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Aeroflexs Battery ManagementElectronics for Lithium Ion Batteries
Achieves TRL 9 for Earth &
Inter-Planetary Orbital Missions
Joseph Castaldo
Global Director, Business Development
Space Power Workshop
April 16 19, 2012
1 Space Power Workshop 20121
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Abstract
Currently the Aeroflex Lithium-Ion battery cell balancingelectronic units are flying on three spacecraft. More units arein manufacturing and are slated to be launched over the nexttwo years. Additionally, a set of cell voltage monitoring andover voltage protection units is scheduled to be launched on
Commercial Orbit Transportation System later this year. Thispaper briefly summarizes the development history, designhighlights and features of these products in addition todocumenting the flight experience, describing the on-goingground test efforts and finally provides information on future
product development efforts.
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Agenda
Introduction Overview of Lithium-Ion Battery Electronics Unit (BEU)
On-orbit Experience and Future Launches
Geosynchronous Earth Orbit (GEO)
Inter-Planetary
BEU Ground Testing Experience
Overview of Battery Interface Electronics (BIE)
NPOESS Preparatory Project (NPP) Update
Future Power Management Products
Summary
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www.aeroflex.com
Headquartered in Plainview, New York
Founded in 1937
An Integrated Power Electronics, Test &
Measurement and Microelectronics
Company Focused on:
Aerospace / Defense Wireless / Broadband Communications
Medical, Industrial
Aeroflex at a Glance
Flip ChipPackaging
Quad, Rad HardVoltage Supervisor
Rad HardASICs
Rad HardPWM
Space GradeVoltage
Regulators
HeritageChip On Board
BatteryElectronics
Unit
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BEU Overview
Lithium-Ion batteries have
become prominent in space
applications, because of their
lighter weight and lower cost
than NiH2 batteries
Lithium-Ion batteries requireelectronic cell balancing to
reduce the possibility of
overcharging or deep
discharging
Cell balancing is required toachieve the maximum
possible mission life for a
Lithium-Ion battery and the
corresponding platform
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BEU Development History
The Aeroflex family of Battery Electronics Units (BEU) was designed,fabricated and tested to meet specifications from Boeing, Northrop
Grumman and Lockheed Martin, for use with Lithium-Ion batteries onthe Boeing HS-702B and other satellites
Basic approach for BEU developed by Boeing, and described inPatent 6,873,134. This patent describes transformer-coupled DC-ACconverters that transfer charge over a bidirectional Share Bus
Additional Patents issued to Aeroflex during the development:
Battery Balancing Including Resonant Frequency Compensation, US 7,592,775 Compensation for Parasitic Resistance in Battery Monitoring, US 7,786,701
Aeroflex has completed the electrical and mechanical design of theoriginal BEU plus multiple derivatives. Engineering Models (EM) andEngineering Qualification Models (EQM) have been fabricated andtested
Multiple Flight units have been delivered & launched In addition to cell balancing, the BEU provides the following
additional functions: Cell voltage monitoring
Battery voltage monitoring
Telemetry (MIL-STD-1553)
Driver circuits to activate external Battery Cell Isolation SwitchesSpace Power Workshop 20126
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Desirable Features of a Cell Balancing System
Autonomous operation
turn-on & forget!
Operate continuously during
charge, discharge & standby modes
Balancing current directly proportional
to voltage difference between cells
Balancing / Monitoring accuracy:
+/-5.0mV BOL
+/-20.0mV EOL (18 years, GEO)
Highly efficient resonant
Power Converters
Fault tolerant, for both cell faults and circuit faults
Negligible degradation due to temperature, life and
radiation
The 24 Cell Unit draws 3W from the battery plus ~9W
from the bus
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BEU Functional Block Diagram
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Mechanical Design of the 24 Cell BEU
Size: 11.5L x 5.25W x 5.25H
Weight: 8.20 lbs (3.75 Kg)
Analyzed, tested and qualified for pyro-
shock, vibration and thermal vacuum
3 machined housings (slices), fastened
with twelve 10-32 bolts
Housings made of nickel-plated
aluminum, painted black for emissivity
Includes 2 Balancing Cards, 2 Control
Cards, 1 Bypass Device Driver Card
Fully redundant for balancing /
telemetry
Balancing Card
Bypass Device Driver CardControl Card
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BEU Physical Construction & Environments
Temperature Range Operational -24oC to 61oC
Qualification -34oC to 71oC
Pyro-shock
2500G SRS
Random Vibration
Peak Spectrum 28G2/Hz X,
17G2/Hz Y & Z ~50 to 400Hz
Compliant with MIL-STD-461E CE01, CE02, CS01, CS02, RE02, RS03
(5V/m and 20V/m)
FMECA
Reliability (Excludes Bypass Slice) Failure Rate: 186.79 FITS
MTBF: 5,353,605 hours Probability of Success: 0.999158, (18 years, GEO)
More than 100 WCAs performed Power Supply
Balancing Circuits
12 Bit A/D Conversion
Monitoring Accuracy +/-10mV BOL, (+/-20mV 18 years, GEO)
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Primary Slice (R):Balancing & Telemetry
Center Slice:
Bypass Drivers
Redundant Slice (L):Balancing & Telemetry
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BEU: Active, Autonomous Cell Balancing
Autonomous Balancing
No need for cell voltage
measurement!
