ves16 cell and battery design · > one sbs in parallel of one ves16 cell > possibility to...

VES16 Cell and Battery DesignDr Y.Borthomieu and D.Reulier

2012 Nasa Battery WorkshopHunstsville, 6th-8th November

S3094-12

2

Agenda

1. VES16 design and performances

2. Battery concept overview

3. VES16 battery range

4. Heritage

S3094-12 NASA Battery Workshop - Hunstville, Al : 6th to 8th November

Cell design and performances

3

1


VES16 cell main features : Low capacity space cell

VES16 Li-ion cell developped, qualified by Saft under CNEScontract in 2011

S3094-12 NASA Battery Workshop - Hunstville, Al : 6th to 8th November4

Dimensions (Ø x H) 33 x 60 mm (D-size)

Weight av 105 g

Volume 0.051 dm3

Voltage range 2.7 V - 4.1 V

Nominal capacity 4.5 Ah @ 4.1V, 20°C

Nominal energy 16 Wh @ 4.1V, 20°C

Specific energy > 150 Wh/kg

Internal resistance ≤ 35 mΩ @ 20% DoD

Operating temperature +10°C / +40°C

Mechanical design margins EWR & ECSS compliant

Circuit-breakerNegative polarity

Positive polarity

Stainless steel case

VES16 chemistry : NCA/graphite


Electrolyte: Carbonate blend LiPF6 based

Positive electrode Li-NixCoyAlzO2

Carbon PVDF

Negative electrode Specific LEO graphite blend Non-fluorinated

binder

3-layer shutdowneffect separator

Mechanical circuit-breaker

Qualification Review done on July 2011

Safety : reliable circuit-breaker

Circuit-breaker:> Pressure-activated in abusive conditions (U, T°)> Operates independantly of any external command> Electrically disconnects the cell (irreversible)> Maintains the cell mechanically closed (no leak)


BEFORE ACTIVATION AFTER ACTIVATION

RUPTURE PLATE

PRESSURE MEMBRANE

(-) TERMINAL (+) POLARITY INSULATION

VES16 versus VES140,180, VL48E & MPS176065


Comparison with parent Saft’s electrochemistries:

=+

MPS176065 VES100/140 VL48E VES180 VES16

Capacity 5.8 Ah 40 Ah 48 Ah 48 Ah 4.5 Ah

Specific energy 135 Wh/kg 128Wh/kg 168 Wh/kg 170 Wh/kg 157 Wh/kg

Positive material LiCoO2 NCA NCA NCA NCA

Negative material Graphite mix Graphite mix Graphite mix Graphite Graphite mix

Electrolyte LiPF6 based LiPF6 based LiPF6 based LiPF6 based LiPF6 based

(SIZE & CIRCUIT BREAKER) (NCA CHEMISTRY)

VES16 capacity vs discharge rate and temperature


Discharges at +20°C

2,7

2,9

3,1

3,3

3,5

3,7

3,9

4,1

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0

Capacity (Ah)

Volta

ge (V

)

2CC

C/2C/3

C/5

Discharges at +40°C

2,7

2,9

3,1

3,3

3,5

3,7

3,9

4,1

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0

Capacity (Ah)

Volta

ge (V

)

2CCC/2

C/3C/5

2,7

2,9

3,1

3,3

3,5

3,7

3,9

4,1

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0

Volta

ge (

V)

Capacity (Ah)

Dischargesat C/2 and varioustemperatures

50°C

40°C

20°C

0°C

-1 0°C

-2 0°C

2,7

2,9

3,1

3,3

3,5

3,7

3,9

4,1

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0

Volta

ge (V

)

Capacity (Ah)

Discharges at -20°C

2C

C

C/2

C/3

C/5

VES16 characterization from -20°C to +50°C, from 2C to C/5:

VES16 energy vs discharge rate and temperature


10

12

14

16

18

20

2C C C/2 C/3 C/5

Ener

gy [W

h]

Continuous discharge rate

50°C 40°C 20°C

0°C -10°C -20°C

10

12

14

16

18

20

-40°C -20°C 0°C 20°C 40°C 60°C

Ener

gy [W

h]

Discharge temperature

2C C C/2 C/3 C/5

VES16 characterization from -20°C to +50°C, from 2C to C/5:

VES16 other electrical characteristics


-2,0E-04

-1,0E-04

0,0E+00

1,0E-04

2,0E-04

3,30 3,50 3,70 3,90 4,10

dV/d

T

Open Circuit Voltage

Thermoneutral potential

VES16

2,7

2,9

3,1

3,3

3,5

3,7

3,9

4,1

0% 20% 40% 60% 80% 100%

Volta

ge (V

)

Depth of Discharge

Cell Open Circuit Voltage at 20°C

OCV

0

25

50

75

100

0% 20% 40% 60% 80% 100%

Ri[m

Ohm

]

Depth o f discharge

Internal resistance vs DoD & Temperature

40°C

30°C

20°C

10°C

0°C

-10°C

0

25

50

75

100

-20°C -10°C 0°C 10°C 20°C 30°C 40°C 50°C

Ri[m

Ohm

]

Temperature

Internal resistance vs Temperature & DoD0%10%20%30%40%50%60%70%80%90%

80

82

84

86

88

90

92

94

96

98

100

0 5 000 10 000 15 000 20 000

Ret

aine

d en

ergy

[%

]

