Engineering topics
Publications and source records attributed to Harkness, J. D..
Statistical information concerning cell performance characteristics and limitations of secondary spacecraft cells is presented. Weaknesses in cell design as well as battery weaknesses encountered in various satellite programs are reported. Emphasis is placed on improving the reliability of space batteries.
An evaluation test program was conducted to insure that all cells put into the life cycle program are of high quality by the screening of cells found to have electrolyte leakage, internal shorts, low capacity, or inability of any cell to recover its open-circuit voltage above 1.150 volts during the internal short test. The 20 cells were manufactured for the National Aeronautics and Space Administration, Goddard Space Flight Center (GSFC). The cells are from a lot of 175 cells procured for the International Ultraviolet Explorer project. Due to a change in requirements, the project selected to use 6.0 ampere-hour cells. Therefore, the remaining cells of this lot have been placed in storage at GSFC for use on a future GSFC project. All the cells are rated at 12.0 ampere-hours and contain double ceramic seals. Test limits specify those values in which a cell is to be terminated from a particular charge or discharge. Requirements are referred to as normally expected values based on past performance of aerospace nickel cadmium cells with demonstrated life characteristics.
Considerable research is being done to find more efficient and reliable means of starting electrical energy for orbiting satellites. Rechargeable cells offer one such means. A test program is described which has been established in order to further the evaluation of certain types of cells and to obtain performance and failure data as an aid to their continued improvement. The purpose of the program is to determine the cycling performance capabilities of packs of cells under different load and temperature conditions. The various kinds of cells tested were nickel-cadmium, silver-cadmium, and silver-zinc sealed cells. A summary of the results of the life cycling program is given in this report.
An evaluation test program was conducted to insure that all cells put into the life cycle program are of high quality by the screening of cells found to have electrolyte leakage, internal shorts, low capacity, or inability of any cell to recover its open-circuit voltage above 1.150 volts during the internal short test. Tests and results are described.
Quality control measures for Ni-Cd spacecraft cells were analyzed. Cells were examined for electrolyte leakage, internal shorts, low capacity, or inability of any cell to recover its open circuit voltage above 1.50 volts during the internal short test. Test results are given in tabular form.
Several groups of nickel cadmium cells were tested for the durability of their separator materials. The cells were rated at 6.0 ampere-hours, and contained double ceramic seals. Two cells in each group were fitted with pressure gauge assemblies. Results are presented for various brands of separator materials.
The cycle life tests to determine the performance capabilities of packs of cells under different loads and temperature conditions are reported. Results are summarized, and the failure of 14 failed cells is analyzed. It was found that the main cause of failure was separator deterioration and migration of the negative plate material.
Evaluation tests are reported for 20 cells to be put into the life cycle program. Leak, capacity, internal resistance, internal short, and overcharge tests are described.
An evaluation test of the 20.0 ampere-hour cells was conducted to insure that all cells put into the life cycle program are of high quality. This is accomplished by the screening of cells found to have electrolyte leakage, internal shorts, low capacity, or inability of any cell to recover its open circuit voltage above 1.150 volts during the internal short test. The results obtained in the test are given, as well as the recommendations based on these findings.
The capacity of the cells ranged from 6.6 to 7.6 ampere hours during the three capacity tests. No voltage requirements or limits were exceeded during any portion of the test. All cells recovered to a voltage in excess of 1.193 volts during the 24-hour open-circuit portion of the internal short test. All the cells reached a pressure of 20 psia before reaching the voltage limit of 1.550 volts during the pressure versus capacity test. The average ampere/hours in and voltages at this pressure were 9.1 and 1.513, respectively. All cells exhibited pressure decay in the range of 1 to 5 psia during the last 30 minutes of the 1-hour open circuit stand. Average capacity out was 7.2 ampere/hours.
The report describes testing and performance of 20.0 ampere-hour Ni-Col spacecraft batteries.
The capacity of the cells ranged from 3.58 to 3.97 amperehours during the three capacity tests. Three cells were removed from test, due to high pressure, during the C/10, 24-hour charge at room ambient temperature. The voltage requirement of 1.480 volts was exceeded by the cells during the C/10, 24-hour charge at 20 C, although the end-of-charge voltage was below this value (1.466-1.475 volts). Average capacity out during the 20 C charge efficiency test was 0.84 AH which represents 48% and is below the minimum requirement of 55%. The cells exhibited no pressure decay during the open-circuit stand portion of the pressure versus capacity test, as all cells reached their voltage limit (1.550 volts) before their pressure reached 20 psia with the highest pressure being 8 psia during charge.
A life cycle test of secondary electric batteries for spacecraft applications was conducted. A sample number of nickel cadmium batteries were subjected to general performance tests to determine the limit of their actual capabilities. Weaknesses discovered in cell design are reported and aid in research and development efforts toward improving the reliability of spacecraft batteries. A statistical analysis of the life cycle prediction and cause of failure versus test conditions is provided.
The development of an inorganic separator material for use in construction of 40 ampere-hour silver zinc cells is discussed. Acceptance tests were conducted to determine real quality, physical defects and ampere-hour capacity. All acceptance tests were performed at an ambient temperature of 23 to 27 C at existing relative humidity and atmospheric pressure. Of the 63 cells tested, only one failed to meet the equipment specifications.
Life cycle test evaluation of secondary spacecraft cells
Acceptance tests of 20 ampere-hour sealed nickel-cadmium secondary spacecraft cells
Acceptance tests of 5.0 ampere-hour silver-zinc cells for spacecraft power supplies