EUSO BALLOONBattery Power Pack

(PWP)

RIKEN/UAHHéctor Prieto, Katsuhiko Tsuno, Marco Casolino

Maintain constant power of 225 W for the phone booth and 25 W for the IR Camera during the time required for the mission, in this case 24 hours of flight.

Zero levels of overloading the circuit due to problems with the battery

Zero levels of overheating in the circuit due to problems with the battery

Mission Objectives with success criteria

Battery Pack technical specifications

Phone Booth IR CameraAltitude 40km 40kmPressure 3mBar 3mBar

Power 225W/192.72Ah, 28V 25W/38Ah, 28V

Operation Duty

24h 24h

Operating Temperature

Range within -40˚C/+70˚C Range within -40˚C/+70˚C

Size (600x250.2x170)mm (225W) (600x50.4x170)mm (25W)

Mass (TBC) (16kg+4.8kg=20.8kg)

Battery Pack design description

Objectives  PWP shall provide the primary power in 30 hours minimum which

includes 24 hours level flight and rising operation. PWP shall provide the primary power in 10 hours minimum including 2

hour level flight and rising operation. PWP shall provide the average power of 225W and 25W (TBD) to the

instruments. PWP shall provide enough transient current generated at instrument

booting. PWP shall be protected from the instrument overload by the fuse, circuit

breaker or current limiter.

Battery Pack design description

Description

At the moment we assume a battery system providing 28V; since the highest voltage is 28V (and HV is produced internally).

The battery pack will be attached to the gondola and provide power to the LV board and the HK board. Relays (commanded by CNES) will control the power ON/OFF.

Battery Pack connection diagramPhone Booth

Battery Pack connection diagramIR Camera

Battery Pack Phone Booth

ComponentBattery Component Selected: Saft G62/1.2 Specification: Li-SO2/28V/34.5Ah Capacity = (Watts required/Volts required)*(Time Hours)Battery SelectionCapacity @ 24hours = (225W/28)*(24h)=192.72Ah•6of 12 Cell Series Saft G62/1.2 = 207Ah

Battery Pack IR Camera

ComponentBattery Component Selected: Saft G62/1.2 Specification: Li-SO2/28V/34.5Ah Capacity = (Watts required/Volts required)*(Time Hours)Battery SelectionCapacity @ 24hours = (25W/20)*(24h)= 30 Ah•1of 10 Cell Series Saft G62/1.2 = 34.5Ah

Battery Pack Mechanical Architecture Phone Booth

Battery Pack Mechanical Architecture IR Camera

Mass Estimation

Upperside and Under side

Front Face and Back

Face

300.24 mm

Battery BoxPhone Booth

500.4 mm

300.24 mm

170 mm

Lateral

500.4 mm

170 mm

Mass Calculations

Density = Aluminum Box = 2.69g/cm3 = 0.00269g/mm3

Thickness = 3mm

Lateral Sides Volume = LSV= 500.4mm*170mm*3mm*2*0.00269g/mm3 = 1373g

Upper and Under Side Volume = USV = 500.4mm*300.24mm*3mm*2*0.00269g/mm3 = 2423g

Front and Back Face Volume = FBV= 170mm*300.24mm*3mm*2*0.00269g/mm3 = 824g

Total Case Mass = LSV + USV + FBV = 1373 + 2423 +824 = 4.62kg

TOTAL MASS INCLUDING CELLS AND CASE = (60Cells*300g) + (Case Mass = 4.62kg) = 22.62kg+20% of margin = 27.14kg

Upperside and Under side

Front Face and Back

Face

100.08 mm

Battery BoxIR Camera

250.2 mm

100.08 mm

170 mm

Lateral

100.08mm

170 mm

Mass Calculations

Density = Aluminum Box = 2.69g/cm3 = 0.00269g/mm3

Thickness = 3mm

Lateral Sides Volume = LSV=170mm*100.08mm*3mm*2*0.00269g/mm3 = 275g

Upper and Under Side Volume = USV =250.2mm*100.08mm*3mm*2*0.00269g/mm3 = 404.14g

Front and Back Face Volume = FBV= 100.08mm*170mm*3mm*2*0.00269g/mm3 =275g

Total Case Mass = LSV + USV + FBV = 275+ 404.14 + 275 = 1kg

TOTAL MASS INCLUDING CELLS AND CASE = (10Cells*300g) + (Case Mass = 1kg) = 4kg+20% of margin = 4.8kg

