YEARS TrendsTrends inin LithiumLithium--ionion BatteriesBatteries forfor AerospaceAerospace ApplicationsApplications Features, Performance, Research, & Development NASA Battery Workshop, Marshall Space Flight Center 27 November 2007 David Gallup Manager, Li-ion Space Systems Yardney Technical Products, Inc. / Lithion 860-599-1100 x494 82 Mechanic Street, Pawcatuck, CT 06379 www.yardney.com www.lithion.com Objectives of Presentation • Overview of Yardney-Lithion battery heritage, developments, applications, performance, & research • Overview of successful results of YTP’s Li-ion Domestic Source Program Yardney Space Heritage Spacecraft Customer Launcher Launch Date Mars Lander NASA/JPL No launch, but battery N/A fully tested & qualified MER Rover Spirit NASA/JPL Delta II June ‘03 MER Rover NASA/JPL Delta II July ‘03 Opportunity XSS-11 Lockheed Martin Minotaur April ‘05 X-37 NASA/AF Atmospheric Demo Various MISSE 5 NRL STS July ‘05 STP-R1 General Dynamics Minotaur Sept ‘05 MiTEx Lockheed Martin Delta II June ‘06 Yardney Space Heritage Spacecraft Customer Launcher Launch Date TacSat 2 Broadreach Eng Minotaur Dec ‘06 /AFRL Orbital Express Ball Aero Atlas V March ‘07 NEXTSat Orbital Express Boeing Atlas V March ‘07 ASTRO Phoenix Lockheed Martin/JPL Delta II August ‘07 Planned Launches BBP Boeing Not Specified Not Specified IBEX NASA/GSFC Pegasus 2008 Mars Science Lab NASA/JPL Delta IV/Atlas V 2009 NASA/JPL MER Rover Mission 2 x 28V, 10 Ah Lithium Ion Batteries • Spirit and Opportunity Energy Storage - Nighttime Power Source - Daytime Augmentation During Peak Loads - Design to Test in Nine Months • Program Extended Multiple Times - Initial Three Month Run-Time Requirement - Operating since Jan 04 – nominal performance Orbital Express Program 30Ah, 28V Li-Ion Battery - NEXTSat (BATC) 43 Ah, 28V Li-Ion Battery - ASTRO (Boeing) • DARPA Technology Demonstration – Validate the Feasibility of Autonomous Robotic Refueling and Reconfiguration – Selective Electronics for Cell Balancing (Automatic/Remote Activated) – Mission to swap NEXTSat Operational Replacement battery from one vehicle to another Boeing 43Ah ASTRO • Launched 8 March 2007 BATC 30 Ah NEXTSat NASA/JPL Phoenix Program Dual 28 Volt, 30 Ah Lithium-ion Battery System Program resurrected from 2001 Mars Lander – Martian Arctic Explorer - Fixed Lander • Determine whether Life ever arose on Mars • Characterize the Climate of Mars • Characterize the Geology of Mars • Prepare for Human Exploration Identical Design as Heritage Battery Customer -- Lockheed Martin Space Systems Launched - Aug 2007 Land - May 2008 NASA/JPL Mars Science Laboratory 2 x 28V, 20Ah Lithium-ion Batteries Design •Retain MER heritage Science •New Li-ion cell - scaled up version • Did/does Mars have of MER cell environmental conditions •20 Ah Nameplate capacity favorable to microbial life? •8S/2P Configuration • Launch schedule: Fall ‘09 •Chemistry identical to MER •JPL low temp electrolyte •No solar arrays – uses radioisotope power source 2009 MSL Rover 2005 MINI Cooper S Design Concept The Look Ahead Lithium-ion Batteries becoming baseline design –Increasing battery power –Increasing battery voltage –Improving cell capacities –Improving life performance –Improving design features High Power Batteries Comprised of (40) NCP55-2 cells in (8) series packs of (5) parallel cells (nom. 300Ah capacity) Voltage Range 24V to 34V Continuous Discharge 100A (C/3) High Voltage Batteries Comprised of (42) NCP12-2 cells in series (nom 12Ah) Voltage range 126V to 172V Peak Discharge capability 72A (6C) Cell Capacities Increasing Process improvements leading to performance improvements Cell Capacities Increasing Process improvements leading to performance improvements 4.2 4.1 4.0 Increase in NCP43-2 Cell Capacity 3.9 3.8 3.7 NCP43-2-321 3.6 lts NCP43-2-480 Vo 3.5 48.27Ah 3.4 3.3 3% BOL capacity growth 3.2 over 15 months 46.67Ah 3.1 3.0 2.9 0246810121416182022242628303234363840424446485052 Amp-Hours Cell Capacities Increasing Process improvements leading to performance improvements 4.2 4.1 4.0 Increase in NCP43-2 Cell Capacity 3.9 3.8 4.2 3.7 4.1 NCP43-2-321 3.6 Increase in NCP12-2 Cell Capacity lts NCP43-2-480 4.0 Vo 3.5 48.27Ah 3.9 3.4 3.8 3.3 3% BOL capacity growth 3.7 3.2 NCP12-2-476 over 15 months 46.67Ah s 3.6 NCP12-2-985 3.1 t Vol 3.5 3.0 13.60Ah 3.4 2.9 0246810121416182022242628303234363840424446485052 3.3 6% BOL capacity growth Amp-Hours 3.2 over 18 months 12.85A 3.1 3.0 2.9 0123456789101112131415 Amp-hours Cell LEO Cycle Testing DOD) ith NCP20 Cells 0.8519 = -3E-06x2 = + 3.4981 y R cling w LEO Cy (C/2 Discharge to 20% End of Discharge Voltage = -6E-06x2 = 0.8014 + 3.319 y R Linear regression modeling predicts 36000 3.6 cell EOL (3.0V) at 34000 32000 3.5 30000 ~ 53,000 cycles (3.7V) and ~ 166,000 cycles (3.9V) 28000 e 26000 g a 4 24000 lt 3. 