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Presentation covers: (1) Safety Certification Process at NASA (2) Safety Testing for Lithium-ion Batteries (3) Limitations Observed with Li-ion Batteries in High Voltage and High Capacity Configurations.
This guideline discusses a standard approach for defining, determining, and addressing safety, handling, and qualification standards for lithium-ion (Li-Ion) batteries to help the implementation of the technology in aerospace applications. Information from a variety of other sources relating to Li-ion batteries and their aerospace uses has been collected and included in this document. The sources used are listed in the reference section at the end of this document. The Li-Ion chemistry is highly energetic due to its inherent high specific energy and its flammable electrolyte. Due to the extreme importance of appropriate design, test, and hazard control of Li-ion batteries, it is recommended that all Government and industry users and vendors of this technology for space applications, especially involving humans, use this document for appropriate guidance prior to implementing the technology.
The topics covered are presented in viewgraph form and include a flight program history and in-house activities. Some of the in-house activities addressed include secondary battery/cell testing and Hubble Space Telescope Test data updates involving the NiCd type 40 test - battery 1 and 2, the NiCd type 41 test battery, the general electric battery, the NiCd six-battery system, the six four-cell packs, fourteen-cell pack, three four-cell packs, the NiH2 six-battery system, and the flight spare battery. A general test data update is also presented for the twelve-cell pack, the four four-cell packs, the reconditioning test, and planned Ni-MH testing.
Results of testing, analysis, and development of lithium, nickel-cadmium, and nickel-hydrogen batteries are reported. Focus is on the improvement of power systems in the areas of high capacity, high energy density, and long cycle and storage life. Applications of these batteries as spacecraft power supplies are discussed. Those spacecraft include deepspace probes, spacecraft in geostationary orbit, and large space systems in low-Earth orbit.
The major objective of the NASA Aerospace Flight Battery Systems Program is to provide NASA with the policy and posture to increase and ensure the safety, performance, and reliability of batteries for space power systems. The program was initiated in 1985 to address battery problems experienced by NASA and other space battery users over the previous ten years. The original program plan was approved in May 1986 and modified in 1990 to reflect changes in the agency's approach to battery related problems that are affecting flight programs. The NASA Battery Workshop is supported by the NASA Aerospace Flight Battery Systems Program. The main objective of the discussions is to aid in defining the direction which the agency should head with respect to aerospace battery issues. Presently, primary attention in the Battery Program is being devoted to issues revolving around the future availability of nickel-cadmium batteries as a result of the proposed OSHA standards with respect to allowable cadmium levels in the workplace. The decision of whether or not to pursue the development of an advanced nickel-cadmium cell design and the qualification of vendors to produce cells for flight programs hinges on the impact of the OSHA ruling. As part of a unified Battery Program, the evaluation of a nickel-hydrogen cell design options and primary cell issues are also being pursued to provide high performance NASA Standards and space qualified state-of-the-art cells. The resolution of issues is being addressed with the full participation of the aerospace battery community.
The primary objectives of the test are: (1) to get a better understanding of the operating characteristics of the NiH2 batteries in the Hubble Space Telescope (HST) Electric Power Subsystem (EPS) by simulating every aspect of the expected operating environment; (2) to determine the optimum charge level and charge scheme for the NiH2 batteries in the HST EPS; (3) to predict the performance of the actual HST EPS; (4) to observe the aging characteristics of the batteries; and (5) to test different EPS anomalies before experiencing the anomalies on the actual HST.
Development of sealed lead-acid battery with lead- calcium grid for space application
Tests performed at NASA/MSFC on the Hubble Space Telescope (HST) nickel-hydrogen batteries (flight spare module and flight spare battery) were used to determine self-discharge and charge-acceptance characteristics when the batteries were exposed to charged wet-stand conditions, pulse charging on the launch pad, and battery capacity at solar array deployment. An equation is presented which was used to predict the capacity that would be available in the HST NiH2 batteries after an extended stand time on the launch pad plus up to 2 days on orbit prior to solar array deployment (either ground power or orbiter power were used to supply HST loads until shortly before the solar arrays were deployed). It is shown that a fairly accurate estimate of the available capacity was made.
The latest results of testing, analysis and development of sealed nickel cadmium cells and batteries and developments in the nickel-hydrogen system are discussed.
Papers discussing the latest results of testing, analysis, and development of the sealed nickel cadmium cell system are presented. Metal hydrogen and lithium cell technology and applications are also discussed. The purpose of the workshop was to share flight and test experience, stimulate discussion on problem areas, and to review the latest technology improvements.
Several aspects of lithium primary cell technology are discussed with respect to aerospace application. Particular attention is given to the statistical analysis of battery data and accelerated testing.
Various topics concerned with advanced battery technology are addressed including lithium cell and battery safety developments, mathematical modelling, charge control of aerospace power systems, and the application of nickel hydrogen cells/batteries vis-a-vis nickel cadmium cells/batteries.
Subjects covered included advanced energy storage programs, lithium cell technology, nickel cadmium technology, testing and flight experience and metal hydrogen technology.
Various topics related to spacecraft power supply systems are discussed. Regenerative fuel cells, lithium molybdenum batteries, nickel hydrogen batteries, nickel cadmium batteries, failure analysis, and performance testing are covered.
The subjects covered include: advanced energy storage, lithium cell technology, nickel-cadmium design evaluation and component testing, simulated orbital cycling and flight experience, and nickel-hydrogen technology.
The subjects covered include: lithium cell technology and safety improvements; nickel-cadmium separator and electrode technology along with associated modifications; flight experience and life testing of nickel-cadmium cell; and nickel-hydrogen applications and technology.
The role of the Power Branch/EP5 of JSC in primary battery applications is to support those JSC organizations having direct application responsibility with trade studies, battery selection recommendations, and with development, qualification, and provisioning of primary batteries. Battery subsystem management is provided. Payload hazard report preparation is supported, as is the review and comment of such reports for the JSC Payload Safety Panel, who approves the flight safety for all Orbiter payloads. JSC battery users are provided with safety analysis and test support to achieve safety approval. Finally, it is the responsibility of the Power Branch to define and maintain battery safety requirement documentation for JSC.
Discussing detailed modeling of Li-air and suggesting possible solutions for space.