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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 NTRS1996

Advanced Welding Torch

In order to more easily join the huge sections of the Space Shuttle external tank, Marshall Space Flight Center initiated development of the existing concept of Variable Polarity Plasma Arc (VPPA) welding. VPPA welding employs a variable current waveform that allows the system to operate for preset time increments in either of two polarity modes for effective joining of light alloys. Marshall awarded the torch contract to B & B Precision Machine, which produced a torch for the Shuttle, then automated the system, and eventually delivered a small torch used by companies such as Whirlpool for sheet metal welding of appliance parts and other applications. The dependability of the torch offers cost and time advantages.

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NASA NTRS1994

Analysis Software

General Purpose Boundary Element Solution Technology (GPBEST) software employs the boundary element method of mechanical engineering analysis, as opposed to finite element. It is, according to one of its developers, 10 times faster in data preparation and more accurate than other methods. Its use results in less expensive products because the time between design and manufacturing is shortened. A commercial derivative of a NASA-developed computer code, it is marketed by Best Corporation to solve problems in stress analysis, heat transfer, fluid analysis and yielding and cracking of solids. Other applications include designing tractor and auto parts, household appliances and acoustic analysis.

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NASA NTRS2002

Powering the Future

Stirling Technology Company (STC) developed the RG-350 convertor using components from separate Goddard Space Center and U.S. Army Natick SBIR contracts. Based on the RG-350, STC commercialized a product line of Stirling cycle generator sets, known as RemoteGen(TM), with power levels ranging from 10We to 3kWe. Under SBIR agreements with Glenn Research Center, the company refined and extended the capabilities of the RemoteGen convertors. They can provide power in remote locations by efficiently producing electricity from multiple-fuel sources, such as propane, alcohol, gasoline, diesel, coal, solar energy, or wood pellets. Utilizing any fuel source that can create heat, RemoteGen enables the choice of the most appropriate fuel source available. The engines operate without friction, wear, or maintenance. These abilities pave the way for self-powered appliances, such as refrigerators and furnaces. Numerous applications for RemoteGen include quiet, pollution-free generators for RVs and yachts, power for cell phone towers remote from the grid, and off-grid residential power variously using propane, ethanol, and solid biomass fuels. One utility and the National Renewable Energy Laboratory are evaluating a solar dish concentrator version with excellent potential for powering remote irrigation pumps.

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NASA NTRS1989

Invisible Braces

Ceradyne, Inc., and 3M Unitek were assisted in the development of Ceramic braces by NIAC/USC. The braces are marketed by Unitek/3M, and are made from translucent polycrystalline alumina (TPA). They are designed for each tooth, connected by a thin metal wire, are strong, aesthetically appealing and as effective clinically as plastic or metal appliances.

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NASA NTRS1984

Portable Welder

A low cost, low power, self-contained portable welding gun designed for joining thermoplastics which become soft when heated and harden when cooled was developed originally by NASA's Langley Research Center for repairing helicopter windshields. Welder has a broad range of applications for joining both thermoplastic materials in the aerospace, automotive, appliance, and construction industries. Welders portability and low power requirement allow its use on-site in any type of climate, with power supplied by a variety of portable sources.

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NASA NTRS1982

Advanced Welding Tool

Accutron Tool & Instrument Co.'s welder was originally developed as a tool specifically for joining parts made of plastic or composite materials in any atmosphere to include the airless environment of space. Developers decided on induction or magnetic heating to avoid causing deformation and it also can be used with almost any type of thermoplastic material. Induction coil transfers magnetic flux through the plastic to a metal screen that is sandwiched between the sheets of plastic to be joined. When welder is energized, alternating current produces inductive heating on the screen causing the adjacent plastic surfaces to melt and flow into the mesh, creating a bond on the total surface area. Dave Brown, owner of Great Falls Canoe and Kayak Repair, Vienna, VA, uses a special repair technique based on operation of the Induction Toroid Welder to fix canoes. Whitewater canoeing poses the problem of frequent gashes that are difficult to repair. The main reason is that many canoes are made of plastics. The commercial Induction model is a self-contained, portable welding gun with a switch on the handle to regulate the temperature of the plastic melting screen. Welder has a broad range of applications in the automobile, appliance, aerospace and construction industries.

