Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith...

31
Judith Jeevarajan/NASA-JSC Certification Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC 2 nd IAASS Conference Chicago, IL May, 2007 https://ntrs.nasa.gov/search.jsp?R=20070020444 2018-05-20T20:02:50+00:00Z

Transcript of Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith...

Page 1: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

Cer

tific

atio

n Pr

oces

s fo

r C

omm

erci

al B

atte

ries

for

Payl

oads

Judi

th J

eeva

raja

n, P

h.D

.N

AS

A-J

SC

2ndIA

ASS

Con

fere

nce

Chi

cago

, IL

May

, 200

7

https://ntrs.nasa.gov/search.jsp?R=20070020444 2018-05-20T20:02:50+00:00Z

Page 2: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

2

Con

tent

s

•In

trod

uctio

n•

Req

uire

men

ts a

nd D

ocum

ents

•B

atte

ry C

ert p

roce

ss•

Exem

ptio

ns•

Bat

tery

App

rova

l For

ms

•N

ew B

atte

ry A

ppro

val F

orm

-03

•B

atte

ry C

hem

istr

ies,

haz

ards

and

con

trol

s

Page 3: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

3

Intr

oduc

tion

•B

atte

ries

are

high

ene

rgy

devi

ces

that

are

us

ed to

pow

er h

ardw

are

for s

pace

ap

plic

atio

ns•

App

licat

ions

incl

ude

IVA

(Int

raV

ehic

ular

Act

ivity

) and

EV

A (E

xtra

Veh

icul

arAc

tivity

) us

e.•

Hig

h en

ergy

bat

terie

s po

se h

azar

ds s

uch

as

cell/

batte

ry v

entin

g le

adin

g to

ele

ctro

lyte

(li

quid

or g

as) l

eaka

ge, h

igh

tem

pera

ture

s,

fire

and

expl

osio

n (s

hrap

nel).

Page 4: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

4

Req

uire

men

t for

Saf

ety

Maj

or R

equi

rem

ent f

or C

OTS

and

no

n-C

OTS

:Tw

o-fa

ult t

oler

ance

to c

atas

troph

ic

failu

res;

one

-faul

t tol

eran

ce to

cr

itica

l fai

lure

sH

azar

d ca

tego

ry is

bas

ed o

n to

xici

ty

of e

lect

roly

te (c

hem

istry

) and

en

ergy

den

sity

Page 5: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

5

Req

uire

men

ts D

ocum

ents

•JS

C 2

0793

, Rev

A “C

rew

ed S

pace

Veh

icle

Saf

ety

Req

uire

men

ts” i

s th

e to

p-le

vel r

efer

ence

for b

atte

ry s

afet

y re

quire

men

ts.

•P

aylo

ad S

afet

y R

equi

rem

ents

: NS

TS 1

700.

7B S

ectio

n 20

0.1b

-S

afet

y P

olic

y an

d R

equi

rem

ents

for P

aylo

ads

usin

g th

e S

TS•

Spa

ce S

tatio

n S

afet

y R

equi

rem

ents

: SS

P 5

0021

Sec

tion

3.3.

6.1.

1 –

Saf

ety

Req

uire

men

ts D

ocum

ent f

or IS

S•

SS

P 5

0094

Joi

nt R

ussi

an a

nd U

S re

quire

men

ts fo

r IS

S•

Spa

ce S

huttl

e S

afet

y R

equi

rem

ents

: NS

TS 2

2254

Sec

tion

1.6

-M

etho

dolo

gy fo

r Con

duct

of S

pace

Shu

ttle

Pro

gram

Haz

ard

Ana

lyse

s an

d S

ectio

n 1D

201.

6 of

NH

B 5

300.

4 (1

D-2

) –S

afet

y,

Rel

iabi

lity,

Mai

ntai

nabi

lity

and

Qua

lity

Pro

visi

ons

for t

he S

SP

.•

Spa

ce S

tatio

n/S

huttl

e S

afet

y R

equi

rem

ents

: JS

C 2

8484

S

ectio

n 3.

