absl’s cots li-ion cell suite development 2007 nasa ... · 000074.--. absl presentation template...

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000074.--.ABSL Presentation Template

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ABSL’s COTS Li-Ion Cell Suite Development2007 NASA Battery Workshop

800011.--.ABSL’s COTS Li-Ion Cell Suite Development

Tami Max, Sales Manager720 300 8817, [email protected]

000074.--. ABSL Presentation Template


© ABSL Space Products 2007800011.--. ABSL’s COTS Li-Ion Cell Suite Development 2

Explain ABSL’s programs for identifying and qualifying Li-Ion COTS cells for space use.

Show some of the benefits this approach to space batteries provides.

Provide a briefing on the current status of ABSL’s next generation COTS cells.

Objective





ABSL Space Battery Experience




Launch Date Program Type Orbit

16 Nov 00 STRV-1c GTO

22 Oct 01 PROBA LEO

02 Jun 03 Beagle I/Planetary

02 Jun 03 Mars Express I/Planetary

02 Mar 04 Rosetta I/Planetary

02 Mar 04 Philae I/Planetary

29 Jun 04 Saudisat2 LEO

29 Jun 04 Demeter LEO

16 Dec 04 NSAT LEO

16 Dec 04 ESSAIM I, II, III, IV LEO

16 Dec 04 Parasol LEO

08 Oct 05 Cryosat LEO

09 Nov 05 Venus Express I/Planetary

28 Dec 05 GIOVE-A LEO

22 Mar 06 ST5 A, B, C GTO

19 Dec 06 SAR-Lupe 1 LEO

16 Feb 07 THEMIS I, II, III, IV, V LEO

09 Mar 07 CFESat LEO

17 Apr 07 SaudiSat3 LEO

15 Jun 07 TerraSAR-X LEO

03 Jul 07 SAR-Lupe 2 LEO

20 Jul 07 Sumbandila (ZaSat) LEO

14 Sep 07 FOTON-M3 LEO

1 Nov 07 SAR-Lupe 3 LEO

Launches Powered by ABSL Lithium Batteries

ABSL has the most launches of Li-ion batteries with 32 spacecraft powered by ABSL batteries without ANY failures




Contracts/Launches “at a glance”

6 space qualified cell (3 launched)

– Lithium-ion secondary

– Lithium primary

32 s/c launched

– LEO, MEO, GTO, HEO, Interplanetary

– Including NASA, AFRL, DOE, ESA missions

– Longest serving LEO Li-ion (6+ years, >30k cycles)

– Three 10 yr LEOs on orbit

Contracts for 80+ spacecraft and launchers

– 2 GEO launches in 2008

– 1st Launch Vehicle flight in 2008

– Many more NASA missions, MDA, AFRL, ESA…




U.S. Customers




Rest of the World Customers





The ABSL COTS Approach




Contents


The ABSL COTS Approach– What is the COTS Approach?

– Process Overview

– The Details

ABSL’s Next Generation COTS Cells




ABSL’s COTS Approach is a proven process for providing space qualified Li-Ion batteries using commercial off-the-shelf (COTS) Li-Ion Cells.– Encompasses everything from identifying candidate COTS

cells, to high fidelity design and qualification testing of space batteries.

– Mitigates the risk of using of COTS cells for space applications to provide customer confidence in the end product.

– Leverages the immense size of the commercial industry to provide cutting edge performance and security of supply.

What Is the COTS Approach?





Cell Assessment & Qualification– Identify the best COTS cells to meet future space battery needs and qualify

them to space industry standards.

The Cell Suite– Readily provide a broad range of battery capabilities and security of supply.

Lot Acceptance Testing (LAT)– Ensuring consistency of cells batch to batch, maximizing the value of

comprehensive cell characterization and life test programs.

Life Test Program– Enabling unmatched EOL performance predictions capabilities.

Standardized Battery Design, Build, & Qualification– Leveraging the consistency and predictability of ABSL’s COTS cells to

efficiently optimize and qualify battery designs for any mission.




