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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.
For abstract, see N75-14266.
A feasibility study was conducted on the design and construction of a flight-worthy replaceable battery module consisting of four 100 A.H. nickel-cadmium rechargeable cells for large manned space vehicles. The module is planned to weigh less than 43 pounds and be fully maintainable in a zero-g environment by one man without use of special tools. An active environmental control system was designed for the temperature control of the module.
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.
The present paper describes some of the results of a 100 Ah battery development program. Background, module design, cell terminal design, and other technology newly used are described. It is shown that the program led to successful production of both cell and module, and that several areas utilized new technology and contributed advances to the sealed secondary battery state-of-the-art.
A pulse charger which uses water-cooled 1000-amp transistor switches has been developed to determine empirically the best methods of rapidly charging large cells in the one- to two-volt range. The pulse charger is capable of delivering a positive current from 0 to 1000 amps and extracting a negative current from 0 to 1000 amps. The charger can supply a 1000-amp DC charge or can switch 1000 amps at a rate of 1000 Hz. Special attention is given to problems associated with rapid switching of high currents through use of transistors.
The results of tests to insure that all cells put into the life cycle program are of high quality are reported. The tests consisted of the following: phenolptalein leak tests, internal short test, charge efficiency test, and overcharge tests. The results of tests for 10 cells are tabulated.
This evaluation test program had the purpose 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. Test limits specify those values at which a cell is to be terminated from charge or discharge. Requirements are referenced to as normally expected values based on past performance of aerospace nickel-cadmium cells with demonstrated life characteristics. A requirement does not constitute a limit for discontinuance from test.
Preliminary tests were performed on 300 amphere-hour nickel-zinc cells containing the Lewis improved inorganic-organic (I/O) separator. These cells also have other design features included to optimize performance and cycle life. The tests carried out were formation tests and characteristic discharge tests. Information obtained include case temperature and maximum power delivered.
Evaluation tests of 10 nickel cadmium cells are described. Although pressures were greater than what normally was exhibited by General Electric cells in the past, it is recommended that these cells be placed on life test simulating the predicted Dynamic Explorer flight profiles.
Evaluation tests of eight nickel cadmium cells are described. Although high cell pressures were observed, it is recommended that these cells be placed on a near orbit life test.
All evaluation tests were performed at room ambient pressure and temperature, with discharges at a 2 hour rate. Tests consisted of phenolphthalein leak tests, three capacity tests, an auxiliary electrode test, a charge retention test, an internal short test, a charge efficiency test, overcharge tests, and a pressure versus capacity test. Results of the tests and recommendations for improvements in manufacturing are presented.
The tests are 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. Test limits specify those values at which a cell is to be terminated from charge or discharge. Requirements are referenced to normally expected values based on past performance of aerospace nickel-cadmium cells with demonstrated life characteristics. Recommendations for the improvement of the manufacturing processes are presented.
Three types of solid state power controllers (SSPC's) for high voltage, high power DC system applications were developed. The first type utilizes a SCR power switch. The second type employes an electromechanical power switch element with solid state commutation. The third type utilizes a transistor power switch. Significant accomplishments include high operating efficiencies, fault clearing, high/low temperature performance and vacuum operation.
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 are addressed. The Active Magnetic Particle Tracer Explorer (AMPTE) cell design was characterized and the effects of specific mission parameters on cell life were demonstrated.
Low Earth orbit cycle, synchronous orbit cycle, general performance, and vibration test results, and gas analyses are reported.
Flight data for 17,000 orbital cycles are reviewed and summarized. The nickel cadmium battery system operated without failure or abnormality. Battery trend analysis used in determining the feasibility of extending mission life is discussed. The life test data for 20% depth of discharge indicates design life requirements would be reached even at a deeper depth of discharge.