Results for “battery failure” — Page 6

NASA NTRS1995

Bending Properties of Nickel Electrodes for Nickel-Hydrogen Batteries

Recent changes in manufacturing have resulted in nickel-hydrogen batteries that fail prematurely by electrical shorting, This failure is believed to be a result of a blistering problem in the nickel electrodes. In this study the bending properties of nickel electrodes are investigated in an attempt to correlate the bending properties of the electrode with its propensity to blister. Nickel electrodes from three different batches of material were tested in both the as-received and impregnated forms. The effects of specimen curvature and position within the electrode on the bending strength were studied, and within-electrode and batch-to-batch variations were addressed. Two color-imaging techniques were employed to differentiate between the phases within the electrodes. These techniques aided in distinguishing the relative amounts of nickel hyroxide surface loading on each electrode, thereby relating surface loading to bend strength. Bend strength was found to increase with the amount of surface loading.

Lerch, Brad A.↗

NASA NTRS1999

Nickel-Hydrogen Cell Testing Experience, NASA/Goddard Space Flight Center

The objectives of the project were to test the Nickel-Hydrogen Cell to: (1) verify the Aerospace Cell Flight Worthiness, (2) Elucidate the Aerospace Cell Thermal Behavior, (3) Develop the Aerospace Battery Assembly Design(s) and In-orbit Battery Management plan(s) and (4) Understand the Aerospace Cell Failure Mechanism. The tests included the LEO and GEO Life cycle tests, Calorimetric Analysis, Destructive Physical analysis, and special tests. Charts show the Mission Profile Cycling Data, Stress Cycling Data. The test data complies with the mission requirements, validating the flight worthiness of batteries. The nominal stress and mission profile cycling performance test shows the charge voltage as high as 1.60V and recharge ratio greater than 1.05. It is apparent that the electrochemical signatures alone do not provide conclusive proof for Nickel precharge. The researchers recommend a gas and positive plate analyses for further confirmation.

Rao, Gopalakrishna M.↗

NASA NTRSDate not supplied

Probability of Obstacle Collision for UAVs in Presence of Wind

For incorporation of unmanned aerial vehicles into the National Airspace, ensuring safety of the airspace including the vehicles, people, and property on the ground is of utmost importance. One of the safety-critical factors for unmanned aviation flights is the risk of deviating from a planned trajectory resulting in a variety of hazards, including potential loss of separation between vehicle and obstacles or unexpected battery energy consumption. Off-nominal conditions introduced by component failures, degraded controllability and environmental disturbances such as wind gusts can lead to unacceptable unexpected deviations from the flight trajectory. It is essential to accurately model such effects on the flight trajectory while computing safety thresholds such as minimum separation from surrounding obstacles, available battery resource to complete the mission or determining delay in the expected time of arrival of flights. In this paper, a tool is presented based on Gaussian Process Regression for wind representation over a pre-defined trajectory for fast, yet approximated, in-time evaluation of possible trajectory deviations caused by wind gusts. The deviation in the planned trajectory caused by wind is further simulated utilizing a 6 degrees-of-freedom (DOF) UAV trajectory simulator comprising of a rotorcraft lumped-mass model with LQRI controller. Both steady-state wind and wind gust effects are investigated. The probability of collision with obstacle is computed and demonstrated on real flight data from experimental flights of an octocopter at NASA Langley Research Center in the presence of simulated obstacles and wind conditions. Effect of varying wind conditions and varying UAV airspeed is further demonstrated on experimental flights in the presence of wind measured by ground based weather service stations. The proposed approach would eventually benefit timely mitigation of current and future safety-critical events in autonomous systems by enabling risk-informed decision making.