Space Qualified Cell Suite

COTS Cell Cycle




Cell Assessment

Phase CQualification testing

Measured performance, project needs, R&D budget

Phase BPreliminary in-house testing

Reported datasheet, manufacturer, and 3rd party performance

Phase AAll cells under investigation in the Technology Watch




Phase A: Technology Watch Database




All Phase B cells are screened and assessed for consistency and build quality

Specific test regime depends on the cell, but any test is fair game: performance characterization, temperature sensitivity, safety, etc.

Phase B: In-House Testing

Lifetesting is initiated as early as possible for promising candidates

This helps identify the best future mission applications of candidate COTS cells




Phase C: Cell Qualification

Basic Parameters

Safety

Environmental

Characterization

Endurance




ABSL Cell Suite

CellEnergy Density

AttributesSpace

QualifiedSpace Proven

Space Application

ABSL18650HC 130 Wh/kgExcellent and Characterised

Cycle Life

All space programs

ABSL18650HR 100 Wh/kgVery high current

delivery >10 C2008 High Power

ABSL18650LV 174 Wh/kgHigh Energy

Density, low temp performance

Low temp, mass pushed

ABSL33111PR 450 Wh/kgHigh energy and

structural integrityPrimary batteries

ABSL 26650HC 120 Wh/kg Excellent cycle life Retired

ABSL 18650LVF 175Wh/kgHigh Energy

DensityRetired




The Cell Suite: ABSL 18650HC

Description: A proven, long-life COTS cell with excellent energy density.

Qualification: The best characterized and understood Li-Ion cell for space, qualified to a broad range of temperatures and vibration environments to meet the needs of nearly any mission.

Lifetesting: A wide range of varied parameters across both storage and operational conditions have been tested.

Heritage: 30 missions flown, and more than 6,000 cell years in space without failure

The HC cell has been employed in batteries ranging from several Ah to more than 100

Ah.

An unrivaled amount of in-house testing and flight

heritage make the HC the most predictable Li-Ion cell

available for space.




The Cell Suite: ABSL 18650HR

Description: An extremely robust, high power cell for satellites and launch vehicles.

Qualification: Focus on high rate characterization, qualified to extremely harsh temperature and vibration environments.

Heritage: World’s first space-qualified 270V Li-Ion battery set to fly in 2008.

Characterization: Extensive testing has proven that the HR is an excellent cell choice for high power applications.

Employment of the HR cell in ABSL’s 270V TVC battery is

crucial to providing the required performance.




The Cell Suite: ABSL 33111PR

Description: US manufactured high rate, high energy density (450 Wh/kg) Lithium Sulfuryl Chloride primary COTS cell.

Qualification: Qualified for the rigorous vibration environment of atmospheric re-entry missions.

Heritage: Successfully completed the FOTON-M3 Earth return mission in September, 2007

Courtesy of




Space Qualified Cell Suite & Stock

COTS Cell Cycle




Lot Acceptance Testing (LAT)

Build variability is the key risk for using COTS cells.

LAT = Zero-tolerance mini-qualification program

Ensures predictable performance batch to batch.




Batch 3

Batch 2

Batch 1

Batch N + LAT

Batch 2 + LAT

Batch 1 + LAT

Life Test Program

Life Test

Initial Qual




0 400 800 1200 1600 2000 2400 2800Storage Duration (Days)

Dis

char

ged

Cap

acity

0 °C 25% Charged 20 °C 25% Charged 40 °C 25% Charged 0 °C 50% Charged20 °C 50% Charged 40 °C 50% Charged 0 °C 100% Charged 20 °C 100% Charged

0 10000 20000 30000 40000 50000 60000 70000 80000Cycle Number

Ret

aine

d C

apac

ity

Life Test Program

A wide range of varied parameters across both storage and operational conditions are tested

– StorageTemperature

SOC

– Operational:Orbital profiles

Temperature

DOD

Charge/Discharge rate

Charge management regimes

8 years of storage data

70k+ cycles of operational data




Stockpiling

Assured access to cells is critical

Short Term (0 to 3 years)– ABSL buy 10k’s of cells at a

time maintain rolling stock

– Last-time buy agreements

Long Term (3+ years)– Cell stockpiling

– Cell selection

– Diverse cell suite

– Commitment to qualify new cells




Space Qualified Batteries

Space Qualified Cell Suite & Stock

COTS Cell Cycle




Cell Screening

Cell Screening Timeline

In addition to performing a LAT on a sample of each batch, all cells are screened twice.