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NASA NTRS1982

Computer Technology for Industry

Shell Oil Company used a COSMIC program, called VISCEL to insure the accuracy of the company's new computer code for analyzing polymers, and chemical compounds. Shell reported that there were no other programs available that could provide the necessary calculations. Shell produces chemicals for plastic products used in the manufacture of automobiles, housewares, appliances, film, textiles, electronic equipment and furniture.

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NASA NTRS2001

NASA Fire Protection Coordinators' Conference

Fire prevention activities at NASA's Stennis Space Center are reviewed in this viewgraph presentation. The Fire Prevention Office of the Fire Department at NASA Stennis conducts inspections and issues small appliance permits, while the Operations Section responds to emergencies.

Clark, Theodore↗

NASA NTRS2004

Design and Experimental Verification of Deployable/Inflatable Ultra-Lightweight Structures

Because launch cost of a space structural system is often proportional to the launch volume and mass and there is no significant gravity in space, NASA's space exploration programs and various science missions have stimulated extensive use of ultra-lightweight deployable/inflatable structures. These structures are named here as Highly Flexible Structures (HFSs) because they are designed to undergo large displacements, rotations, and/or buckling without plastic deformation under normal operation conditions. Except recent applications to space structural systems, HFSs have been used in many mechanical systems, civil structures, aerospace vehicles, home appliances, and medical devices to satisfy space limitations, provide special mechanisms, and/or reduce structural weight. The extensive use of HFSs in today's structural engineering reveals the need of a design and analysis software and a database system with design guidelines for practicing engineers to perform computer-aided design and rapid prototyping of HFSs. Also to prepare engineering students for future structural engineering requires a new and easy-to- understand method of presenting the complex mathematics of the modeling and analysis of HFSs. However, because of the high flexibility of HFSs, many unique challenging problems in the modeling, design and analysis of HFSs need to be studied. The current state of research on HFSs needs advances in the following areas: (1) modeling of large rotations using appropriate strain measures, (2) modeling of cross-section warpings of structures, (3) how to account for both large rotations and cross- section warpings in 2D (two-dimensional) and 1D structural theories, (4) modeling of thickness thinning of membranes due to inflation pressure, pretension, and temperature change, (5) prediction of inflated shapes and wrinkles of inflatable structures, (6) development of efficient numerical methods for nonlinear static and dynamic analyses, and (7) filling the gap between geometrically exact elastic analysis and elastoplastic analysis. The objectives of this research project were: (1) to study the modeling, design, and analysis of deployable/inflatable ultra-lightweight structures, (2) to perform numerical and experimental studies on the static and dynamic characteristics and deployability of HFSs, (3) to derive guidelines for designing HFSs, (4) to develop a MATLAB toolbox for the design, analysis, and dynamic animation of HFSs, and (5) to perform experiments and establish an adequate database of post-buckling characteristics of HFSs.

