Large Volume Production of Lithium-Ion Battery Units for the Space Industry

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Large Volume Production of Lithium-ion Battery Units for the Space Industry

November 2015

David Curzon – Product Line Manager Kevin Schrantz - Director, Space & Medical Introduction

 Presenting • EnerSys’s solution to a developing market demand  Challenge • High volume production for large satellite constellations  Discuss • Meeting the market demands for Li-ion space batteries • Challenges to be considered • Solutions • Is this a healthy progression for the industry?

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 2 advance authorization from the U.S. government. Industry Demand  The emerging large constellation market is pushing for higher volume, lower cost batteries with demanding schedules.  Questions the industry faces include what does this new demand mean, what will be the long term affects, what pressure will be passed onto suppliers, and will the risk tolerance change in proportion?  If a higher risk tolerance is accepted for some missions, will the industry turn to commercially available products (such as commercial battery packs or batteries) qualified & characterized for space?  As an industry, this market is asking all of us to look at methods for increasing throughput, design for manufacturability, modularity, and common systems.

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 3 advance authorization from the U.S. government. Lithium-ion Battery Market Evolution  Lithium-ion implementation has steadily grown  Power consumption trending upwards - driving for higher performance, cells, batteries & modules  Number of different applications has increased year on year

Proba – Longest EMU – Manned Applications SDO – Interplanetary TerraSAR – Earth/Remote serving Li-ion in Science Support Sensing Space (14 yrs. and counting) EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 4 advance authorization from the U.S. government. Steady Growth – Demonstrated by EnerSys’s Growth  120 spacecraft launched using ABSL lithium-ion batteries (237 modules flying in total)  66 further spacecraft using ABSL batteries awaiting launch  38 further spacecraft using ABSL batteries awaiting delivery  Over 1 billion cell hours of operation in space

ABSL Accrued In-Orbit Cell Hours PROBA Beagle 2 Mars Express Rosetta Philae SaudiSat2 Demeter NSat Essaim I, II, III & IV Parasol Venus Express GIOVE-A ST5 A, B & C SAR-Lupe 1 Themis (& ARTEMIS) CFESat SaudiSat3 TerraSAR-X SAR-Lupe 2 SAR-Lupe 3 TecSAR SAR-Lupe 4 SAR-Lupe 5 RapidEye THEOS Chandrayaan-1 Spirale Kepler GOCE N/A Herschel Planck TacSat3 / 3a LRO LCROSS Deimos-1 UK-DMC 2 KSLV-1 Sumbandila (ZaSat) SDO CryoSat-2 Picard TanDEM-X ALSAT-2A N/A X-Sat SAC-D N/A NigeriaSat-2 NigeriaSat-X RASAT-R Megha-Tropiques ELISA Pleiades-HR 1A SSOT NuSTAR (US) exactView-1 VNIIEM SPOT 6 (AstroTerra) Pleiades-HR 1B KSLV-1 Proba V VNREDSat-1 GSAT-7 LADEE Cassiope Mangalyaan SWARM GAIA GPM Sentinel-1a KazEOSat 1 SPOT 7 (AstroTerra) Galileo-FOC 1&2 SMAP DSCOVR KompSat 3A Galileo-FOC 3&4 Sentinel-2a

 Market demand evolution

• ABSL’s first market was small, low-power NASA ST5 spacecraft o THEMIS; NASA ST5 A, B, C … NASA SDO

• Industry demand drove the development of large, high-power battery systems o NASA SDO; LRO; GPM…

• We are now seeing larger production Galileo quantities required o Sentinel-1a, Galileo, OneWeb…

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 7 advance authorization from the U.S. government. Where are we going  Looking back and forward • 2004 NASA GSFC adopts Lithium-ion, THEMIS o Single battery @ 0.5kg • 2006 ST-5 Constellation project Battery module o Single battery @ 0.5kg each • 2008 SDO / LRO Multiple Deck Battery o Large, single battery @ 43kg • 2012 SGEO / S1 Multiple Battery Modules on Panel o Medium, multiple unit battery system @ 17 kg / 13 kg each • 2015 Galileo Multiple battery modules o Large, multiple unit battery system @ 37 kg each • 2017 Constellation satellites (LEOSAT / OneWeb) o Small/medium, multiple units for multiple spacecraft, high volume production @ 12kg each

