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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 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 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 5 advance authorization from the U.S. government. Shift in Power Demand 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 6 advance authorization from the U.S. government. Increasing Module Size/Multiple 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 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 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 9 advance authorization from the U.S. government. Dichotomy of the space industry 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 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 11 advance authorization from the U.S. government. Challenges & Risks Demanding schedules Space quality Low cost How do we tackle the challenges? Scaled production Design for manufacture Pertinent qualification Automation of process 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 12 advance authorization from the U.S. government. Solutions to meet large volume production 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 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 13 advance authorization from the U.S. government. Healthy Progression? 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 15 advance authorization from the U.S. government. Volume Production of Battery 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
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