Pai, P. Frank↗

NASA NTRS2004

Nickel-Hydrogen and Lithium Ion Space Batteries

The tasks of the Electrochemistry Branch of NASA Glenn Research Center are to improve and develop high energy density and rechargeable, life-long batteries. It is with these batteries that people across the globe are able to power their cell phones, laptop computers, and cameras. Here, at NASA Glenn Research Center, the engineers and scientists of the Electrochemistry branch are leading the way in the development of more powerful, long life batteries that can be used to power space shuttles and satellites. As of now, the cutting edge research and development is being done on nickel-hydrogen batteries and lithium ion batteries. Presently, nickel-hydrogen batteries are common types of batteries that are used to power satellites, space stations, and space shuttles, while lithium batteries are mainly used to power smaller appliances such as portable computers and phones. However, the Electrochemistry Branch at NASA Glenn Research Center is focusing more on the development of lithium ion batteries for deep space use. Because of the limitless possibilities, lithium ion batteries can revolutionize the space industry for the better. When compared to nickel-hydrogen batteries, lithium ion batteries possess more advantages than its counterpart. Lithium ion batteries are much smaller than nickel-hydrogen batteries and also put out more power. They are more energy efficient and operate with much more power at a reduced weight than its counterpart. Lithium ion cells are also cheaper to make, possess flexibility that allow for different design modifications. With those statistics in hand, the Electrochemistry Branch of NASA Glenn has decided to shut down its Nickel-Hydrogen testing for lithium ion battery development. Also, the blackout in the summer of 2003 eliminated vital test data, which played a part in shutting down the program. from the nickel-hydrogen batteries and compare it to past data. My other responsibilities include superheating the electrolyte that is used in the nickel-hydrogen cell in a calorimeter to test its performance under various conditions. 1 used a program called Arbin to study my data. The Arbin allows me to look at different parameters such as pressure and time and how they affect the changing temperature of the electrolyte that is being tested. In addition, I had the responsibility of taking apart and modifying battery coolers that would be used. My mentors told me that the batteries kept shutting down, so it was my responsibility to remove excess fan grilles, rotate the fans, and then switch the aluminum standoffs with nylon ones so that the coolers could operate without problems. My last task is to collect all the battery test data and organize them into charts using Microsoft Excel, before the Branch is able to conduct its research on lithium ion batteries. Therefore, during my tenure, it is my responsibility to take down final test data

Reid, Robert O., II↗

NASA NTRS2002

Commercial-Off-The-Shelf Microelectromechanical Systems (MEMS) Flow-Measurement Probes Fabricated And Assembled

As an alternative to conventional tubing instrumentation for measuring airflow, designers and technicians at the NASA Glenn Research Center have been fabricating packaging components and assembling a set of unique probes using commercial-off-the-shelf microelectromechanical systems (MEMS) integrated circuits (computer chips). Using MEMS as an alternative has some compelling advantages over standard measurement devices. Sensor technologies have matured through high-production usage in industries such as automotive and aircraft manufacturers. Currently, MEMS are the choice in applications such as tire pressure monitors, altimeters, pneumatic controls, cable leak detectors, and consumer appliances. Conventional instrumentation uses tubing buried in the model aerodynamic surfaces or wind tunnel walls. The measurements are made when pressure is introduced at the tube opening. The pressure then must travel the tubing for lengths ranging from 20 to hundreds of feet before reaching an electronic signal conditioner. This condition causes a considerable amount of damping and requires measurements to be made only after the test rig has reached steady-state operation. The electronic MEMS pressure sensor is able to take readings continuously under dynamic states in nearly real time. The use of stainless steel tubing for pressure measurements requires many tubes to be cleaned, cut to length, carefully installed, and delicately deburred and spliced for use. A cluster of a few hundred 1/16-in.- (0.0625-in.-) diameter tubes (not uncommon in research testing facilities) can be several inches in diameter and may weigh enough to require two men to handle. Replacing hard tubing with electronic chips can eliminate much of the bulk. Each sensor would fit on the tip of the 1/16-in. tubing with room to spare. The P592 piezoresistive silicon pressure sensor (Lucas NovaSensor, Fremont, CA) was chosen for this project because of its cost, availability, and tolerance to extreme ambient conditions. The chip is 1 mm square by 0.6 mm thick (0.039 by 0.023 in.) with 0.12-mm (0.005-in.) wire connection tabs. Three MEMS chips were used to build the first type of flow-angularity probe. This MEMS probe will be demonstrated as an alternative to a standard tube type "Cobra Probe" now used routinely in wind tunnel and aeronautical hardware applications. The response time and accuracy would allow the probe to be translated on an actuator across a flow field, yielding precision dynamic measurements not possible with conventional instrumentation. The low profile, the minimal power requirement, the rugged construction, and the moderate cost all contribute to making MEMS sensors the enticing choice instrument in future research measurement needs. The MEMS probe efforts are a continuation of work initiated by Brian Willis, without whose foresight and efforts this project would never have been realized. This task was funded through cooperation with the NASA Electronic Parts and Packaging (NEPP) program at the Jet Propulsion Laboratory.