3.6

-Pro

gram

Req

uire

men

ts D

ocum

ent f

or J

SC

Non

-cr

itica

l GFE

.•

Rus

sian

Req

uire

men

ts D

ocum

ent:

P32

928-

103

Page 6: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

6

Bat

tery

Req

uire

men

ts D

ocum

ent

•Tw

o ba

ttery

requ

irem

ents

doc

umen

ts:

JSC

207

93R

evA

Cre

wed

Spa

ce V

ehic

le B

atte

ry

Req

uire

men

ts(o

ld M

anne

d Sp

ace

Veh

icle

Bat

tery

Han

dboo

k)an

d E

A-C

WI-

033

Bat

tery

Pro

cess

ing

Cur

rent

ly b

oth

are

foun

d on

the

Inte

rnal

JSC

-EA

web

site

Expo

rt C

ontro

l cle

ared

for p

ublic

acc

ess

Inte

rnat

iona

l Par

tner

PO

Csa

t ESA

and

RSC

E ha

ve c

opie

s

Page 7: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

7

Com

plia

nce

•C

ompl

ianc

e w

ith th

ese

esta

blis

hed

requ

irem

ents

for C

OTS

and

non

-CO

TS

requ

ires

data

.•

Cer

tific

ate

of C

ompl

ianc

e (C

of C

) fro

m

the

vend

or is

insu

ffici

ent f

or s

afet

y ce

rtific

atio

n.•

Exe

mpt

ions

exi

st fo

r bat

terie

s th

at fa

ll un

der t

he n

on-c

ritic

al h

azar

d ca

tego

ry

Page 8: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

8

CO

TS

Bat

tery

Cer

tific

atio

n Pr

oces

s

New

Bat

tery

Abu

se

Cel

l and

Bat

tery

Tes

t

Flig

ht A

ccep

tanc

eTe

st o

f Bat

terie

sQ

ualif

icat

ion

Test

of

Bat

terie

s

Perf

orm

ance

Engi

neer

ing

/C

ertif

icat

ion

Test

Envi

ronm

ent T

est

New

Bat

tery

Abu

se

Cel

l and

Bat

tery

Tes

t

Flig

ht A

ccep

tanc

eTe

st o

f Bat

terie

sQ

ualif

icat

ion

Test

of

Bat

terie

s

Perf

orm

ance

Engi

neer

ing

/C

ertif

icat

ion

Test

Envi

ronm

ent T

est

Page 9: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

9

Subs

eque

nt N

ew L

ot o

f Cer

tifie

d B

atte

ries

New

Lot

/ B

atch

of

Bat

terie

s Flig

ht A

ccep

tanc

e Te

stLo

t Sam

ple

Test

Crit

ical

eng

inee

ring

/ qua

lific

atio

n te

sts

on b

atte

ries a

nd c

ells

Page 10: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

10

Cur

rent

Saf

ety

Cer

tific

atio

n Pr

oces

s

Safe

ty D

ata

Pack

age

Stan

dard

: Fo

rm 1

230/

1230

Ror

U

niqu

e H

azar

d R

epor

t

Form

906

for T

rans

port

on

Rus

sian

Veh

icle

s an

d Fo

rm 9

07 F

or O

pera

tion

of B

asic

Sta

tion

Equi

pmen

t

Page 11: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

11

Exe

mpt

ions

•A

lkal

ines

: 12

V a

nd 6

0 W

h; o

nly

in s

erie

s or

onl

y in

par

alle

l; no

co

mbi

natio

ns o

f ser

ies-

para

llel,

no g

astig

ht b

atte

ry c

ompa

rtmen

t–

Flig

ht c

ells

and

bat

teri

es sh

ould

pas

s acc

epta

nce

test

s tha

t inc

lude

vis

ual

exam

inat

ion,

OC

V, C

CV

/func

tiona

l che

ck, v

acuu

m le

ak c

heck

(0.1

psi

afo

r 6

hour

s)–

App

licat

ion

and

prot

ectiv

e ci

rcui

t sch

emat

ic to

be

revi

ewed

and

app

rove

d by

ea

ch a

genc

ies a

ppoi

nted

Bat

tery

app

rove

r/te

am.

Nee

d fo

r V

ente

d B

atte

ry C

ompa

rtm

ent:

Ene

rgy

Con

tent

: W

ater

: KO

H e

lect

roly

te is

30

-45

% w

eigh

t in

wat

er.

KO

H is

el

ectr

olyt

e in

alk

alin

e ce

lls.

If e

lect

roly

zed

by in

adve

rten

t cha

rge

or

over

disc

harg

e, it

yie

lds a

H2/O

2m

ixtu

re th

at h

as a

n eq

uiva

lent

of 5

783

Btu

/lb

(Oxy

gen

is n

on-f

lam

mab

le b

ut su

ppor

ts a

nd v

igor

ousl

y ac

cele

rate

s com

bust

ion

of fl

amm

able

s; h

ydro

gen

is in

itse

lf a

fuel

).

