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Torpedo White Paper FINAL V4 090612.Pages Lithium-ion battery technology – the most promising approach for exercise torpedoes A Saft white paper Authors: Franck Poirier, Business Development Specialist – Saft Space & Defence Division Louis D’Ussel, Torpedo Product Manager – Saft Space & Defence Division A Saft industry white paper page 2 About the authors Franck Poirier is Business Development Specialist for Saft’s Space & Defence Division. Louis D'Ussel joined Saft in France in 1980 initially as a development engineer for missile batteries and then later for torpedoes. He moved to the US to develop Li-ion batteries for the automotive industry (electric and hybrid vehicles). In 2000, Louis returned to France as product manager for torpedo applications with responsibility for sales to torpedo OEMs. A Saft industry white paper page 3 Summary This white paper has been produced by Saft, world specialist in the design and manufacture of high- tech batteries, to outline the various battery technologies currently available to power electrically propelled lightweight and heavyweight exercise torpedoes (LWTs and HWTs). The paper discusses how rechargeable lithium-ion (Li-ion) battery technology offers significant advantages over secondary Silver-Zinc (Ag-Zn) technology. Saft expects to see Li-ion established as the preferred battery technology to meet the requirements of navies worldwide. Although the initial purchase cost is currently higher than for secondary Ag-Zn batteries, the reusability of Li-ion batteries will ensure low lifecycle costs, as each battery can be used for a much higher number of exercises. The reduction in associated maintenance and logistic costs will also provide a considerably more cost-effective solution. A Saft industry white paper page 4 List of contents Introduction ......................................................................................................................................................................5 Current torpedo battery technologies ..................................................................................................................6 Seawater-activated (primary) ............................................................................................................................................6 Silver-Zinc (primary and rechargeable) .........................................................................................................................6 Silver-oxide aluminium (primary) ......................................................................................................................................7 Lithium-ion (rechargeable) ..................................................................................................................................................7 The current state-of-the-art for exercise torpedo batteries ........................................................................8 Lightweight torpedoes (LWTs) ..........................................................................................................................................8 Heavyweight torpedoes (HWTs) ......................................................................................................................................8 High sea trial costs .................................................................................................................................................................8 Why lithium-ion? .............................................................................................................................................................9 Potential lithium-ion cell candidates ....................................................................................................................10 HWT – speed greater than 45 knots ........................................................................................................................11 HWT – speed up to 45 knots ........................................................................................................................................11 LWT – speed up to 45 knots .........................................................................................................................................11 Lithium-ion battery technical challenges ............................................................................................................13 LWT – power and energy trade-off .............................................................................................................................13 HWT – safety issues ..........................................................................................................................................................13 Mechanical issues ...............................................................................................................................................................13 Voltage profile issues ..........................................................................................................................................................13 Economic advantages of lithium-ion batteries .................................................................................................15 Lithium-ion battery system architecture ...........................................................................................................17 Battery management system (BMS) ..........................................................................................................................17 Safety design considerations ..........................................................................................................................................18 Future developments in rechargeable lithium battery technology .........................................................19 Conclusion ......................................................................................................................................................................20 Appendices .....................................................................................................................................................................21 About Saft ................................................................................................................................................................................21 Saft torpedo experience ...................................................................................................................................................21 Saft underwater vehicle experience ............................................................................................................................25 Note: all photographs and illustrations used in this white paper are courtesy of Saft, except where credited. A Saft industry white paper page 5 1 Introduction Lightweight torpedoes (LWTs), typically 324 mm (12.75”) in diameter, are intended for anti submarine warfare, where they are deployed from fixed or rotary wing aircraft, or from surface vessels. Heavyweight torpedoes (HWTs), typically 533 mm (21”) in diameter, are mainly intended for anti surface ship warfare, and are usually launched by submarines. During sea tests and training exercises, navies conduct a number of test firings of electrically propelled LWT and HWT training and exercise torpedoes equipped with dummy warheads. These torpedoes require an onboard battery system to power the electric propulsion system as well as other electronic control and guidance circuits. The battery must provide realistic performance, comparable to the combat version, so may be called upon to propel the torpedo at speeds over 45 knots. The use of primary (non-rechargeable) batteries that can only be used once results in a significant additional cost for a sea trial each time a torpedo is fired. This means there is a growing demand for rechargeable battery systems that can be reused many times. A Saft industry white paper page 6 2 Current torpedo battery technologies There are four main battery technologies suitable for torpedoes: 2.1 Seawater-activated (primary) The battery is stored without electrolyte and activated by seawater after the torpedo has been launched. A continuous flow of electrolyte is provided through a scoop in the hull to remove the heat, gas and mineral mud produced by the discharge and corrosion reactions. Seawater-activated batteries have a specified storage life of a minimum of five years when stored in their containers and protected V616 battery as used in some against humidity. A244 LWT models. 2.2 Silver-Zinc (primary and rechargeable) Silver-zinc (Ag-Zn) cells provide the basis for making both primary and secondary (rechargeable) batteries. In cells for primary batteries, the anode is zinc and the cathode is silver oxide. In cells for secondary batteries, the anode is zinc oxide and the cathode is silver. In both cases, the electrolyte is based on potassium hydroxide. Ag-Zn batteries have a high energy and power density. In torpedo applications, rechargeable batteries are used for exercises and primary batteries for combat. For reasons of safety and performance, the batteries are only activated, by electrolyte injection, at the last minute.!They can have a shelf life of over eight years. MAIT 6 HWT torpedo battery (left) and (right) Ag-Zn cells. A Saft industry white paper page 7 2.3 Silver-oxide aluminium (primary) Silver oxide-aluminium (AgO-Al) cells feature an aluminium anode and a silver oxide cathode. They are used to create a Volta pile stack for
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