Redding, Chip↗

NASA NTRS2005

Lithium-Ion Batteries Being Evaluated for Low-Earth-Orbit Applications

The performance characteristics and long-term cycle life of aerospace lithium-ion (Li-ion) batteries in low-Earth-orbit applications are being investigated. A statistically designed test using Li-ion cells from various manufacturers began in September 2004 to study the effects of temperature, end-of-charge voltage, and depth-of-discharge operating conditions on the cycle life and performance of these cells. Performance degradation with cycling is being evaluated, and performance characteristics and failure modes are being modeled statistically. As technology improvements are incorporated into aerospace Li-ion cells, these new designs can be added to the test to evaluate the effect of the design changes on performance and life. Cells from Lithion and Saft have achieved over 2000 cycles under 10 different test condition combinations and are being evaluated. Cells from Mine Safety Appliances (MSA) and modules made up of commercial-off-the-shelf 18650 Li-ion cells connected in series/parallel combinations are scheduled to be added in the summer of 2005. The test conditions include temperatures of 10, 20, and 30 C, end-of-charge voltages of 3.85, 3.95, and 4.05 V, and depth-of-discharges from 20 to 40 percent. The low-Earth-orbit regime consists of a 55 min charge, at a constant-current rate that is 110 percent of the current required to fully recharge the cells in 55 min until the charge voltage limit is reached, and then at a constant voltage for the remaining charge time. Cells are discharged for 35 min at the current required for their particular depth-of-discharge condition. Cells are being evaluated in four-cell series strings with charge voltage limits being applied to individual cells by the use of charge-control units designed and produced at the NASA Glenn Research Center. These charge-control units clamp the individual cell voltages as each cell reaches its end-of-charge voltage limit, and they bypass the excess current from that cell, while allowing the full current flow to the remaining cells in the pack. The goal of this evaluation is to identify conditions and cell designs for Li-ion technology that can achieve more than 30,000 low-Earth-orbit cycles. Testing is being performed at the Naval Surface Warfare Center, Crane Division, in Crane, Indiana.

McKissock, Barbara I.↗

NASA NTRS2006

Adaptive Inner-Loop Rover Control

Adaptive control technology is developed for the inner-loop speed and steering control of the MAX Rover. MAX, a CMU developed rover, is a compact low-cost 4-wheel drive, 4-wheel steer (double Ackerman), high-clearance agile durable chassis, outfitted with sensors and electronics that make it ideally suited for supporting research relevant to intelligent teleoperation and as a low-cost autonomous robotic test bed and appliance. The design consists of a feedback linearization based controller with a proportional - integral (PI) feedback that is augmented by an online adaptive neural network. The adaptation law has guaranteed stability properties for safe operation. The control design is retrofit in nature so that it fits inside the outer-loop path planning algorithms. Successful hardware implementation of the controller is illustrated for several scenarios consisting of actuator failures and modeling errors in the nominal design.

Kulkarni, Nilesh↗

NASA NTRS1978

Shock Prevention

The electrician pictured is installing a General Electric Ground Fault Interrupter (GFI), a device which provides protection against electrical shock in the home or in industrial facilities. Shocks due to defective wiring in home appliances or other electrical equipment can cause severe burns, even death. As a result, the National Electrical Code now requires GFIs in all new homes constructed. This particular type of GFI employs a sensing element which derives from technology acquired in space projects by SCI Systems, Inc., Huntsville, Alabama, producer of sensors for GE and other manufacturers of GFI equipment. The sensor is based on the company's experience in developing miniaturized circuitry for space telemetry and other spacecraft electrical systems; this experience enabled SCI to package interruptor circuitry in the extremely limited space available and to produce sensory devices at practicable cost. The tiny sensor measures the strength of the electrical current and detects current differentials that indicate a fault in the functioning of an electrical system. The sensing element then triggers a signal to a disconnect mechanism in the GFI, which cuts off the current in the faulty circuit.