Not

e: D

cel

l is 1

8 A

h ca

paci

tyW

h: V

x A

h (V

olta

ge x

Cap

acity

)

Page 12: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

12

Shor

t Cir

cuit

Tes

t on

Alk

alin

e C

ells

5060708090100

110

120

Dur

acel

l (C

T)D

urac

ell (

Ultr

a)En

ergi

zer (

E2)E

nerg

izer

(Std

)R

ayov

ac

Temperature ( deg C)o

)

9-V

AA

AA

AC

5060708090100

110

120

Dur

acel

l (C

T)D

urac

ell (

Ultr

a)En

ergi

zer (

E2)E

nerg

izer

(Std

)R

ayov

ac

Temperature ( deg C)o

)

9-V

AA

AA

AC

Page 13: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

13

Exe

mpt

ions

•B

utto

n ce

lls o

f Li p

rimar

y ty

pes

(LiC

F x, L

iMnO

2, Li

FeS

2, Li

V2O

5, Li

-iodi

ne, e

tc.),

Li r

echa

rgea

bles

(incl

udes

all

li-io

n, L

iV2O

5, Li

MnO

2, et

c.),

NiM

H, N

iCd,

Ag/

Zn, o

f 300

mA

hor

less

and

cel

ls

are

not i

n a

gas-

tight

com

partm

ent.

•N

o Li

BC

X, L

iSO

2, Li

SO

2Cl 2

or L

iSO

Cl 2

–Fl

ight

cel

ls a

nd b

atte

ries s

houl

d pa

ss a

ccep

tanc

e te

sts t

hat i

nclu

de v

isua

l ex

amin

atio

n, O

CV

, CC

V/fu

nctio

nal c

heck

, vac

uum

leak

che

ck (0

.1 p

sia

for 6

hou

rs)

–A

pplic

atio

n an

d pr

otec

tive

circ

uit s

chem

atic

to b

e re

view

ed a

nd a

ppro

ved

by e

ach

agen

cies

app

oint

ed B

atte

ry a

ppro

ver/t

eam

.–

Abo

ve a

ccep

tanc

e te

stin

g fo

r but

ton

cells

in S

ectio

n 9.

2 w

hich

are

so

lder

ed to

a c

ircui

t boa

rd in

com

mer

cial

equ

ipm

ent (

not a

pplic

able

to

thos

e bu

tton

cells

in a

sprin

g-lo

aded

clip

) is l

imite

d to

a fu

nctio

nal c

heck

of

the

equi

pmen

t util

izin

g th

e su

bjec

t bat

tery

.

Page 14: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

14

Exe

mpt

ions

for

Red

uced

Tes

ting

•C

OTS

NiM

H, N

iCd

and

Ag/

Zn c

ells

and

bat

terie

s fo

r IV

A u

se u

p to

20

V a

nd 6

0 W

h–

Cel

ls a

nd b

atte

ries p

urch

ased

in o

ne lo

t; pa

ss a

ccep

tanc

e te

sts t

hat

incl

ude

load

ed a

nd o

pen

circ

uit v

olta

ge m

easu

rem

ents

, vis

ual

exam

inat

ion,

leak

age

chec

k un

der v

acuu

m (e

.g 6

hou

rs a

t 0.1

psia

)an

d vi

brat

ion

to w

orkm

ansh

ip le

vels

with

func

tiona

l che

cks w

hich

incl

ude

char

ge/d

isc

–R

equi

re th

e us

e of

For

m-0

3 fo

r the

app

rova

l pro

cess

. M

anuf

actu

rer’

s spe

cific

atio

n, b

atte

ry p

rote

ctiv

e fe

atur

es a

nd

char

ger s

chem

atic

shal

l be

prov

ided

for a

ppro

val f

rom

the

resp

ectiv

e B

atte

ry a

ppro

ver/t

eam

for e

ach

agen

cy.

Page 15: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

15

Exe

mpt

ions

for

Red

uced

Tes

ting

•C

OTS

Li-i

on b

atte

ries

up to

10

V a

nd 6

0 W

hfo

r IV

A u

se

–B

atte

ries a

nd c

harg

er sh

all b

e fr

om a

sing

le lo

t; sh

all s

how

one

-fau

lt to

lera

nce

at b

atte

ry le

vel a

nd sh

all p

ass a

ccep

tanc

e te

sts t

hat i

nclu

de

load

ed a

nd o

pen

circ

uit v

olta

ge m

easu

rem

ents

, vis

ual e

xam

inat

ion,

le

akag

e ch

eck

unde

r vac

uum

(e.g

6 h

ours

at 0

.1ps

ia) a

nd v

ibra

tion

to

envi

ronm

ent o

r dou

ble

the

wor

kman

ship

leve

l, w

hich

ever

is h

ighe

r; an

d fu

nctio

nal c

heck

s whi

ch in

clud

e ch

arge

/dis

char

ge c

ycle

s. –

Req

uire

the

use

of F

orm

-03

for t

he a

ppro

val p

roce

ss.