The first screening is on receipt of the cells from the manufacturer, the second is just before use of the cells.

This approach allows two opportunities to identify cells with abnormally high self-discharge rates.




Standardized Battery Design

Battery performance is highly dependant on the complex interplay of electrical, thermal, and structural design aspects.

For optimal results, all three disciplines must be approached collectively through iteration.

Strong expertise in all aspects is critical for excellence.

Electrical Design

Thermal DesignStructural Design




Electrical Design

LIFE BEASTDOD

EOL Capacity & Resistance


Comparison against in-orbit telemetry shows a high degree of accuracy for complex mission profiles and long

mission durations.

17

18

19

20

21

22

23

24

25

26

0 50 100 150 200 250 300 350 400

Time (mins)

Bat

tery

Vol

tage

(V)

-3

-2

-1

0

1

2

3

4

5

6

Cha

rge

/ Dis

char

ge C

urre

nt (A

)

Measured Battery Terminal Voltage BEAST Predicted Battery VoltageMeasured Battery Discharge Current Measured Battery Charge CurrentBEAST Imported Current Data

PROBA In-Orbit Battery Performance06/02/05

MEX In-Orbit Performance




Electrical Design

LIFE BEASTDOD


Structural Design

CAD Design

Battery

Config

uratio

n


Max Deflection & Stress

Structural Design

Cell Leve

l

Vibration

Worst Case Loading

Cell Level Vibration

Modes & Frequencies

Structural Design

Random Vibration Natural Frequencies

& Mode Shapes




Electrical Design

LIFE BEASTDOD


Structural Design

CAD Design

Battery

Config

uratio

n


Modes & Frequencies

Structural Design

Max Deflection & Stress

Structural Design

Cell Leve

l

Vibration

Worst Case Loading

Cell Level Vibration

Thermal Dissipation, Battery Configuration

Cell Temperatures

Thermal Design

Structural Design

BATS

Cell Temperatures

Random Vibration Natural Frequencies

& Mode Shapes

10

11

12

13

14

15

16

17

18

19

20

0 100 200 300 400 500 600 700

Time (minutes)

Tem

pera

ture

(°C

)

Coldest Cell on Failed Block Coldest Cell on Lower Deck Warmest Cell on Lower DeckWarmest Cell on Failed Block Coldest Cell on Upper Deck Average Battery TemperatureWarmest Cell on Upper Deck BEAST cell

10.0°C11.0°C12.0°C13.0°C14.0°C15.0°C16.0°C17.0°C18.0°C

Temperature




Standardized Battery Build

28V Batteries

>100Ah Spacecraft

Primary Batteries

270V LV Batteries




Space Battery Qualification

Custom batteries qualified to different levels at customers’request.ABSL has pre-qualified “build to print” designs as well, to reduce cost and lead time.

Design & Analysis, Build

Thermal TestingOperational & Non-Operational

Thermal Cycling in Vacuum

Structural TestingLLS, HLS, Random Vibration,

Shock

Additional TestingMission Specific

InspectionICD Verification, Functional

Checks





Cell Assessment & Qualification– Identify the best COTS cells to meet future space battery needs and qualify

them to space industry standards.

The Cell Suite– Readily provide a broad range of battery capabilities and security of supply.

Lot Acceptance Testing (LAT)– Ensuring consistency of cells batch to batch, maximizing the value of

comprehensive cell characterization and life test programs.

Life Test Program– Enabling unmatched EOL performance predictions capabilities.

