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The evolution of an advanced Ni-Cd space battery cell design continues to prove very promising. High oxygen/hydrogen gas recombination rates (currently up to a C/5 charge rate) and increased electrolyte activation level tolerance (currently up to 5.6 grams Ah of positive capacity) were demonstrated by test. A superior performance, extended life battery cell offering advantages should soon be available for mission applications
This document contains the proceedings of the 34th annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center, November 27-29, 2001. The workshop was attended by scientists and engineers from various agencies of the US Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind. The subjects covered included nickel-hydrogen, nickel-cadmium, lithium-ion, and silver-zinc technologies.
Passive thermal control is necessary as space exploration becomes increasingly widespread. Materials with superior optical properties (high solar reflectance and infrared emittance) are critical for passive thermal control because they can reject most of the incident solar radiation and promote thermal emission from cryogenic propellant storage tanks, enabling the extraterrestrial storage of cryogens. We have demonstrated in previous studies that electrospun nanofibers exhibit exceptional optical properties, offering significant benefits for passive radiative cooling in space. Particularly, electrospun polyvinylidene fluoride-co-hexafluoropropylene PVDF-HFP nanofibers demonstrate exceptionally high solar reflectance (>99%) and strong thermal emittance (measured at ~300 K). However, they exhibit nanostructural changes in the presence of atomic oxygen, which is prevalent in Low Earth Orbit. This study focuses on creating a unique blend of polymeric (PVDF-HFP) and ceramic-based (silica) nanofibers by leveraging the chemical stability and atomic oxygen resistance of silica, using the dual electrospinning manufacturing method. This approach aims to preserve the structural properties of the polymeric counterpart without compromising its optical performance, thereby providing an innovative method for manufacturing environmentally resilient passive thermal control nanofibers with desirable optical and thermal control functionalities for extraterrestrial storage of cryogenic propellants.
This presentation provides information on battery passivation of spacecraft at the end of mission (EOM) life. The goal of battery passivation is to tackle the growing problem of orbital debris and its impact on space sustainability. NASA is increasingly using commercially produced buses in NASA missions, and this presentation provides information on EOM spacecraft passivation for NASA missions.
Synthetic battery cycling makes use of the fast growing capability of computer graphics to illustrate some of the basic characteristics of operation of individual electrodes within an operating electrochemical cell. It can also simulate the operation of an entire string of cells that are used as the energy storage subsystem of a power system. The group of techniques that as a class have been referred to as Synthetic Battery Cycling is developed in part to try to bridge the gap of understanding that exists between single cell characteristics and battery system behavior.
Thermal management for battery is important for electric aircraft because battery temperature is critically important to vehicle safety, and it also has direct impact on the efficiency of the battery system. Because ambient air is a readily available resource for aircraft, this paper considers an active cooling concept with forced convection of ambient air through the battery pack. Conjugate heat transfer analysis is used to solve the coupled aero-thermal problem, which consists of a finite-volume computational fluid dynamics solver for the fluid domain, and a conduction heat transfer solver for the solid domain. A mixed Neumann and Dirichlet boundary condition is developed for the fluid-solid interface, which allows the solid domain to completely submerge in the fluid domain. A gradient-based optimization method is adopted, and the discrete adjoint approach implemented in DAFoam is used to efficiently compute the gradients. The aero-thermal coupling for primal analysis and gradient computation is handled using the OpenMDAO-based MPhys framework. A constant heat source is prescribed for the battery cells, and the battery shape (design variable) is optimized to minimize cooling pump power and battery weight (composite objective function) while keeping the battery temperature below a threshold (constraint). The optimized design achieves a 44.6% and 1.5% reduction in the cooling pump power and battery weight, respectively, and the maximal temperature constraint is satisfied. This work has the potential to reduce battery-pack weight, improve performance, and reduce the weight of thermal management systems for electric vertical take-off and landing aircraft.
India's first experimental communication satellite, APPLE, carried a 12 AH Ni-Cd battery for supplying power during eclipse. Failure to deploy one of the two solar panels resulted in the battery operating in a high temperature environment, around 40 C. This also resulted in the battery being used in diurnal cycles rather than just half yearly eclipse seasons. The management and performance of the battery during its life of two years are described. An attempt to identify the probable degradation mechanisms is also made.
Thermal management for battery is important for electric aircraft because battery temperature is critically important to vehicle safety, and it also has direct impact on the efficiency of the battery system. Because ambient air is a readily available resource for aircraft, this paper considers an active cooling concept with forced convection of ambient air through the battery pack. Conjugate heat transfer analysis is used to solve the coupled aero-thermal problem, which consists of a finite-volume computational fluid dynamics solver for the fluid domain, and a conduction heat transfer solver for the solid domain. A mixed Neumann and Dirichlet boundary condition is developed for the fluid-solid interface, which allows the solid domain to completely submerge in the fluid domain. A gradient-based optimization method is adopted, and the discrete adjoint approach implemented in DAFoam is used to efficiently compute the gradients. The aero-thermal coupling for primal analysis and gradient computation is handled using the OpenMDAO-based MPhys framework. A constant heat source is prescribed for the battery cells, and the battery shape (design variable) is optimized to minimize cooling pump power and battery weight (composite objective function) while keeping the battery temperature below a threshold (constraint). The optimized design achieves a 44.6% and 1.5% reduction in the cooling pump power and battery weight, respectively, and the maximal temperature constraint is satisfied. This work has the potential to reduce battery-pack weight, improve performance, and reduce the weight of thermal management systems for electric vertical take-off and landing aircraft.