Portia Banerjee↗

NASA NTRS2021

Design and Development of Nano-electro Fuel Batteries and Rim-driven Motors for Electrified Aircraft Applications

The National Aeronautics and Space Administration Convergent Aeronautics Solutions project seeks to determine feasibility of emerging technologies in aeronautics. The Aqueous, QUick-Charging Battery Integration For Electric flight Research study pursued the feasibility of nano-electro fuel and rim-driven motor technologies integrated together for aircraft implementation. Development of the NEF technology was in partnership with Influit Energy, LLC (Chicago, Illinois). A rim-driven motor, designed by the project team, sized to represent one of 24 motors in the propulsion system of the tandem electric super-short takeoff and landing aircraft is discussed. The development of this electric super-short takeoff and landing concept was in partnership with The Boeing Company (Chicago, Illinois). The integrated system design of the nano-electro fuel and rim-driven motor technologies within the wing section was in partnership with Empirical Systems Aerospace, Inc. (ESAero) (San Luis Obispo, California). The feasibility benchmark for the nano-electro fuel battery was to attain 100 mA/sq. cm within two years, a 50-fold increase over the demonstrated cell performance before the Convergent Aeronautics Solutions Aqueous, QUick-Charging Battery Integration For Electric flight Research activity. The team achieved 85 mA/sq. cm in the nano-electro fuel flow cell at the end of the two years. The Aqueous, QUick-Charging Battery Integration For Electric flight Research project team determined the technology to be both inflammable and nonexplosive (unless multiple, simultaneous system failures occur) which would provide a safer alternative to conventional lithium-ion based battery systems.

Kurt V. Papathakis↗

NASA NTRSDate not supplied

Development of Aluminum/Air Battery as High-Capacity Primary Battery Energy Source for SUSAN Electrofan Project

High-capacity, high-performance, and safe battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. These battery technologies, including both secondary (i.e., rechargeable) batteries for hybrid/electric propulsion and primary batteries (i.e. non-rechargeable or single-use) for backup/emergency use in case of turbine engine failure, are important and vital components in SUSAN concept design. This paper is focused on aluminum (Al)-air battery, which is considered to be the most promising candidate to meet the energy goal of primary batteries for SUSAN project. However, there are challenges for Al-air batteries, including aluminum self-corrosion with hydrogen (H2) gassing and sluggish kinetics of oxygen reduction reaction (ORR) in air-cathode. In this paper, the preliminary results on investigation of electrolytes and additives on controlling aluminum self-corrosion/H2 gassing suppression and the study of air-cathode design for ORR improvement are presented and discussed.

James Wu↗

NASA NTRS1985

High discharge rate characteristics of nickel-cadmium batteries for pulse load filtering

Several tests of specially fabricated nickel-cadmium batteries having circular disk type electrodes were considered. These batteries were evaluated as filter elements between a constant current power supply and a five hertz pulsed load demanding approximately twice the power supply current during the load on portion of the cycle. Short tests lasting 10,000 cycles were conducted at up to a 21 C rate and an equivalent energy density of over 40 Joules per pound. In addition, two batteries were subjected to 10 to the 7 charge/discharge cycles, one at a 6.5 C rate and the other at a 13 C rate. Assuming an electrode to battery weight ratio of 0.5, these tests represent an energy density of about 7 and 14 Joules per pound respectively. Energy density, efficiency, capacitance, average voltage, and available capacity were tracked during these tests. After 10 to the 7 cycles, capacity degradation was negligible for one battery and about 20% for the other. Cadmium electrode failure may be the factor limiting lifetime at extremely low depth of discharge cycling. The output was examined and a simple equivalent circuit was proposed.

Gearing, G. M.↗

NASA NTRS1987

A knowledge-based system for monitoring the electrical power system of the Hubble Space Telescope

The design and the prototype for the expert system for the Hubble Space Telescope's electrical power system are discussed. This prototype demonstrated the capability to use real time data from a 32k telemetry stream and to perform operational health and safety status monitoring, detect trends such as battery degradation, and detect anomalies such as solar array failures. This prototype, along with the pointing control system and data management system expert systems, forms the initial Telemetry Analysis for Lockheed Operated Spacecraft (TALOS) capability.