Battery Protection and Support

•FireThe Battery pack will have thermal fuse overheating protector which will protect the PWP against fire risk•ExplosionThe box itself will be a protection against explosion due to the batteries will be confined there•BreakingThis mechanical issue shall be discused with the mechanical engineers in charged of the EUSO-Balloon mechanical StructureMechanical SupportECAL-Riken will provide the mechanical structure, which will be made of aluminum to avoid risk of explosion and fire propagation.

Battery Cells, Connectors and Cables

•Cells

•Connectors

•Cables

Option I: In case of 225W power consumption it will be necessary 60 cells of Saft G62/1.2Option II: In case of 25W power consumption it will be necessary12cells of Saft G62/1.2

The Connectors we are going to use are 9 pins D-Sub connectors for all interfaces and subsystems.

The Cables we are going to use are THERMAX MIL-DTL-22759/91,92 for all interfaces and subsystems.

Battery Switches, Fuses

•Switches

•Fuses

The Fuses we are going to use are Thermal Fuse Klixon C Series and MIL-PRF-23419 Space Coast IC

The Switches we are going to use are APEM-M3500

Why using 25W?

Interface Power Consumption

IR Camera 22W

Total Power Budget: 20W +20% of Security Margin = 25W

25W

Why using 225W ?

Interface Power ConsumptionHigh Voltage Power Supply 9.2W

LVPS DP1 7.2WLVPS DP2 7.2W

Housekeeping 6WLVPS-PDM 2.4W

CPU 14.4WCCB 5W

Data Storage 18WGPS 1.2WCLK 3.6W

Additional Spare 15WHeaters TBC

Total: 89.2W+20% of security Margin = 107.04W Additional Heaters and backup = 70W(180)+20% of security Margin = 216WThis version should be discussed

225W

Battery Pack Budget/90W

Equipment Specification Model Quantity Price/Unit Total Pack

BatteryOption 3

Li-SO2/28V/34.0Ah Saft G62/1.2 10 75.5€ Option 3TBC

SwitchV: 20VW =25WCurrent = 1ATemp = -600C /+700C

APEM-M3500 10 TBC

Thermal FuseV: 20 VW: 25W Steady Current = 25W/20V = 1.25ATemp = -600C /+700C

Thermal Fuse Klixon C Series

10 TBC

Electrical Fuse

V: 20 VW: 25W Steady Current = 25W/20V = 1.25ATemp = -600C /+700C

MIL-PRF-23419Space Coast IC

10 TBC

CableV: 20VW =25WCurrent = 1.25ATemp = -600C /+700C

THERMAX MIL-DTL-22759/91,92

1m TBC

Battery Pack Budget Phone Booth /225W

Equipment Specification Model Quantity Price/Unit Total Pack

BatteryOption 3

Li-SO2/28V/34.5Ah Saft G62/1.2 60 75.5€ Option 3TBD

SwitchV: 28V; worse scenario 20VW =225WCurrent = 12.5A; Steady Current=225/20=11.25A*2PWP in parallel = 22.5ATemp = -400C /+700C

APEM-M350010 TBC

Thermal FuseV: 28 VW: 225W Steady Current = 225W/20V+Security range = 11.25A+50% security range= 17A.Temp = -400C /+700C

Thermal Fuse Klixon C Series

10 TBD

Electrical FuseV: 28 V; worse scenario =20VW: 225W Steady Current = 225W/20V = 11.25ATemp = -400C /+700C

MIL-PRF-23419Space Coast IC

50 TBC

CableV: 20VW =225WCurrent = 11.25ATemp = -400C /+700C.AWG= 14

THERMAX MIL-DTL-22759/91,92

30m 230$

THANK YOU!!!