing life tests have been among cells subjected to 100 per cent discharge daily; this operation is far in excess of the expected duty cycle of satellite cells.
Phenolphthalein leakage, capacity, cell short, immersion seal, overcharge, and internal resistance tests on nickel-cadmium battery
Active compound formation on battery nickel oxide electrode during charge, overcharge, and discharge
Manufacturing process prevents damage to hermetically sealed nickel-cadmium secondary cells by buildup of gas pressure during overcharging and reversed charging conditions. The cells are manufactured with less charge capacity in the positive electrode than in the negative electrode, and two additional electrodes are added.
Leak, capacity, overcharge, and internal resistance tests of ceramic sealed nickel cadmium secondary spacecraft cells
Leak, capacity, overcharge, and internal resistance tests of sealed lead-calcium secondary spacecraft cells
Analytical method predicting heat generation in sealed batteries, noting overcharge ratio effects