Share Bus uses Transformer
Coupled Charge Sharing to
distribute charge from high
voltage cells to low-voltage cells
Long Term Stability is not
affected by environment
(temperature cycles, aging,
radiation)
Balancing / Monitoring accuracy:
+/-5.0mV BOL
+/-20.0mV EOL (18 years, GEO)
Active & Continuous vs.
Dissipative & Periodic Balancing
High voltage cells help charge low
voltage cells
Highly efficient resonant converters
draw 1/8 W per cell from battery
Ideal for any mission life and orbit Continuous Balancing is
beneficial to LEO Missions
Easy to use and interface to existing
systems
Turn-on and forget!
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BEU On-Orbit Experience&
Ground Test Results
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BEU On-orbit Experience & Future Launches
8 Cell
Dual Redundant
JUNO - 28V BUS
LaunchedAug 5, 2011
24 Cell
Dual
Redundant
HS-702HP
SkyTerra 1
Launched Nov. 2010
HS-702MP
Intelsat Flight 22
Launched Mar. 2012
HS-702HP
Mexsat-1
Launch 2013
HS-702MP
Intelsat Flight 21
Launch Fall 2012
INTER- PLANETARY
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GEO
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BEU Ground Testing & Evaluation
8 Cell Balancer Lab Unitwith the same Aeroflex
Autonomous Balancing
Technology used in Flight
Organization Test Test Duration Status Remarks
Aerospace Corp Cycle Life Multiple Years Anticipated Unit on Order
Boeing Cycle Life On going, >6years to date
BEU performing asexpected
Identical BEUs forLEO & GEO
NASA Glenn Rover Study,2 units installed
Multiple Years Assembled & in cue Yet to commence
NASA JPL Planetary Cycle Life Multiple Years Anticipated Under Discussion
Naval SurfaceWarfare Center
Comparison of 3 cellbalancing designs
Multiple Years In progress NSWC will presentin 2013
NorthropGrumman
LEO Cycle Life 910 Cycles Concluded Results presentedherein
SpaceSystems/Loral
GEO Cycle Life 3 years to date BEU performing asexpected
Results presentedherein
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Government
FundedLEO Ground Test
24 Cell, Non-Redundant
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BEU Ground Testing Results
An Aeroflex BEU is being used on a 24 cell battery in real time life test at SS/L. The test
is in its third year and the BEU has consistently balanced the cells to within a few mV
(A direct quote from Space Systems/Loral)
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4mV
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BEU LEO Test Setup and Overview
Balancing Features of BEU* (CME) Tested
with Actual Li-ion Battery Battery Composed of 12 Lithium Ion Cells (48Ah) in Series (12s)
12 Channel BEU Performing Cell Management on the Battery
Test Regime
Battery and BEU Subjected to LEO cycling 100 minute orbit - 36 minute eclipse
30% Depth of Discharge
Resistor Values (1000, 500 , and 233 ) Placed in Parallel
Across an Individual Cell to Simulate Various Levels of Internal
Cell soft short
Response of Individual Cell Voltages and Overall Dispersion
Monitored Throughout LEO Cycling to Evaluate BEU Operation
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* BEU is also known as CME (Cell Management Electronics) at NGC
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LEO Evaluation Cycling Summary
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3.540
3.545
3.550
3.555
3.560
3.565
3.570
3.575
3.580
3.585
3.590
3.595
3.600
0 100 200 300 400 500 600 700 800 900 1000
EODV(volts)
Cycle Number
12-Cell Average EODV
Cell 6 EODV
12s Pack Test - CME Evaluation
CME ON
CME OFF1 kR
across cell 6
CME ON1 kR
remainsacross Cell 6
CME OFF"natural" cell
divergance takingplace
CME OFF1 kR
remainsacrossCell 6
CME OFF1kR across Cell6 replaced with
500 R
CME ON500 R
remainsacross Cell 6
CME ON233 R
across Cell 6
Cell-to-cell voltage dispersion WithBEU balancing during LEO cycling
End of Discharge Voltage (EODV)
as a Function of Cycle Numberand Test Article Configuration
Overall performance of the BEU (CME) during test and evaluation was nominal
The share bus was able to correct the imbalance conditions created when the
1000 ohm, 500 ohm, and 233 ohm resistors were connected across the terminals
of cell 6 to simulate cell shorts
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For more information, please visit:
www.aeroflex.com/BEU
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Battery Interface Electronics (BIE)
The Aeroflex BIE was designed, fabricated and tested to meet
specifications provided by Orbital Sciences Corp. for use with Lithium-Ionbatteries in the Commercial Orbital Transportation System (COTS) todeliver cargo to the International Space Station at low earth orbit (LEO)
Aeroflex has completed the electrical and mechanical design of the BIE.Engineering Models (EM), Engineering Qualification Models (EQM) and
flight units have been fabricated, tested, qualified and delivered to Orbital The BIE includes the following features:
Analog telemetry for monitoring of cell voltages, battery voltage and celltemperatures
Independent Overvoltage Protection (OVP) / Overcharge Protection(OCP)
Battery on/off control through two series 50A contactors
Access port for connection to external cell balancing circuit
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Ideal for Short Missions where cell balancing is optional!