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 8 advance authorization from the U.S. government. Constellations  IRIDIUM Next  Galileo  Demand: Lighter, cheaper, faster,  LEOSAT higher volume  OneWeb  ESA / ARTES Program

 Must satisfy all three characteristics, but how do we do that and make a the business case? EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 10 advance authorization from the U.S. government. Demands

 Large Volume Production • Move from previously large quantity (20) to new large quantity (800) • Produce battery quantities to demanding schedule  Reduced Mass / Battery Size • High incentive to reduce launch costs ($/kg)  Low price • Price targets set to business model  High Quality • Acceptable reliability

How do we tackle the challenges?  Scaled production  Design for manufacture  Pertinent qualification  Automation of process

 Design: Design for manufacture (both unit/equipment level as well as satellite level – touch labor and integration simplicity)  Manufacturing: Cost of materials / scope of supply  Production: Techniques & equipment enhancements  Testing: Improved development of test equipment  Document management system: Configurations

 EnerSys’s solution is to leverage previous space volume experience plus EnerSys’s high volume production expertise for other markets

 EnerSys believes so • Evolves our business and the industry with innovative concepts • Provides competitive advantages • Opens new markets and users • Develop IP that can be shared for mutual benefit

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 14 advance authorization from the U.S. government. Heritage in Large scale production  ABSL has experience in what was considered large scale, but we are in a new world now  Over the last 10 years, ABSL have provided a number of projects that required what was considered large scale production capability: • Galileo: 22 Modules • GSAT7A: 5 Modules • SaudiSat: 22 Modules • Sentinel1: 22 Modules • SGEO Project: 16 Modules

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 16 advance authorization from the U.S. government. Materials & Parts Selection  Battery Hardware (Specifically, ABSL’s small cell solution for high volume production) • Cells make up 85% of the battery mass • Cells: Use a higher energy density • 15% of battery is chassis / wire –minimal saving • Chassis material / design to reduce mass  Analysis • Optimized design for mission • Use of software / analysis based on required performance  Redundancy • Move risk & redundancy from battery to satellite • Remove redundant string (save 0.5 kg mass/battery) • 0.5 kg/ Battery represents potential saving of $5M launch costs* *Figures based on OneWeb delivery requirements EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 17 advance authorization from the U.S. government. System Level Design Approach for Higher Volume Production

 Large scale production efficiencies • Aluminum extrusion of side and end walls of module (molded) • Integrated bus bar / tag design (sheet) • Single top plate battery cover • Cell qualification, LAT and screening under project control • Standardization of size screw and length • Minimize / simplify parts kit (trading mass for decreased cost)

 Low cost but not at any cost • Best trade between performance & cost • Pertinent & successful qualification • Reliable satellites • Meeting all key requirements • Suitable for large production • On time

 Cost increase of $1K per component means additional $1M overall for the constellation

 Best trade between performance & cost  Simplified design for assembly (made available because of high volume)  Modularity  Assembly line production – six sigma  Value based process flow enhancements  Bulk parts inspection, handling & delivery  Volume based efficiencies for documentation sign- off and inspection points  Volume based work stations

 Qualification at system level  Random sample testing  Automatic matrix relay battery function tester

 Leverage existing quality approach for high volume production • Serial production control (unit level) • Lot Acceptance Tests at Equipment level • Quality is embedded in the design, the manufacturing process, and in the test flow

 Pertinent & successful qualification • Qualify processes, not just components

 Reliability across mission duration • Quality is built in – it’s the end result EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 22 advance authorization from the U.S. government. Conclusion

 EnerSys has evaluated and studied high volume space production.  EnerSys understands higher volume market requirements– trade between cost and performance without sacrificing delivery or reliability.  High volume space production is now a reality.  Other industries such as aviation and automotive have provided greater benefit to society through higher volume efficiencies.  Challenges are as expected, but not insurmountable from a battery supplier standpoint.  EnerSys is ready for the evolution - what we have to achieve to meet the challenges is only an incremental step from where we are today.

EnerSys Proprietary © 2015 EnerSys. Export or re-export of information contained herein may be subject to restrictions and requirements of U.S. export laws and regulations and may require 23 advance authorization from the U.S. government. With Special Thanks  EnerSys Team  Batteries pictured represents 3  ABSL UK months of production  ABSL US  Quallion LLC  David Curzon – Product Line Manager

GSAT7 x 3

Galileo x 1 EDRS x 3

CSG x 1

SaudiSat x 10