Eddy, Pat↗

NASA NTRS1991

Evaluation of advanced NiCd cell designs for NASA applications

It is pointed out that an advanced NiCd cell based on a Hughes Aircraft Company design appears to show the most promise in the current generation of aerospace NiCd batteries. The cell was designed to ameliorate the major failure mechanisms of NiCd cells. This required cell design and process modifications and the use of alternate materials for some of the components (the most notable one being the substitution of zirconia cloth for nylon as the separator material). Recent reports in the literature indicate that the improvement in the performance of this technology appears to have been verified for GEO (geosynchronous)-type applications. The authors report on initial results of the evaluation of the advanced NiCd technology for applications of interest to NASA. They summarize the characteristics of cells based on the advanced technology from the time of manufacture to their current cell cycling status.

Di Stefano, S.↗

NASA NTRS2017

Materials Processes (MP) Engineering Internship Projects

This poster illustrates my major and minor projects worked on during my entire time interning at KSC in the Materials Science Branch. My major projects consist of three Failure Analyses, a research project on Magnesium Alloys, and the manufacturing and mechanical testing of the Advanced Plant Habitat. My three Failure Analyses are Umbilical Testing Ground Plates, Lithium Ion Battery Locking Spring Blade, and a Liquid Oxygen Poppet.

Tomsik, Elizabeth↗

NASA NTRS2016

An Influenced Future

Phobos is a vital precursor and catalyst before our next giant leap to Mars. The principle period of a Phobos' mission could be a series of robotic precursor missions for experimental perception, soil examination, ecological approval and landing site distinguishing proof. For my summer intern position at Johnson Space Center I chipped away at creating a GUNNS (General Use Nodal Network Solver) based power subsystem model for the miniATHLETE hopper, which is a conceptual (idea-based) robotic lander that will operate on Phobos. Keeping in mind the end goal to begin on my venture, I needed to comprehend my undertaking before whatever else, in which I concentrated on C++ to see how to implement the code that GUNNS generates to a Trick S_define file. Prior to coming to this internship at Johnson Space Center Dr. Edwin Zack Crues provided a class on modeling and simulation, which introduced me to the Trick simulation environment. The goal of my project was to develop a GUNNS based power subsystem model for the miniATHLETE hopper. The model needed to incorporate a solar array, battery, hopping legs, and onboard scientific instruments (sensitive measuring/recording devices). The secondary bonus goal after I completed the electrical aspect of my model was to develop a GUNNS based thermal subsystem model for the miniATHLETE hopper. Stringing the two aspects together, I would need to code up a signal aspect to make the system work as one. Accomplishing my goals would not be an easy thing, however I had successfully completed the electrical aspect model with twenty-four servos, six cameras, and multiple sensors. Venturing to complete my project has eluded me to many failures in my design to tune many things like the battery to the proper voltage and the load to the proper wattage. During this time I had touched up on advanced topics in calculus in which I implemented in the converter in my electrical model. I am currently working with my mentor Zu Qun Li to create a signal aspect to control the temperatures inside my electrical aspect model. During my time at JSC I had effectively figured out how to create subsystem models utilizing Trick and GUNNS. I obtain essential knowledge of power and thermal subsystem design for a robotic vehicle. I also learned how to work and communicate in a team effectively to accomplish a goal. Before coming to Johnson Space Center my future career and educational goals included uncertainty, however now I have a completely new look on my path to a prosperous future. My NASA experience has unquestionably impacted me to accomplish and surpass my own particular desires. After my time at Johnson Space Center I plan to apply for a coop position for NASA. This has been a dream come true that I adored each moment being at JSC realizing that I am far fit for doing things most individuals can just long for.