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NASA NTRS1979

Restoration Process

In the accompanying photos, a laboratory technician is restoring the once-obliterated serial number of a revolver. The four-photo sequence shows the gradual progression from total invisibility to clear readability. The technician is using a new process developed in an applications engineering project conducted by NASA's Lewis Research Center in conjunction with Chicago State University. Serial numbers and other markings are frequently eliminated from metal objects to prevent tracing ownership of guns, motor vehicles, bicycles, cameras, appliances and jewelry. To restore obliterated numbers, crime laboratory investigators most often employ a chemical etching technique. It is effective, but it may cause metal corrosion and it requires extensive preparatory grinding and polishing. The NASA-Chicago State process is advantageous because it can be applied without variation to any kind of metal, it needs no preparatory work and number recovery can be accomplished without corrosive chemicals; the liquid used is water.

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NASA NTRS2007

An Update on the Lithium-Ion Cell Low-Earth-Orbit Verification Test Program

A Lithium-Ion Cell Low-Earth-Orbit Verification Test Program is being conducted by NASA Glenn Research Center to assess the performance of lithium-ion (Li-ion) cells over a wide range of low-Earth-orbit (LEO) conditions. The data generated will be used to build an empirical model for Li-ion batteries. The goal of the modeling will be to develop a tool to predict the performance and cycle life of Li-ion batteries operating at a specified set of mission conditions. Using this tool, mission planners will be able to design operation points of the battery system while factoring in mission requirements and the expected life and performance of the batteries. Test conditions for the program were selected via a statistical design of experiments to span a range of feasible operational conditions for LEO aerospace applications. The variables under evaluation are temperature, depth-of-discharge (DOD), and end-of-charge voltage (EOCV). The baseline matrix was formed by generating combinations from a set of three values for each variable. Temperature values are 10 C, 20 C and 30 C. Depth-of-discharge values are 20%, 30% and 40%. EOCV values are 3.85 V, 3.95 V, and 4.05 V. Test conditions for individual cells may vary slightly from the baseline test matrix depending upon the cell manufacturer s recommended operating conditions. Cells from each vendor are being evaluated at each of ten sets of test conditions. Cells from four cell manufacturers are undergoing life cycle tests. Life cycling on the first sets of cells began in September 2004. These cells consist of Saft 40 ampere-hour (Ah) cells and Lith ion 30 Ah cells. These cells have achieved over 10,000 cycles each, equivalent to about 20 months in LEO. In the past year, the test program has expanded to include the evaluation of Mine Safety Appliances (MSA) 50 Ah cells and ABSL battery modules. The MSA cells will begin life cycling in October 2006. The ABSL battery modules consist of commercial Sony hard carbon 18650 lithium-ion cells configured in series and parallel combinations to create nominal 14.4 volt, 3 Ah packs (4s-2p). These modules have accumulated approximately 3000 cycles. Results on the performance of the cells and modules will be presented in this paper. The life prediction and performance model for Li-ion cells in LEO will be built by analyzing the data statistically and performing regression analysis. Cells are being cycled to failure so that differences in performance trends that occur at different stages in the life of the cell can be observed and accurately modeled. Cell testing is being performed at the Naval Surface Warfare Center in Crane, IN.

Reid, Concha M.↗

NASA NTRS2001

Methods of use for sensor based fluid detection devices

Methods of use and devices for detecting analyte in fluid. A system for detecting an analyte in a fluid is described comprising a substrate having a sensor comprising a first organic material and a second organic material where the sensor has a response to permeation by an analyte. A detector is operatively associated with the sensor. Further, a fluid delivery appliance is operatively associated with the sensor. The sensor device has information storage and processing equipment, which is operably connected with the device. This device compares a response from the detector with a stored ideal response to detect the presence of analyte. An integrated system for detecting an analyte in a fluid is also described where the sensing device, detector, information storage and processing device, and fluid delivery device are incorporated in a substrate. Methods for use for the above system are also described where the first organic material and a second organic material are sensed and the analyte is detected with a detector operatively associated with the sensor. The method provides for a device, which delivers fluid to the sensor and measures the response of the sensor with the detector. Further, the response is compared to a stored ideal response for the analyte to determine the presence of the analyte. In different embodiments, the fluid measured may be a gaseous fluid, a liquid, or a fluid extracted from a solid. Methods of fluid delivery for each embodiment are accordingly provided.

Lewis, Nathan S.↗