Bat

tery

pro

tect

ive

feat

ures

and

cha

rger

sche

mat

ic sh

all b

e pr

ovid

ed fo

r app

rova

l fro

m th

e re

spec

tive

Bat

tery

app

rove

r/tea

m fo

r eac

h ag

ency

.N

ote:

Oth

er le

vels

of c

ontro

l sha

ll be

from

har

dwar

e us

ing

batte

ry, a

nd/o

r ch

arge

r; ex

istin

g da

ta fr

om p

ast e

xper

ienc

e; c

rew

mem

ber p

roce

dure

s in

the

even

t of a

n em

erge

ncy

Page 16: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

16

New

Bat

tery

App

rova

l For

ms

Mul

tilat

eral

Bat

tery

Mee

ting

was

hel

d be

twee

n:U

S, R

SC

-E, E

SA

and

JA

XA

at N

AS

A-J

SC

Upd

ates

gen

erat

ed a

s a

resu

lt of

thes

e m

eetin

gs:

•E

P-F

orm

-03

will

be

nece

ssar

y fo

r app

rova

l of U

S a

nd E

SA

bat

terie

s.

•E

P-F

orm

-17

and

EP

-For

m -1

7R fo

r inf

orm

atio

n ex

chan

ge w

ith R

SC

-E–

Aft

er a

ppro

val o

f the

For

m-0

3, th

e B

atte

ry e

xper

t will

com

plet

e a

EP-

Form

-17

on th

e U

S si

de.

•Th

e E

P-F

orm

-17s

hav

e le

ss in

form

atio

n bu

t will

let t

he c

ount

er-a

genc

y kn

ow th

at th

e ba

ttery

saf

ety

has

been

app

rove

d by

the

Bat

tery

exp

ert.

•E

P-F

orm

-17

will

be

subm

itted

by

the

Bat

tery

exp

ert a

long

with

the

Form

12

30 a

nd F

orm

907

sub

mitt

ed b

y th

e ha

rdw

are

owne

rs.

Uni

que

Haz

ard

Rep

orts

nee

d no

t be

subm

itted

to c

ount

er-a

genc

y if

the

EP

-For

m-1

7 is

sub

mitt

ed.

How

ever

, Uni

que

Haz

ard

Rep

orts

sha

ll be

su

bmitt

ed to

the

resp

ectiv

e ag

enci

es in

the

Saf

ety

Dat

a P

acka

ge fo

r ap

prov

al b

y th

e B

atte

ry e

xper

t.

•U

pdat

ed F

orm

907

to b

e co

nsis

tent

with

For

m 1

230.

Page 17: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

17

EP-

Form

-03

•R

equi

res

the

loca

tion

and

envi

ronm

ent (

tem

pera

ture

, pr

essu

re, e

tc.)

of h

ardw

are/

batte

ry•

Req

uire

s in

form

atio

n on

pre

fligh

t, on

-orb

it an

d po

st

fligh

t bat

tery

pro

cess

es•

Req

uire

s in

form

atio

n on

two-

faul

t tol

eran

ce

•V

erifi

es if

app

rova

ls fo

r tox

icity

and

mat

eria

ls

com

patib

ility

wer

e ob

tain

ed

Ref

er to

EA

-CW

I-033

for d

etai

ls o

n B

atte

ry P

roce

ssin

g

Page 18: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

18

Bat

tery

Che

mis

trie

san

dH

azar

ds

Page 19: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

19

Com

mon

ly U

sed

Lith

ium

Pri

mar

y B

atte

ries

Li-M

nO2

(Man

gane

se d

ioxi

de)

Li-S

OC

l 2(th

iony

lchl

orid

e)

Li-B

CX

(thi

onyl

chlo

ride

with

bro

min

e/ch

lorid

e ad

ditiv

e)

Li-S

O2C

l 2(s

ulfu

rylc

hlor

ide)

Li-S

O2

(sul

fur d

ioxi

de)

Li-C

F x(p

oly-

carb

on m

onof

luor

ide)

Li-F

eS2

(iron

dis

ulfid

e)

Page 20: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

20

Li P

rim

arie

s with

Org

anic

Ele

ctro

lyte

sH

azar

ds A

nd C

ontr

ols

Type

s: L

iMnO

2, Li

CF x

, LiV

2O5,

LiFe

S 2, e

tc.

