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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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A Li/Polypyrrole secondary battery was designed and built, and the effect of controlling the morphology of the polymer on enhancement of counterion diffusion in the polymer phase was explored. The experimental work was done at Colorado State University, while the mathematical modeling of the battery was done at Texas A and M University. Manuscripts and publications resulting from the project are listed.
Report presents analysis of anticipated thermal conditions in and around 250-A h Li/SOCI2 battery developed for use aboard Centaur rocket.
NASA has traditionally sought to reduce the likelihood of a single cell thermal runaway (TR) in their aerospace batteries to an absolute minimum by employing rigorous screening program of the cells. There was generally a belief that TR propagation resulting in catastrophic failure of the battery was a forgone conclusion for densely packed aerospace lithium-ion batteries. As it turns out, this may not be the case. An increasing number of purportedly TR propagation-resistant batteries are appearing among NASA partners in the commercial sector and the Department of Defense. In the recent update of the battery safety standard (JSC 20793) to address this paradigm shift, the NASA community included requirements for assessing TR severity and identifying simple, low-cost severity reduction measures. Unfortunately, there are no best-practice guidelines for this work in the Agency, so the first project team attempting to meet these requirements would have an undue burden placed upon them. A NASA engineering Safety Center (NESC) team set out to perform pathfinding activities for meeting those requirements. This presentation will provide contextual background to this effort, as well as initial results in attempting to model and simulate TR heat transfer and propagation within battery designs.
Urban Air Mobility seeks to transport passengers, deliver cargo, and provide emergency medical transportation in major metropolitan areas. This will be accomplished with distributed electric powered vertical takeoff and landing aircraft vehicles. The low specific energy of the current generation lithium-ion battery packs limit the operational range of the electric aircraft. Limited range impacts safety by reducing the amount of time available for analyzing the potential impact of errors and failures and responding to them, and for flying to an alternative landing area or returning to the base. It is therefore critical to understand the impact of flight and environmental conditions on the onboard lithium-ion battery pack’s health. With this as the motivation, the procedure for evaluating the performance of battery packs in a laboratory setting and the results obtained using this procedure on battery packs subject to power draw characteristics of a simulated flight of a NASA conceptual quadrotor aircraft model are described. The fully charged battery is allowed to discharge at specific C-rates based on the power draw profile during the experiment, and the current and voltages are recorded as a function of time. Observed results under different operating conditions and mission profiles are discussed.
Station Power and Energy Evaluation Determiner (SPEED) is a Java application program for analyzing the supply and demand aspects of the electrical power system of the International Space Station (ISS). SPEED can be executed on any computer that supports version 1.4 or a subsequent version of the Java Runtime Environment. SPEED includes an analysis module, denoted the Simplified Battery Solar Array Model, which is a simplified engineering model of the ISS primary power system. This simplified model makes it possible to perform analyses quickly. SPEED also includes a user-friendly graphical-interface module, an input file system, a parameter-configuration module, an analysis-configuration-management subsystem, and an output subsystem. SPEED responds to input information on trajectory, shadowing, attitude, and pointing in either a state-of-charge mode or a power-availability mode. In the state-of-charge mode, SPEED calculates battery state-of-charge profiles, given a time-varying power-load profile. In the power-availability mode, SPEED determines the time-varying total available solar array and/or battery power output, given a minimum allowable battery state of charge.
The use of spirally wound lithium-thionyl chloride (Li-SOCl2) cells is currently limited because of their hazardous behavior. Safety hazards have ranged from mild venting of toxic materials to violent explosions and fires. These incidents may be related to both user- and manufacturer-induced causes. Many explanations have been offered to explain the unsafe behavior of the cells under operating and abuse conditions. Explanations fall into two categories: (1) thermal mechanisms, and (2) chemical mechanisms. However, it is quite difficult to separate the two. Both may be responsible for cell venting or explosion. Some safety problems encountered with these cells also may be due to design deficiencies and ineffective quality control during cell fabrication. A well-coordinated basic and applied research program is needed to develop safe Li-SOCl2 cells. Recommendations include: (1) learnig more about Li-SOL2 cell chemistry; (2) modeling cell and battery behavior; (3) optimizing cell design for safety and performance, (4) implementing quality control procedures; and (5) educating users.
The hardware and software design of a nickel-hydrogen (Ni-H2) battery simulator (BS) with application to the NASA Earth Observation System (EOS) satellite is presented. The battery simulator is developed as a part of a complete testbed for the EOS satellite power system. The battery simulator involves both hardware and software components. The hardware component includes the capability of sourcing and sinking current at a constant programmable voltage. The software component includes the capability of monitoring the battery's ampere-hours (Ah) and programming the battery voltage according to an empirical model of the nickel-hydrogen battery stored in a computer.
The overcharge condition in secondary lithium batteries employing redox additives for overcharge protection has been theoretically analyzed in terms of a finite linear diffusion model. The analysis leads to expressions relating the steady-state overcharge current density and cell voltage to the concentration, diffusion coefficient, standard reduction potential of the redox couple, and interelectrode distance. The model permits the estimation of the maximum permissible overcharge rate for any chosen set of system conditions. The model has been experimentally verified using 1,1-prime-dimethylferrocene as a redox additive. The theoretical results may be exploited in the design and optimization of overcharge protection by the redox additive approach.
