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NASA NTRS2001

Performance of Li-Ion Cells Under Battery Voltage Charge Control

A study consisting of electrochemical characterization and Low-Earth-Orbit (LEO) cycling of Li-Ion cells from three vendors was initiated in 1999 to determine the cycling performance and to infuse the new technology in the future NASA missions. The 8-cell batteries included in this evaluation are prismatic cells manufactured by Mine Safety Appliances Company (MSA), cylindrical cells manufactured by SAFT and prismatic cells manufactured by Yardney Technical Products, Inc. (YTP). The three batteries were cycle tested in the LEO regime at 40% depth of discharge, and under a charge control technique that consists of battery voltage clamp with a current taper. The initial testing was conducted at 20 C; however, the batteries were cycled also intermittently at low temperatures. YTP 20 Ah cells consisted of mixed-oxide (Co and Ni) positive, graphitic carbon negative, LIPF6 salt mixed with organic carbonate solvents. The battery voltage clamp was 32 V. The low temperature cycling tests started after 4575 cycles at 20 C. The cells were not capable of cycling. at low temperature since the charge acceptance at battery level was poor. There was a cell in the battery that showed too high an end-of-charge (EOC) voltage thereby limiting the ability to charge the rest of the cells in the battery. The battery has completed 6714 cycles. SAFT 12 Ah cells consisted of mixed-oxide (Co and NO positive, graphitic carbon negative, LiPF6 salt mixed with organic carbonate solvents. The battery voltage clamp was for 30.8 V. The low temperature cycling tests started after 4594 cycles at 20 C. A cell that showed low end of discharge (EOD) and EOC voltages and three other cells that showed higher EOC voltages limited the charge acceptance at the selected voltage limit during charge. The cells were capable of cycling at 10 C and 0 C but the charge voltage limit had to be increased to 34.3 V (4.3 V per cell). The low temperature cycling may have induced poor chargeability since the voltage had to be increased to achieve the required charge input. The battery has completed 6226 cycles. MSA 10 Ah cells consisted of Co oxide positive, graphitic carbon negative, LiPF6 salt mixed with organic carbonate solvents. The battery voltage clamp was 30.8 V. The low temperature cycling tests were started after 2182 cycles at 20 C. The cells were capable of cycling at 10 C and 0 C. Like SAFT, the voltage limit on charge had to be increased to 36 V (4.5 V per cell). There was a cell (cell S/N 13) in the battery that showed poor performance features such as low EOD voltage and high EOC voltage. The battery has completed 3441 cycles. A reconditioning procedure that consisted of C15 charge to a taper current of C/100 and C/20 discharge improved the voltage behavior of SAFT and MSA cells with no significant effect on YTP cells. We have demonstrated that the charge operation with VT clamp at battery rather than at cell level is feasible for onboard Li-Ion battery operation.

Rao, Gopalakrishna M.↗

NASA NTRS2004

Lithium-Ion Verification Test Program

In order to assess the capabilities of current aerospace lithium-ion cells to perform long-term NASA missions, low-earth-orbits (LEO) testing to evaluate long-term cycle life was initiated. A flexible program was developed at NASA Glenn Research Center to enable assessment of technology developments as they occur as well as provide information about different cell vendors and cell designs. Following extensive characterization testing, cells are tested using LEO charge and discharge profiles under ten different combinations of test conditions that were statistically chosen to determine the effects of depth-of-discharge, temperature, and end-of-charge voltage on LEO cycle life. Four cells from each vendor are tested at each specific combination of conditions. Conditions included in the test matrix are depth-of-discharges of 20%, 30, 35%, and 40%; temperatures of 20, 30, and 40 C; and end-of-charge voltages of 3.85 V, 3.95 V, and 4.05 V. Cells are randomly assigned to packs and packs are randomly assigned to test conditions. The capacity of the cells to 3.0 V at the conditions of the test is being periodically measured. The results of this testing will be used to model cell performance and degradation as a function of test operating conditions. Cells are being evaluated in 4-cell series strings with charge voltage limits being applied to individual cells by charge control units designed and built at NASA Glenn Research Center. Testing is being performed at the Naval Surface Warfare Center/Crane Division in Crane, IN. Testing was initiated in September 2004 with 40 Ah cells from Saft and 30 Ah cells from Lithion. The test program is being expanded with the addition of cells from MSA and the addition of small cell modules is being considered. Preliminary results showing voltage, temperature, usable capacity per unit mass, and voltage dispersion as their changes over time for the cells at 20 C is presented.

McKissock, Barbara↗

NASA NTRSDate not supplied

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗

NASA NTRS1971

Investigation of intermittent enhancement of ion emission from a tungsten surface using the field-ion microscope.

The blinking effect, or the intermittent enhancement of ion emission, which is observed when a few parts per million neon are added to the imaging gas in a helium-tungsten field-ion microscope, has been investigated. Measurements of the characteristic quantities involved - i.e., blinking rate, voltage limits, etc. - and their variation with temperature, field, and gas pressure, are described.