Owens, Christopher↗

NASA NTRSDate not supplied

Flight Deck Design of a Hybrid Turbine/Electric Passenger Aircraft

NASA is exploring the development of a 180-passenger subsonic single engine aft turbine aircraft, The aft turbine provides electric power in a hybrid design to wing mounted electric engines, creating a highly efficient, high-bypass-ratio fan equivalent. The SUbsonic Single Aft eNgine (SUSAN) aircraft is being developed as a sustainable subsonic regional aircraft that seeks to reduce emission levels by 50% in the next few decades. Pilot-in-the-loop studies were conducted at the NASA Langley Research Center in Hampton, Virginia, to explore the flight deck design for the hybrid electric aircraft. Following modern trends in commercial aircraft flight decks with full time augmented controls and a quiet and dark philosophy, single throttle and simplified engine displays were developed for the SUSAN aircraft. The aircraft includes a single aft mounted turbine engine and 16 wing mounted electric fans. The final design was developed from feedback received during an earlier pilot-in-the-loop study where one, two, and three throttles were tested in standard airline operations, including various failures of the turbine and electric engines. Current flight deck designs normally provide control inceptors for each propulsion engine and an engine display for all primary aircraft engine parameters. With full time augmentation expected, a single throttle control with autothrottle always engaged, even during failures, is desired. Augmentation of flight controls using distributed thrust also requires full time control of the electric engines using automation. Additionally, electric engine thrust is augmented during climb based on battery state of charge. Thrust augmentation changes faster than human reaction time and therefore requires full-time automation. A pilot-in-the-loop study was conducted at the NASA Langley Research Center in Hampton, Virginia, to test the final design of the single throttle with simplified engine displays. Fourteen airline pilots evaluated the single throttle and engine display concept. Electric engine failures included one, four symmetric, and eight non-symmetric electric engine failures. The turbine engine was evaluated for complete and partial failure during critical phases of flight to include takeoff as well as enroute. Unexpected go-arounds increase workload and require significant throttle manipulation. Go-arounds were included to ensure the single throttle was usable for all phases of flight. Failures during takeoff required a return to the departure field and failures enroute required a diversion except for one and four electric engine failures as these failures did not affect aircraft flyability or range. There are currently no Part 25 aircraft certified with hybrid systems or electric engines with batteries as emergency propulsion. For turbine engine failures in the SUSAN aircraft design, range is limited to 30 minutes at full power. Battery state of charge and battery health displays were developed and tested for usability and to determine how well they supported pilot decisions for alternate airports during emergency diversions. Novel displays using shape and color were developed to provide immediate feedback when state of charge became critical. This paper details the pilot study including pilot feedback supporting the potential for increased automation and a single throttle control. Detailed recommendations are provided for a novel single throttle control and additional pilot controls to support selection of engines during start, shutdown, and engine troubleshooting procedures. This design deviates significantly from current practice of providing throttles for each propulsion engine. Engine display recommendations are provided based on pilot feedback during a guided post-evaluation interview. Battery state of charge and battery health display recommendations were collected from all airline crews. The simplified engine displays design was rated excellent as measured with a usability scale. Quantitative metrics include airspeed tracking, time to complete checklists, time to make diversion decisions and the quality of the diversion decision. Recommendations for future studies are documented with supporting research and current observations about upcoming flight deck certifications.