Xenon arc lamps developed during the Apollo program by Streamlight, Inc. are the basis for commercial flashlights and emergency handlights. These are some of the brightest portable lights made. They throw a light some 50 times brighter than automobile high beams and are primarily used by police and military. The light penetrates fog and smoke and returns less back-scatter light. They are operated on portable power packs as boat and auto batteries. An infrared model produces totally invisible light for covert surveillance.
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.
Scale model performance tests on automatically activated silver zinc battery for deep space exploration
In this work, we propose a hybrid model for Li-ion battery discharge and aging prediction that leverages fleet-wide data to predict future capacity drops.The model is built upon an hybrid approach merging physics-based and empirical equations, as well as neural network models in a recurrent neural network cell. The hybrid physics-informed neural network can predict voltage discharge cycles given the loading profile, and estimate the used capacity of the battery under random-loading conditions by tracking aging parameters connected to the residual capacity of the battery. By merging information on the battery aging parameters with existing fleet-wide aging data, the model can predict the future residual capacity of the battery that is being monitored, and therefore enable predictions of voltage discharge curves far ahead in the battery life cycle. We validated the approach using the NASA Prognostics Data Repository Battery data-set, which contains experimental data on Li-ion batteries discharged at random loading conditions in a controlled environment. The approach also allows the identification of discrepancies between the battery aging trend and the trend observed at the fleet level, so that batteries behaving differently from the rest of the fleet can be subject to closer monitoring and further testing to refine predictions.
The progress which has been made in modeling the lithium/thionyl chloride cell over the past year and proposed research for the coming year are discussed. A one-dimensional mathematical model for a lithium/thionyl chloride cell has been developed and used to investigate methods of improving cell performance. During the course of the work a problem was detected with the banded solver being used. It was replaced with one more reliable. Future work may take one of two directions. The one-dimensional model could be augmented to include additional features and to investigate in more detail the cell temperature behavior, or a simplified two-dimensional model for the spirally wound design of this battery could be developed to investigate the heat flow within the cell.
A mathematical model to simulate the charge/discharge behavior of a lithium/lithium perchlorate-propylene carbonate/polypyrrole secondary battery cell is presented. The model can be used to gain a better understanding of the behavior of this cell and to provide guidance toward the design of new secondary batteries which utilize an electronically conductive polymer such as polypyrrole as the cathode. The model includes the capability of handling charge and discharge behavior and is used to study the effect of various design parameters on the performance of the cell.
The dynamic response of a solar generator is of primary importance as much for the design and development of electrical power conditioning hardware as for the analysis of electromagnetic compatibility. A mathematical model of photo-batteries was developed on the basis of impedance measurements performed under differing conditions of temperature, light intensity, before and after irradiation. This model was compared with that derived from PN junction theory and to static measurements. These dynamic measurements enabled the refinement of an integration method capable of determining, under normal laboratory conditions, the dynamic response of a generator to operational lighting conditions.
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.
The present study uses an empirical model to assess the feasibility of using the Li-TiS2 bipolar battery for high power applications. Predicted performance outputs at a variety of conditions were calculated. The effects of the design parameters on the performance of bipolar Li-TiS2 batteries are presented. Specific energies greater than 150 Wh/kg can be achieved at low rates. Specific power levels in excess of 100 W/kg can be reached at high rates but with a reduction of the specific energy to less than 70 Wh/kg.
The needs and requirements for an electrochemical energy storage for deep space exploration is well explored. It is often understood that different mission sites and environmental conditions require different battery chemistries or technologies. Additionally, various engineering solutions are deployed to overcome specific chemical challenges. One often overlooked need is the “health” monitoring of an electrochemical storage system. The term generalized health monitoring, as envisioned in this work, refers to the monitoring of various aspects such as electrode health, electrolyte health, reaction pathway health, cooling system health, sensor health, and BMS health [1]. Generalized health monitoring allows mission leads, engineers, and scientists to incorporate flexibility in mission designs, make on-the-fly mission changes, and extend the duration of science missions. Moreover, it enables automation and data-driven decision-making without compromising safety and performance. Recently, our group developed a hierarchy of thermal reduced-order models (TROM) by combining a physics-based modeling approach and data-driven model reduction techniques applied to flight data [2]. The resulting TROMs were found to be not only accurate but also identifiable from the flight data. Consequently, the coefficient of variance of the model parameters is small over the course of hundreds of flights, allowing for monitoring the parameter evolution trajectories as the battery ages and degrades. These parameters constitute the metrics of the generalized health of a battery. Monitoring their evolution allows such models to be used for anomaly detection and prognostics, improving early detection of abnormal behavior and thus enabling timely maintenance, longer battery life, and enhanced battery safety. For this presentation, the practicality of the thermal model will be validated on a pack of 14cells under various topology configurations such as 1S14P, 2P7S, 7S2P, and 1P14S. It is well known that manufacturing and non-uniform aging lead to variability in the performance of a cell, which is exacerbated by cell balancing during active load. Additionally, in extreme scenarios, the paramount objective is to complete the mission, regardless of the stresses on the battery. Topology-induced balancing issues further stress the battery. The goal of this study is to determine if the noise (identifiability) in the reduced-order thermal model parameters is sensitive to topology, cell spacing, cooling strategy, and manufacturing or age variability. The variability in cells is considered by assuming a multimodal distribution for microscopic parameters of a cell (such as porosity, tortuosity, reaction kinetics, volumetric thermal conductivity, and volumetric heat capacity). The compounded effect of manufacturing variability, topological selection, cooling strategies, and cell balancing ages each cell in a battery differently. The study aims to clarify whether the challenge in extracting maximum information depends on the minimum number of sensors or models used for data extraction.