Weizer, V. G.↗

NASA NTRS1972

Observation of defect annealing in neutron-irradiated silicon by space-charge-limited current.

Use of space-charge-limited current (SCLC) to observe defect annealing in neutron-irradiated silicon. From the observation of the trap-filled-limit voltage a deep-trap concentration in the irradiated unannealed crystals is found to be at least 1.4 x 10 to the 12th power per cu cm. Shallow traps are also observed. This deep-trap concentration decreases with anneal temperature up to 200 C, above which SCLC can no longer be observed. There is evidence that at least some of this decrease is due to the conversion of the deep traps to shallow traps.

Magee, T. J.↗

NASA NTRS1973

Evaluation program for secondary spacecraft cells. Initial evaluation tests of Eagle-Picher Industries, Incorporated 3.0 ampere-hour nickel-cadmium spacecraft cells

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.

Harkness, J. D.↗

NASA NTRS1975

Auxiliary propulsion thruster performance with ion machined accelerator grids

A substantial improvement in the performance of an 8-centimeter-diameter auxiliary propulsion thruster was achieved by reducing the diameter of the accelerator grid apertures. The accelerator grid hole geometry was defined by ion machining accelerator grids on an 8-centimeter thruster at thrust levels of 2.2, 4.4, and 6.7 millinewtons was (mN). A thruster with an ion machined accelerator grid was operated at a thrust of 4.4 mN for 1000 hours. The discharge propellant utilization was 92% at an eV/ion of 338. Thruster performance and accelerator grid hole geometry was documented as a function of thrust level. It was also determined that the small hole accelerator grid has a very low backstreaming voltage limit. In fact the thruster can be operated with the acclerator grid held at neutralizer tip potential.

Hudson, W. R.↗

NASA NTRS1975

Auxiliary propulsion thruster performance with ion machined accelerator grids

A substantial improvement in the performance of an 8-centimeter-diameter auxiliary propulsion thruster has been achieved by reducing the diameter of the accelerator grid apertures. The accelerator grid hole geometry has been defined by ion machining accelerator grids on an 8-centimeter thruster at thrust levels of 2.2, 4.4, and 6.7 millinewtons (mN). A thruster with an ion machined accelerator grid has been operated at a thrust of 4.4 mN for 1000 hours. The discharge propellant utilization was 92% at an eV/ion of 338. Thruster performance and accelerator grid hole geometry has been documented as a function of thrust level. It was also determined that the small hole accelerator grid has a very low backstreaming voltage limit. In fact the thruster can be operated with the accelerator grid held at neutralizer tip potential.

Hudson, W. R.↗

NASA NTRS1977

Battery single-cell protection system

Protective circuit consists of solid state comparator switch and high current switching device combined into single module, which can be mounted directly on each cell as part of cell or battery case construction. System prohibits driving cells beyond set voltage limits and allows deeper discharge without cell reversal.

Thomas, R. D.↗

NASA NTRS1976

Development of single cell protectors for sealed silver-zinc cells, phase 1

A single cell protector (SCP) assembly capable of protecting a single silver-zinc (Ag Zn) battery cell was designed, fabricated, and tested. The SCP provides cell-level protection against overcharge and overdischarge by a bypass circuit. The bypass circuit consists of a magnetic-latching relay that is controlled by the high and low-voltage limit comparators. Although designed specifically for secondary Ag-Zn cells, the SCP is flexible enough to be adapted to other rechargeable cells. Eighteen SCPs were used in life testing of an 18-cell battery. The cells were sealed Ag-Zn system with inorganic separators. For comparison, another 18-cell battery was subjected to identical life test conditions, but with battery-level protection rather than cell-level. An alternative approach to the SCP design in the form of a microprocessor-based system was conceptually designed. The comparison of SCP and microprocessor approaches is also presented and a preferred approach for Ag-Zn battery protection is discussed.

Imamura, M. S.↗

NASA NTRS1975

The SAS-3 power and thermal systems

Solar array configurations of the SAS-3 are described: a configuration with two sets of coplanar panels in the horizontal and two others in the vertical position, and two other configurations with either four horizontal or four vertical sets of panels. The nickel-cadmium battery of the power subsystem is described in detail, with emphasis on voltage limits and charge-discharge characteristics. The characteristic of 'solar-only' operation in the case of damage to the battery is discussed. The thermal subsystem of SAS-3 is considered, with discussions of thermal design criteria and the thermal environment. Temperature is controlled by using internal thermal louvers that regulate the rate at which the heat load from electronic equipment is transmitted to the outer surface for dumping to space.