autothrottle↗

NASA NTRSDate not supplied

Flight Deck Design of a Hybrid Turbine/Electric Passenger Aircraft

NASA is exploring the development of a 180-passenger subsonic single engine aft turbine aircraft, The aft turbine provides electric power in a hybrid design to wing mounted electric engines, creating a highly efficient, high-bypass-ratio fan equivalent. The SUbsonic Single Aft eNgine (SUSAN) aircraft is being developed as a sustainable subsonic regional aircraft that seeks to reduce emission levels by 50% in the next few decades. Pilot-in-the-loop studies were conducted at the NASA Langley Research Center in Hampton, Virginia, to explore the flight deck design for the hybrid electric aircraft. Following modern trends in commercial aircraft flight decks with full time augmented controls and a quiet and dark philosophy, single throttle and simplified engine displays were developed for the SUSAN aircraft. The aircraft includes a single aft mounted turbine engine and 16 wing mounted electric fans. The final design was developed from feedback received during an earlier pilot-in-the-loop study where one, two, and three throttles were tested in standard airline operations, including various failures of the turbine and electric engines. Current flight deck designs normally provide control inceptors for each propulsion engine and an engine display for all primary aircraft engine parameters. With full time augmentation expected, a single throttle control with autothrottle always engaged, even during failures, is desired. Augmentation of flight controls using distributed thrust also requires full time control of the electric engines using automation. Additionally, electric engine thrust is augmented during climb based on battery state of charge. Thrust augmentation changes faster than human reaction time and therefore requires full-time automation. A pilot-in-the-loop study was conducted at the NASA Langley Research Center in Hampton, Virginia, to test the final design of the single throttle with simplified engine displays. Fourteen airline pilots evaluated the single throttle and engine display concept. Electric engine failures included one, four symmetric, and eight non-symmetric electric engine failures. The turbine engine was evaluated for complete and partial failure during critical phases of flight to include takeoff as well as enroute. Unexpected go-arounds increase workload and require significant throttle manipulation. Go-arounds were included to ensure the single throttle was usable for all phases of flight. Failures during takeoff required a return to the departure field and failures enroute required a diversion except for one and four electric engine failures as these failures did not affect aircraft flyability or range. There are currently no Part 25 aircraft certified with hybrid systems or electric engines with batteries as emergency propulsion. For turbine engine failures in the SUSAN aircraft design, range is limited to 30 minutes at full power. Battery state of charge and battery health displays were developed and tested for usability and to determine how well they supported pilot decisions for alternate airports during emergency diversions. Novel displays using shape and color were developed to provide immediate feedback when state of charge became critical. This paper details the pilot study including pilot feedback supporting the potential for increased automation and a single throttle control. Detailed recommendations are provided for a novel single throttle control and additional pilot controls to support selection of engines during start, shutdown, and engine troubleshooting procedures. This design deviates significantly from current practice of providing throttles for each propulsion engine. Engine display recommendations are provided based on pilot feedback during a guided post-evaluation interview. Battery state of charge and battery health display recommendations were collected from all airline crews. The simplified engine displays design was rated excellent as measured with a usability scale. Quantitative metrics include airspeed tracking, time to complete checklists, time to make diversion decisions and the quality of the diversion decision. Recommendations for future studies are documented with supporting research and current observations about upcoming flight deck certifications.

autothrottle↗

NASA NTRS2019

Short Course on Lithium-Ion Batteries: Fundamental Concepts, Battery Safety, and Modeling Techniques

When developing this course several years back I asked myself, "What do I think the TFAWS community needs to know about lithium-ion batteries and why should they care?" I think the answers to these questions can be boiled down to the following statements: 1. Lithium-ion (Li-ion) battery electrical performance and efficiency are heavily driven by thermal conditions. 2. Li-ion battery assemblies can experience single cell thermal runaway events which can lead to cell-to-cell propagation; these are thermally driven failure events that can be controlled with effective thermal management systems. 3. Knowledge of BOTH Li-ion battery fundamentals AND traditional thermal design principles are required to develop safe battery assemblies that are both gravimetrically and volumetrically optimized.This year the Short Course on Lithium-ion Batteries will be presented in a 2-part series. The first portion, "Fundamentals, Battery Safety, and Thermal Runaway," will focus on educating participants on the fundamental aspects of Li-ion batteries and on battery safety related topics (i.e. thermal runaway, cell-to-cell propagation, safe handling practices, et...). The second portion, "Practical Thermal Simulation Techniques," will provide participants with a real time demonstration of how to use Thermal Desktop to model of Li-ion battery assemblies. This part of the lesson will cover geometry simplification, mesh development, boundary conditions, and heat loads for both nominal operations (charge and discharge) and for thermal runaway events.