The Long Life (Lithium Ion) Battery is designed to replace the current Extravehicular Mobility Unit Silver/Zinc Increased Capacity Battery, which is used to provide power to the Primary Life Support Subsystem during Extravehicular Activities. The Charger is designed to charge, discharge, and condition the battery either in a charger-strapped configuration or in a suit-mounted configuration. This paper will provide an overview of the capabilities and systems engineering development approach for both the battery and the charger
In recent years following several spacecraft battery anomalies, it was determined that managing the operational factors of NASA flight NiCd rechargeable battery was very important in order to maintain space flight battery nominal performance. The optimization of existing flight battery operational performance was viewed as something new for a Taguchi Methods application.
A rechargeable lithium molybdenum disulfide battery which has a number of superior performance characteristics which includes a high energy density, a high power density, and a long charge retention time was developed. The first cell sizes developed included a C size cell and an AA size cell. Over the last two years, a project to demonstrate the feasibility of the scale up to this technology to a BC size cell with 65 Ah capacity was undertaken. The objective was to develop, build, and test a .6 kWh storage battery consisting of 6 BC cells in series.
A prototype battery status monitor system has been developed. The functions of the system are: (1) to provide the energy status of the battery, (2) to measure and transmit basic battery parameters, (3) to process these measurements required to determine abnormal functioning of the battery, and (4) to transmit warning signals of the abnormal condition along with a go/no go signal. The system was developed for use with the space shuttle.
Embodiments include an iron-air rechargeable battery having a composite electrode including an iron electrode and a hydrogen electrode integrated therewith. An air electrode is spaced from the iron electrode and an electrolyte is provided in contact with the air electrode and the iron electrodes. Various additives and catalysts are disclosed with respect to the iron electrode, air electrode, and electrolyte for increasing battery efficiency and cycle life.
A battery model is developed based on time averaging the current or power, and is shown to be an effective means of predicting the performance of a lead acid battery. The effectiveness of this battery model was tested on battery discharge profiles expected during the operation of an electric vehicle following the various SAE J227a driving schedules. The averaging model predicts the performance of a battery that is periodically charged (regenerated) if the regeneration energy is assumed to be converted to retrievable electrochemical energy on a one-to-one basis.
The National Aeronautics and Space Administration (NASA) is visiting the moon again. This time, the objective is to explore establishing a permanent lunar base. To achieve both longterm human habitation on the moon and future deep space travel, it is crucial to make the most of the in-situ resources and build autonomous systems on the moon to support the construction of a lunar habitat. NASA’s In-situ Resource Utilization (ISRU) program aims to minimize the need to ship heavy prefabricated structures, reducing cost and enhancing sustainability. Here, we developed an economical extrusion method for printing lunar regolith-based composites using shape memory vitrimer as a binder. A rheological study is conducted to determine the extrudability of the composite with different regolith weight percentages. Several characterizations were conducted on the composites. The as-printed composites exhibited compressive and flexural strengths of 73.32 MPa and 156.59 MPa, respectively, and good impact tolerance. The composite maintained 57.92% of its mechanical properties even after the second crack healing cycle. The composites also exhibit shape fixity ratio of 90.02% and shape recovery ratio of 83.46%. The simple synthesis method, sustainability, and good thermomechanical properties make the 3D printed composite an ideal material for lunar construction applications.
The proceedings of the 29th Aerospace Mechanisms Symposium, which was hosted by NASA Johnson Space Center and held at the South Shore Harbour Conference Facility on May 17-19, 1995, are reported. Technological areas covered include actuators, aerospace mechanism applications for ground support equipment, lubricants, pointing mechanisms joints, bearings, release devices, booms, robotic mechanisms, and other mechanisms for spacecraft.
Objective: Consider a new battery design for EMU. Results: a) Electrovaya s aerospace cell production line is improving, but must further improve to achieve acceptable reliability; b) Completed functional, vibration, and thermal cycling of LIB; c) So far, electrical safety tests have produced good results; d) Completed functional, vibration, thermal cycling, power quality and EMI of LIB Charger; e) Completed CDR on 9/23/04; and f) Manufacturing Readiness Review for flight cell/battery production scheduled for Dec 04.
This paper reviews the development of the Electro Energy, Inc.'s bipolar nickel metal hydride battery. The advantages of the design are that each cell is individually sealed, and that there are no external cell terminals, no electrode current collectors, it is compatible with plastic bonded electrodes, adaptable to heat transfer fins, scalable to large area, capacity and high voltage. The design will allow for automated flexible manufacturing, improved energy and power density and lower cost. The development and testing of the battery's component are described. Graphic presentation of the results of many of the tests are included.