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BIE Functional Block Diagram & External Interfaces
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Battery Interface Electronics (BIE) Application
Commercial Orbit Transportation System
Expected Launch 2013, Multiple Units
Orbital Sciences Cygnus Spacecraft, 28V Bus
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Provides electrical interface
between battery and spacecraft
Analog Conditioning circuits,
provide 0 - 5V conditioned telemetry
outputs for each cell, for the total
battery, and for 8 thermistor
temperature sensors
OVP circuits monitor each cell
voltage. If any cell voltage exceeds
4.5 V, isolation relays open,
disconnecting battery from charger.
Circuit is dual redundant, and no
single point failure can cause relays
to open inadvertently Isolation relays can be controlled
from external sources, to isolate
the battery from the charger
A connector port provides access
for an external balancing circuit
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BIE Mechanical Design
Size: 11.7 L x 6.95 W x 3.63 H
(excluding connectors)
Weight (Complete BIE Unit):
6.6 lbs (3.0 Kg)
BME-1 Slice: 0.46 lbs (0.21 Kg)
BME-2 Slice: 0.51 lbs (0.23 Kg)
Analyzed and tested for pyro-shock,
vibration and thermal vacuum
Fastened to Battery Assembly with
eight bolts, 8-32 size
Housing made of nickel-platedaluminum, painted black for emissivity
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BIE
OverVoltage
ProtectionSlice
VoltageTemp
AnalogConditioning
Slice
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NPP Satellite LaunchOctober 28th, 2011
AEROFLEX launches its latestChip-On-Board Product
Contributed two Chip-On-Board PowerSupplies to CrIS Instrument: 8621 Digital and
8622 Quiet Power Supplies
DIGITAL FLIGHT PWB QUIET FLIGHT PWB
Digital Power PWB
SMT SideQuiet Power PWB
Encapsulated Side
6.4L x 5.5W x 0.97 H
28V Input with Outputs:
+3.3V, +5.0V, +/-12.0V
125W
6.4L x 5.5W x 0.97 H
28V Input with Outputs:
+/-12V, +/-5.2V
41W
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Future Power Management Products
Input range = 95 105Vdc
Output range = 26 48 Vdc
1.50L x 1.05W x 0.29H, SMT
Density > 150Watts / In3
92% Efficiency
Built-In Protection
Input overvoltage & undervoltage shutdown
Overcurrent/ short circuit protection
Over-temperature protection
Adaptive Loop feedback
ZVS buck-boost regulator
Total dose: 100 krads (Si)
SEL: immune up to 80 MeV-cm2/mg
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InputRegulator
Module
Input range = 26.0V 48.0Vdc
Output range
1.0Vdc for 32.0Vdc In
1.5Vdc for 48Vdc In
1.60L x 0.95W x 0.29H, SMT
Density > 170Watts / In3
>90% Efficiency
Built-In Protection
Input overvoltage & undervoltage shutdown
Overcurrent/short circuit protection
Over-temperature protection
ZVS / ZCS Resonant Converter topology Total dose: 100 krads (Si) SEL: immune up to 80 MeV-cm2/mg
Isolated Pointof Load
Module
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Summary
The Battery Electronics Unit (BEU) is an elegant, fully autonomousand continuous, Lithium-Ion cell balancing system with very low heat
dissipation and current consumption Risk Mitigation: Available to serve multiple missions on an immediate
basis
The Battery Interface Electronics (BIE) is a lower cost Lithium-Ionbattery management system that facilitates monitoring of cell voltages,
temperatures and provides overcharge/overvoltage protection.Suitable for missions where balancing is not used or necessary
Both products can be tailored to customer needs and can be suppliedat slice levels to be housed in other spacecraft avionics enclosures.
Aeroflex has strongly demonstrated its commitment to the missions
supported by this audience
Our Space proven Lithium-Ion Cell Balancing and Battery Management
Electronics coupled with your batteries, is the Ultimate Solution!
Turn On and Forget!
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f
Recognition
Aeroflex would like to offer sincere thanksto the following organizations who
contributed to this presentation
Aerospace Corporation
Boeing Northrop Grumman
Orbital Sciences
Space Systems/Loral
NASA
Naval Surface Warfare Center
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