9V 3. 7V) 22000 o 3. O t 7V o 20000 E o 3. O t 9V) rge Vo rge 3. 3 O t E o 18000 a 3. 315 L E O t h X 325 L E 16000 er 325 L (X sc i X ear 315 L 14000 in (X D 2 L 3. near 12000 ycle numb Li C 10000 End of End 8000 3.1 6000 4000 2000 3.0 0 HV Battery LEO Cycle Testing At a battery lower limit of 126V, the battery linear regression model predicts XEOL ≈ 35,200 cycles (8% DOD). 12Ah / 150V Battery Life Cycle Test Results End-of-Discharge Voltage 170 165 160 ) s 155 t ol y = -0.0011x + 164.77 (V 150 R2 = 0.7713 age t 145 Vol y 140 er tt a B 135 130 125 120 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Cycle Number HV Battery LEO Cycle Testing At a lower limit of 3V, the cell linear regression model predicts XEOL≈ 30,700 cycles (8% DOD). 12Ah / 150V Battery Life Cycle Test Results End-of-Discharge Voltage (cells) 4.00 3.90 3.80 3.70 ) y = -3E-05x + 3.9218 ts l 3.60 R2 = 0.876 3.50 e (Vo g 3.40 Volta 3.30 Cell 3.20 3.10 3.00 2.90 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Cycle Number LV Battery LEO Cycle Testing At a battery lower limit of 24V, the battery linear regression model predicts XEOL ≈ 32,800 cycles (20% DOD). 43Ah / 28V Battery Life Cycle Test Results End-of-Discharge Voltage 32.0 31.5 31.0 30.5 30.0 29.5 ts) l 29.0 y = -0.0002x + 30.568 o V 28.5 2 ( R = 0.8524 e 28.0 ltag 27.5 27.0 26.5 ery Vo 26.0 Batt 25.5 25.0 24.5 24.0 23.5 23.0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Cycle Number LV Battery LEO Cycle Testing At a lower limit of 3V, the cell linear regression model forecasts XEOL ≈ 27,300 cycles (20% DOD). 43Ah / 28V Battery Life Cycle Test Results, End-of-Discharge Voltage (cells) 3.90 3.80 3.70 3.60 ) y = -3E-05x + 3.8184 olts 3.50 R2 = 0.8987 e (V 3.40 ag t l Vo 3.30 Cell 3.20 3.10 3.00 2.90 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Cycle Number Electronics Externalization Modular Electronics Used with battery dummy for acceptance testing Simplified EMI protection Lends itself to rapid field replacement, eliminating need for depot-level service Electronics Research & Development Issues of: – Time & expense to develop unique electronics for different battery applications – Availability of certified space-grade electronics components for Space and Aerospace Applications. Electronics Research & Development Issues of: – Time & expense to develop unique electronics for different battery applications – Availability of certified space-grade electronics components for Space and Aerospace Applications. Significant Impacts on: – Schedule (12+ months for certain key components) – High Costs – NRE, component qualification Electronics Research & Development Issues of: – Time & expense to develop unique electronics for different battery applications – Availability of certified space-grade electronics components for Space and Aerospace Applications. Significant Impacts on: – Schedule (12+ months for certain key components) – Cost (high demand + scarce supply = high cost) These are industry-wide issues and impacts which affect all suppliers and consumers Electronics Research & Development Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility Electronics Research & Development Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility – Assess commonality between applications to identify ways to streamline development of electronics packages Electronics Research & Development Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility – Assess commonality between applications to identify ways to streamline development of electronics packages – Development of “standard” design to reduce recurring costs and improve deliveries Electronics Research & Development Yardney Electronics Development Program – Significant expansion of in-house Electronics Development Group to bring engineering inside for increased control and flexibility – Assess commonality between applications to identify ways to streamline development of electronics packages – Development of “standard” design to reduce recurring costs and improve deliveries – Continuing efforts to resolve supply chain issues Materials Research: Active Materials Domestic Source Program Overseas source of supply for premium quality specially formulated Li-ion active materials lost for all aerospace battery vendors – Business decision to focus on much larger