Haz

ards

:–

Elec

troly

te le

akag

e-co

rros

ive,

flam

mab

le, i

rrita

nt–

Ven

ting

and

fire

at h

igh

tem

pera

ture

s•

Failu

re M

odes

–in

adve

rten

t cha

rgin

g, o

verd

isch

arge

into

re

vers

al, s

hort

circ

uit a

nd h

igh

tem

pera

ture

exp

osur

e•

Con

trol

s –

Lot

test

ing,

100

% fl

ight

AT

P te

stin

g w

ith le

ak c

heck

s–

Dem

onst

rate

tole

ranc

e to

inte

rnal

shor

t, m

anuf

actu

ring

qua

lity

cont

rol r

ecor

d, o

r sc

reen

ing

of fl

ight

bat

teri

es (e

g. V

ibra

tion)

–T

est d

ata

on e

xter

nal s

hort

, ina

dver

tant

char

ge, o

verd

isch

arge

into

rev

ersa

l with

pro

tect

ion

agai

nst a

ll th

ree

–T

empe

ratu

re m

onito

ring

whe

re n

eces

sary

Page 21: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

21

Li P

rim

arie

s with

Inor

gani

c E

lect

roly

te

LiB

CX

, LiS

OC

l 2, L

iSO

2Cl 2,

LiS

O2

TNT:

192

9 B

tu/lb

LiSO

Cl 2/

LiB

CX

: 200

0 B

tu/lb Pr

essu

re re

cord

ed d

urin

g H

eat-t

o-Ve

nt te

st o

n a

sing

le C

si

ze L

iBC

Xce

ll

Page 22: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

22

Haz

ards

:–

Elec

troly

te le

akag

e-co

rros

ive-

harm

ful t

o th

e lu

ngs,

eyes

and

skin

, can

be

leth

al–

Expl

osio

n at

hig

h te

mpe

ratu

res

•Fa

ilure

Mod

es –

inad

vert

ent c

harg

ing,

ove

rdis

char

gein

to

reve

rsal

, sho

rt c

ircui

t and

hig

h te

mpe

ratu

re e

xpos

ure

•C

ontr

ols

–L

ot te

stin

g, 1

00 %

flig

ht A

TP

test

ing

with

leak

che

cks

–D

emon

stra

te to

lera

nce

to in

tern

al sh

ort,

man

ufac

turi

ng q

ualit

y co

ntro

l rec

ord,

or

scre

enin

g of

flig

ht b

atte

ries

(eg.

Vib

ratio

n)–

Tes

t dat

a on

ext

erna

l sho

rt, i

nadv

erta

ntch

arge

, ove

rdis

char

gein

to r

ever

sal w

ith

prot

ectio

n ag

ains

t all

thre

e–

Tem

pera

ture

mon

itori

ng w

here

nec

essa

ry

–C

ells

shal

l be

herm

etic

ally

seal

ed

Haz

ards

and

Con

trol

s

NO

T A

llow

ed in

Cre

w C

abin

on

Shut

tle a

nd

Stat

ion

Page 23: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

23

Typ

ical

Pro

tect

ion

agai

nst E

xter

nal S

hort

and

O

verd

isch

arge

into

Rev

ersa

l

Page 24: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

24

Typ

ical

Pro

tect

ion

agai

nst I

nadv

erte

nt C

harg

e,

Ext

erna

l sho

rt a

nd O

verd

isch

arge

into

Rev

ersa

l

Page 25: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

25

Oth

er P

rote

ctiv

e D

evic

es fo

r P

rimar

y an

d S

econ

dary

B

atte

ries

Page 26: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

26

Fuse

sSi

ngle

Use

–m

ostly

in p

rimar

y ba

tterie

s

Mul

tiple

Use

–m

ostly

in re

char

geab

leba

tterie

s

Switc

hes/

PTC

switc

h

Page 27: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

27

NiC

dan

d N

iMH

Haz

ards

: –

Ele

ctro

lyte

leak

age

–co

rros

ive,

cau

stic

–H

igh

tem

pera

ture

s

Failu

re M

odes

:–

Ove

rcha

rge,

ove

rdis

char

gein

to r

ever

sal,

exte

rnal

shor

t cir

cuit,

hig

h te

mpe

ratu

res

Con

trol

: –

Goo

d en

d-of

-cha

rge

cuto

ff, p

erio

dic

mai

nten

ance

/con

ditio

ning

(to

rem

ove

mem

ory

effe

ct),

good

equ

ipm

ent o

r ot

her

unde

rvol

tage

cuto

ff, g

ood

shor

t ci

rcui

t and

ther

mal

pro

tect

ion

(pol

ywitc

hes,

ther

mal

fuse

s, et

c.)