Standardized Battery Design, Build, & Qualification– Leveraging the consistency and predictability of ABSL’s COTS cells to

efficiently optimize and qualify battery designs for any mission.





ABSL’s Next Generation Cells




Contents



ABSL’s Next Generation COTS Cells– Next Gen Summary

– Cells G & F

– ABSL 18650LV




Current Next-Gen COTS Cell Status:

More than 140 COTS cells currently in Phase A (Technology Watch Database)

Approximately 10 COTS cells currently in Phase B (In-House Testing)

Multiple COTS cell under investigation via cooperative efforts with NASA/ESA

One COTS cell starting Phase C(Cell Qualification)

One COTS cell about to complete Phase C (Cell Qualification)

Next Generation Cells




“Cell G”: Lifetesting

Next Gen Cells: Phase B

100% DOD 20% DOD LEO

Cell G shows improved percent capacity retention performance relative to the HC at both low and high DOD




“Cell G”: Additional Completed Characterization– Consistency & Build Quality Testing

– Capacity at Temperature, -40° C to 60° C

– Rate & Pulse Characterization, up to 3C

– Resistance Characterization, -40° C to 60° C

– Overcharge Testing

ABSL has assessed prototype rather than production cells

Further testing & characterization planned upon initiation of full-scale production





“Cell F”: Lifetesting



Cell F shows improved percent capacity retention performance relative to the HC at low DOD, but not at high DOD




“Cell F”: Additional Completed Characterization– Consistency & Build Quality Testing

– Capacity at Temperature, -40° C to 60° C

– Rate & Pulse Characterization, up to 7C

– Resistance Characterization, -40° C to 60° C

– Overcharge Testing

More tests are currently underway

A full BEAST cell model will be available Dec. 2007





ABSL 18650LV: Lifetesting

Next Gen Cells: Phase C


The LV shows very similar percent capacity retention to the HC at both high and low DODs




ABSL 18650LV: Performance Characterization


2070

2090

2110

2130

2150

2170

2190

0 50 100 150 200 250 300 350 400Cell Number

Cap

acity

(Ah)

Discharge Capacity Charge CapacityAverage Discharge Capacity Average Charge Capacityl

3.0

3.2

3.4

3.6

3.8

4.0

4.2

0 10 20 30 40 50 60 70 80 90 100SoC (%)

EM

F (V

)

Charge Discharge

2.50

2.70

2.90

3.10

3.30

3.50

3.70

3.90

4.10

4.30

0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00

Capacity (Ah)

Vol

atge

(V)

1.2 A Discharge 2.4 A Discharge 4.8 A Discharge 7.2 A Discharge

Rate Characterization

EMF vs. SOC

Batch Consistency




ABSL 18650LV: Safety Testing


0.01

0.1

1

10

100

1000

10 15 20 25 30 35 40 45 50 55 60

Current (A)

PTC

Trip

Tim

e (s

)

100% SoC at 22 deg C 50% SoC at 22 deg C 100% SoC at 70 deg CTrendline (22 deg C) Trendline (70 deg C)

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

5.0

5.1

5.2

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8

Overcharge Capacity (Ah)

Cel

l Vol

tage

(V)

0.6 A1.2 A2.4 A4.8 A

PTC Characterization

Overcharge

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22Time (hrs)

Vol

tage

(V)

20

25

30

35

40

45

50

55

60

65

Tem

pera

ture

(°C

)

Cell Voltage Cell Temperature

Over Discharge TV & Vibration & Safety testing is

done – the key risk areas have been

mitigated




Currently ABSL has more than 140 COTS cells under investigation in Phase A.

Approximately 10 COTS cells in are presently under going in-house testing in Phase B

“Cell F” is about to graduate from Phase B to C

The ABSL 18650LV has completed key portions of the qualification testing, and is ready for a mission!

Next Generation Summary





Questions?

absl’s cots li-ion cell suite development 2007 nasa ... · 000074.--. absl presentation template...

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