Walker, William↗

NASA NTRS1980

Cycles till failure of silver-zinc cells with completing failures modes: Preliminary data analysis

One hundred and twenty nine cells were run through charge-discharge cycles until failure. The experiment design was a variant of a central composite factorial in five factors. Preliminary data analysis consisted of response surface estimation of life. Batteries fail under two basic modes; a low voltage condition and an internal shorting condition. A competing failure modes analysis using maximum likelihood estimation for the extreme value life distribution was performed. Extensive diagnostics such as residual plotting and probability plotting were employed to verify data quality and choice of model.

Sidik, S. M.↗

NASA NTRS2009

Modular Battery Charge Controller

A new approach to masterless, distributed, digital-charge control for batteries requiring charge control has been developed and implemented. This approach is required in battery chemistries that need cell-level charge control for safety and is characterized by the use of one controller per cell, resulting in redundant sensors for critical components, such as voltage, temperature, and current. The charge controllers in a given battery interact in a masterless fashion for the purpose of cell balancing, charge control, and state-of-charge estimation. This makes the battery system invariably fault-tolerant. The solution to the single-fault failure, due to the use of a single charge controller (CC), was solved by implementing one CC per cell and linking them via an isolated communication bus [e.g., controller area network (CAN)] in a masterless fashion so that the failure of one or more CCs will not impact the remaining functional CCs. Each micro-controller-based CC digitizes the cell voltage (V(sub cell)), two cell temperatures, and the voltage across the switch (V); the latter variable is used in conjunction with V(sub cell) to estimate the bypass current for a given bypass resistor. Furthermore, CC1 digitizes the battery current (I1) and battery voltage (V(sub batt) and CC5 digitizes a second battery current (I2). As a result, redundant readings are taken for temperature, battery current, and battery voltage through the summation of the individual cell voltages given that each CC knows the voltage of the other cells. For the purpose of cell balancing, each CC periodically and independently transmits its cell voltage and stores the received cell voltage of the other cells in an array. The position in the array depends on the identifier (ID) of the transmitting CC. After eight cell voltage receptions, the array is checked to see if one or more cells did not transmit. If one or more transmissions are missing, the missing cell(s) is (are) eliminated from cell-balancing calculations. The cell-balancing algorithm is based on the error between the cell s voltage and the other cells and is categorized into four zones of operation. The algorithm is executed every second and, if cell balancing is activated, the error variable is set to a negative low value. The largest error between the cell and the other cells is found and the zone of operation determined. If the error is zero or negative, then the cell is at the lowest voltage and no balancing action is needed. If the error is less than a predetermined negative value, a Cell Bad Flag is set. If the error is positive, then cell balancing is needed, but a hysteretic zone is added to prevent the bypass circuit from triggering repeatedly near zero error. This approach keeps the cells within a predetermined voltage range.

Button, Robert↗

NASA NTRS1969

Analysis and evaluation of spacecraft battery life test data /phase 2/ Summary report

Nickel-cadmium spacecraft battery cell life tests with reliability analysis of acceptance data and failure analysis

Kent, J. R.↗

NASA NTRS1981

FSA field test

The 12 continental remote sites were decommissioned. Testing was consolidated into a five-site network consisting of the four Southern California sites and a new Florida site. 16 kW of new state-of-the-art modules were deployed at the five sites. Testing of the old modules continued at the Goldstone site but as a low-priority item. Array testing of modules is considered. Additional new testing capabilities were added. A battery-powered array data logger is discussed. A final set of failure and degradation data was obtained from the modules.

Jaffe, P.↗

NASA NTRS1985

Automatic Monitoring of Switching Power Supplies

Fast analysis of switching waveforms allows detection of impending failures. Switching power conditioner converts dc power from source such as battery or solar cell array to well regulated dc at convenient voltages and currents. Concept originally developed for space stations and spacecraft also suitable for power conditioning equipment in aircraft and in terrestrial photovoltaic power systems.

Moser, R. L.↗