Sullivan, R. M.↗

NASA NTRS1976

Design of the High Energy Astronomy Observatory /HEAO/ power subsystem

Observatory power is generated by a partially deployable solar array which is modularized to facilitate adaptation to three missions having different power requirements. Three nickel-cadmium batteries are controlled independently from dedicated modular chargers to increase subsystem adaptability and decrease sensitivity to temperature differences between batteries. Battery level redundancy is employed, enabling mission completion with two of three battery/charger combinations operational. Bus voltage limiting is accomplished by a modularized shunt regulator which can survive any single part failure and meet all mission requirements. Relatively low shunt electronics power dissipation internal to the observatory is achieved by sequenced operation of linear shunt segments which are coupled to a large area resistive shunt radiator. Summaries of solar array, battery and subsystem breadboard test results are provided.

Reppucci, G. M.↗

NASA NTRS1977

ITOS power system design

A brief description of the ITOS power systems is presented. The descriptions are from viewgraphs shown to the participants of the Workshop. A block diagram of ITOS power supply subsystem is presented along with graphs representing: ITOS voltage limit versus temperature; and battery charge-discharge current profiles over an orbit period.

Obenschain, A. F.↗

NASA NTRS1978

A new battery charger/discharger converter

A new optimum topology dc-to-dc switching converter is extended to provide bidirectional current flow. The resulting two-quadrant converter can be employed to eliminate the discontinuous current mode in normal unidirectional applications, but is especially suited for spacecraft battery conditioning as a charge-discharge regulator in place of the conventional separate converters. Implementation of the control features and the battery charge current and voltage limits are discussed.

Middlebrook, R. D.↗

NASA NTRS1978

Evaluation program for secondary spacecraft cells: Initial evaluation tests of General Electric Company 40.0 ampere-hour nickel-cadmium spacecraft cells for the tracking data relay satellite system

Five cells provided by NASA's Goddard Space Flight Center were evaluated at room temperature and pressure (25 C plus or minus 2 C) with discharges at the 2 hour rate. Measurements of the cell containers following test, indicated an average increase of .006 inches at the plate thickness. Average end of charge voltages and pressures, and capacity output in ampere hours were determined. Three cells exceeded the voltage requirements of 1.52 volts during both c/10 charges at 20 C. All cells exceeded the voltage requirement of 1.52 volts during the 0 C overcharge test, although their end charges were below 1.50 volts. The pressure requirement of 65 psia was exceeded by both pressure transducer cells during c/10 charges at 25 C and 20 C and also during the 0 C overcharge test. The cells with pressure transducers reached a pressure of 20 psia before reaching the voltage limit of 1.550 volts during the pressure versus capacity test, and exhibited a pressure decay of 2 psia during the last 30 minutes of the 1 hour open circuit stand. Average capacity was 51.3 ampere hours.

Harkness, J. D.↗

NASA NTRS1981

Nickel hydrogen cell tests

Some parametric tests followed by cycling tests are described for the characterization of the service life of nickel hydrogen cells. Three cells were automatically cycled in simulated low Earth orbit in 35 minute discharge, 55 minute charge, with charging voltage limited, temperature compensated. The cells were mounted in a fixture that conducts heat to an aluminum baseplate. The baseplate in turn, is bounded in a temperature controlled bath to remove the heat from the mounted fixture. One cell was tested with a zircar separator, which failed after 2473 cyles. Two other cells were tested one with a zircar separator; the other with asbestos. More than 400 cycles were achieved.

Mueller, V. C.↗

NASA NTRS1980

Thin n-i-p silicon solar cell

A space solar cell concept which combines high cell output with low diffusion length damage coefficients is presented for the purpose of reducing solar cell susceptibility to degradation from the radiation environment. High resistivity n-i-p silicon solar cells ranging from upward of 83 micron-cm were exposed to AM0 ultraviolet illumination. It is shown that high resistivity cells act as extrinsic devices under dark conditions and as intrinsic devices under AM0 illumination. Resistive losses in thin n-i-p cells are found to be comparable to those in low resistivity cells. Present voltage limitations appear to be due to generation and recombination in the diffused regions.

Meulenberg, A., Jr.↗

NASA NTRS1982

NASA Redox cell stack shunt current, pumping power, and cell performance tradeoffs

The NASA Redox energy storage system is under active technology development. The hardware undergoing laboratory testing is either 310 sq. cm. or 929 sq. cm. (0.33 sq. ft. or 1.0 sq. ft. per cell active area with up to 40 individual cells connected to make up a modular cell stack. This size of hardware allows rather accurate projections to be made of the shunt power/pump power tradeoffs. The modeling studies that were completed on the system concept are reviewed along with the approach of mapping the performance of Redox cells over a wide range of flow rates and depths of discharge of the Redox solutions. Methods are outlined for estimating the pumping and shunt current losses for any type of cell and stack combination. These methods are applicable to a variety of pumping options that are present with Redox systems. The results show that a fully developed Redox system has acceptable parasitic losses when using a fixed flow rate adequate to meet the worst conditions of current density and depth of discharge. These losses are reduced by about 65 percent if variable flow schedules are used. The exact value of the overall parasitics will depend on the specific system requirements of current density, voltage limits, charge, discharge time, etc.

Hagedorn, N.↗