Qualification and Flight Screening of Liion Batteries for the AMS02 Based on SOW Appendix B

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Qualification and Flight Screening of Li-ion
Batteries for the AMS-02(Based on SOW Appendix B)

• Jonq-Ren Lee
• Dec. 05, 2003

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PHYSICAL CHARACTERISTICS

• Label and number.
• Dimensions and weight.
• Statistical information (average values and
  standard deviation).
• Visual inspection record.

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ELECTROCHEMICAL CHARACTERISTICS

• Open Circuit Voltage (OCV)
• 28.8 V ? OCV ? 32.8 V
• Closed Circuit Voltage (CCV)
• _at_1.5 C ? 30 sec,CCV ? 20.8 V
• 1.5 C discharge current42 A for 28 Ah Battery

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Charge/Discharge Cycle

• Two charge/discharge cycles before tests.
• Charging
• C/5 current (I ? 5.6 A) to 32.8 V
• Holding until I ? 50 mA.
• Discharge
• C/5 to cutoff voltage 24.0 V.

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Vacuum Leak Test

• Depressure to 0 psia at the rate of 8 psi/min.
• Held under vacuum for 6 hours.
• Repressure to 14 psia at the rate of 9 psi/min.
• Visual checked and weight.
• One discharge/charge/discharge cycle.

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QUALIFICATION TESTS - 1Performance Test
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QUALIFICATION TESTS - 1Performance Test

• Battery Performance Testing Equipment
• Maccor S-4000 battery test system
• Capacity 200 A ? 70 V
• Accuracy 0.02 Full scale
• Time resolution 10 msec
• Operating modes
• Constant current/voltage/power/resistance
• Step end conditions
• Voltage/current/time/Ah/Wh etc.

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QUALIFICATION TESTS - 2Thermal Environment Test

• 10 charge/discharge cycles at each temperatures.
  
• Testing Temperature
• 25?C, 0 ?C,20 ?C and 40 ?C.
• 45 A/150 msec pulses test
• at 100 , 75 ,50 and 25 SOC during
  discharge.
• SOC is based on nominal capacity.
• Pulse test every 75 min. at C/5 discharge rate.

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QUALIFICATION TESTS - 3 Overcharge

• Overvoltage -1
• Charge battery to 40.0 V at C/10 rate.
• BMS should protect the battery at V? 33.6 V.
• Fast charge
• Charge battery at 3 C rate (I ? 84 A) to 32.8 V
• Charging wire 3?20 AWG, safe current limit 6A
• Overvoltage -2
• Overcharge a fully charged battery at C/10 rate
  for 50 minutes with a 12 V limit.
• BMS should protect the battery at V? 33.6 V.

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QUALIFICATION TESTS - 4 Overdischarge

• Discharge into Reversal
• Discharge a fully charged battery down to 0 V and
  take it into reversal until 150 of the original
  capacity
• BMS should protect the battery at V ? 20.0 V.
• Fast Discharge
• Discharge battery at 3 C rate to 20.8 V.
• 3C 84 A
• BMS over current software limit 80 A, delay 2-3
  sec
• Battery output wire 3 ?12 AWG,
• Safe current limit 69 A (23 A/wire)

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QUALIFICATION TESTS - 5External Short Circuit

• short circuit test
• Load50 mohm _at_ 32.8 V.
• BMS Hardware trip at 85 A,100 ?sec delay
• Visual checked and weight.
• discharge/charge/discharge on the battery.

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QUALIFICATION TESTS - 6Thermal Cycle

• Fully charged battery undergo 24 thermal cycles
• Visual inspection and discharge/charge cycles

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QUALIFICATION TESTS - 7 Vibration

• Two fully charged batteries vibrate for 15
  minutes in each of the x, y and z axes. Moniter
  OCV.

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SCREENING OF FLIGHT BATTERIES - 1 Vibration

• Fully charged battery is vibrated for one minute
  in each of x, y, and z axes
• Vibration spectrum

Frequency Level 20-80 Hz 3 dB/Oct
80-350 Hz 0.067 g2/Hz 350-2000 Hz ? 3 dB/Oct
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SCREENING OF FLIGHT BATTERIES - 2 Discharge /
Charge Cycles

• One discharge
• C/5 rate after vibration, 20.8 V cutoff
• Two full charge/discharge cycles
• Pass/Fail criteria
• OCV and capacity shall be within ? 5 before
  and after vibration.

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SCREENING OF FLIGHT BATTERIES - 3 Thermal Cycle

• Eight thermal cycles at ?50?C and ?25?C
• Visual inspection
• Perform discharge/charge/discharge test

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SCREENING OF FLIGHT BATTERIES - 4 Storage

• With BMS connected
• Charge to 31.0 V at max. 6A rate
• Packed in air tight plastic box or bag
• Stored at 0?C ? 10?C
• Check and recharge battery every 4 weeks

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Typical Thermal Vacuum Test ProfileSpecification
TBD