Page 28: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

28

Li-i

on/L

i-ion

Pol

ymer

Bat

teri

es

Haz

ards

: –

Ele

ctro

lyte

leak

age

–ir

rita

nt, f

lam

mab

le

Failu

re M

odes

:–

Ove

rcha

rge,

ext

erna

l sho

rt c

ircu

it, h

igh

tem

pera

ture

s

Con

trol

: –

Cel

l Ban

k vo

ltage

mon

itori

ng, p

rote

ctio

n ag

ains

t ove

rvol

tage

, und

ervo

ltage

and

over

curr

ent(

IC c

hips

, MO

SFE

Ts,

PTC

s, fu

ses)

–V

ibra

tion

scre

enin

g or

man

ufac

turi

ng c

ontr

ol d

ocum

ent r

ecor

ds fo

r in

tern

al

shor

t con

trol

s–

Hig

h te

mpe

ratu

re p

rote

ctio

n –

tem

pera

ture

mon

itori

ng, t

herm

al fu

ses

Page 29: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

29

Tox

icity

Ref

eren

ce In

form

atio

n

Tox

mem

o sh

ould

be

obta

ined

from

the

toxi

colo

gist

who

mak

es

the

final

dec

isio

n.•

KO

H:

alka

line,

NiC

d, N

iMH

, AgZ

n–

caus

tic a

nd c

orro

sive

-will

bu

rn s

kin

and

eyes

. Ty

pica

lly T

ox2.

•H

2SO

4: Le

ad a

cid-

acid

ic a

nd c

orro

sive

, will

cre

ate

acid

fum

es

that

can

dam

age

thro

at a

nd lu

ngs.

Typ

ical

ly T

ox2

unle

ss th

e am

ount

is s

igni

fican

tly la

rge.

•S

OC

l 2: L

iSO

Cl 2

and

BC

X-b

urn

skin

, eye

s, d

amag

e th

roat

and

lu

ngs

to a

hig

her d

egre

e th

an a

bove

and

can

be

leth

al. T

ox4;

co

uld

be lo

wer

if e

lect

roly

te q

uant

ity is

neg

ligib

le.

•Li

(CF)

xan

d Li

MnO

2, Li

-ion:

affe

cts

skin

and

eye

s on

con

tact

; el

ectro

lyte

is fl

amm

able

and

can

cau

se fi

re in

the

pres

ence

of a

n ig

nitio

n so

urce

. To

x2

depe

ndin

g on

nat

ure

of s

alt i

n el

ectro

lyte

.

Page 30: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

30

Con

clus

ions

•Th

e ne

w p

roce

ss s

houl

d si

mpl

ify th

e in

form

atio

n pr

oces

sing

load

on

Inte

rnat

iona

l pa

rtner

s.

•Al

thou

gh it

requ

ires

mor

e w

ork

on th

e pa

rt of

th

e B

atte

ry E

xper

ts, i

t red

uces

the

amou

nt o

f da

ta tr

ansf

erre

d be

twee

n th

e ag

enci

es.

•Th

e ne

w re

quire

men

ts d

ocum

ents

pro

vide

de

taile

d in

form

atio

n on

saf

ely

proc

essi

ng

batte

ries

for f

light

.

Page 31: Judith Jeevarajan, Ph.D. IAASS Conference … Process for Commercial Batteries for Payloads Judith Jeevarajan, Ph.D. NASA- JSC Judith Jeevarajan/NASA-JSC 2 nd IAASS Conference Chicago,

Judi

th J

eeva

raja

n/N

ASA

-JSC

31

Ack

now

ledg

men

t

Inte

rnat

iona

l Par

tner

s –

ES

A a

nd R

SC

-EA

ll m

embe

rs o

f the

saf

ety

pane

ls (P

SR

P, S

MA

RT,

S

RP

, SS

RP

)JA

RS

WG

, JC

CT

mem

bers