Cycles

VES16, 20% DoD, 20°C, 4.05V

VES16, 20% DoD, 20°C, 3.90V

VES16, 20% DoD, 20°C, 4.00V

VES16, 20% DoD, 20°C, 4.05V

VES16, 30% DoD, 20°C, 4.05V

VES16, 20% DoD, 30°C, 4.05V

VES100 15% DoD, 20°C, 3.85V

VES100 15% DoD, 20°C, 3.95V

VES100 15% DoD, 20°C, 4.05V

MPS 18% DoD, 20°C, 4,10V

VES16 accelerated test

<= VES16 reference test

LEO - VES16 real-time cycling : Good performancesat high DOD

VES16 cycling performance in LEO (12,000 LEO cycles and counting):> VES16 charge current (real-time test) : C/5 at 20%DoD, C/3 at 30% DoD


LEO - VES16 real-time cycling : 20 % DOD 4.05 V 20°C


3,0

3,1

3,2

3,3

3,4

3,5

3,6

3,7

3,8

3,9

4,0

4,1

juin-10 août-10 oct.-10 déc.-10 févr.-11 avr.-11 juin-11 août-11 oct.-11 déc.-11 févr.-12 avr.-12 juin-12

EOD

V (V

) +

EO

CV (

V)GEO - VES16 accelerated cycling - 70% DoD


Accelerated GEO cycling at 70% DoD, 20°C (completed):Voltage loss ~50mV from season 1 to season 45

30 seasons (15y GEO)

3,370

3,380

3,390

3,400

3,410

3,420

0 5 10 15 20 25 30 35 40 45Eo

DV [V

]Seasons

GEO - VES16 accelerated cycling - 70% DoD

Comparison of cell voltage during longest eclipse from season 1 to 37:> Constant power discharge at C/1.8 for 72 min> Very slow and stable decay of EoDV through season 1 to 45 (about 50 mV loss)


3,0

3,1

3,2

3,3

3,4

3,5

3,6

3,7

3,8

3,9

4,0

4,1

00:00:00 00:15:00 00:30:00 00:45:00 01:00:00 01:15:00

Cell

volta

ge (

V)

Time (h:min:sec)

Ucell in discharge (season 1 to 29) EoDV at 72 min (season 1 to 45)

(15y GEO)

GEO - VES16 accelerated cycling – check-up


VES16 cycling performance in GEO (45 seasons done - completed):> Accelerated GEO life-test w/o solstice (worst case compared to real-time or semi-accelerated life-test)> Energy loss: ~2% loss after 30 seasons (15 years of GEO cycling)

15y GEO

90%

92%

94%

96%

98%

100%

0 5 10 15 20 25 30 35 40 45

Var

iatio

n

Seasons

Energy 60% DoD Energy 70% DoD

Autonomous balancing system

16

5


Simplified Balancing System (SBS)

Principle:> The bypassed current Ib is stopped when the cell voltage is lower

than an adjustable threshold (U0)> No command or monitoring required

Hardware:> One SBS in parallel of one VES16 cell> Possibility to fine tune U0 and Ib by modifying R1/R2 and RS values.> Core component is a reference voltage available with military and

space grades (QML-Q or QML-V according to MIL-PRF-38535).> High reliability: λSBS = 1.5 FIT

Advantages:> Simple, autonomous and low cost.> Low leakage current during stand by phases, applicable to

GEO/MEO missions (stand-by in solstice, when Ucell < U0).

Application :> Iridium Next batteries


U cellU0

Ib

I0

Ucell

Ib

R2

R1RS

SBS

C

0

10

20

30

0°C 20°C 40°C

SBS characteristics

SBS characteristics:> I0 ~250 to 500 µA (i.e. < C/12,000) when U_cell is below 3.9V (storage or cycling)> SBS operational beyond activation voltage of circuit-breaker (overcharge)> U0 spread around 10 mV among SBS units> U0 variation +/-5mV on [0°C;+40°C] corresponding to 0.25 mV/°C


0

10

20

30

<10mV spread

U0

Spread

Umax

T° sensitivity

+/- 5mV variation

I bal

anci

ng[m

A]

I bal

anci

ng[m

A]

U0 Umax

0,1

1

10

100

1000

U0 Umax Ucircuit-breaker

Storage/cycling Overcharge

Umin

SBS behavior in GEO cycling

4S3P VES16 in real-time GEO cycling (i.e. 1st eclipse 21 min, 23rd eclipse 72 min, etc.):> Initial spread forced to 150 mV> Discharge at C/1.8 (i.e. 66% DoD in 72 min)> !!!!!! !! !!! !!!! !!!!k + % 0 → 0 → 0@ 6→ : w $S = )4 + ?# * 6)) @ :

%&'! (( k ! ( - " #$&

@

@

@

%

%

%

% '

%

% "

'

'

-- '-- '"-- ?-- &-- --

7 7 7% 7'7@ 7 7? 7"7& 7 7 7

!

!"

!

!'

!

'

"

%

'

@

?

-- '-- '"-- ?-- &-- --

7 $ H $

Battery concept overview

20

2


Battery system layout


Simple interface: each SBS work autonomously & independantlyTM/TC: heaters & thermistors (redunded)Access to each cell voltage possible through Test Connector during MAIT

SBS

SBS

SBS

SBS

SBS

SBS

SBS

SBS

SBS

SBS

SBS

SBS

TM/TC CONNECTOR

POWER CONNECTOR

TEST CONNECTORTEST CONNECTORTEST CONNECTOR

TH2

TH1

H2H1

H3

6S

8S

10S

0 Wh

500 Wh

1000 Wh

1500 Wh

4P

5P

6P

8P 384

480

576

768

512

640

768

1024

640

800

960

1280

VES16 standard range

Standard range:> Voltage step: 6S , 8S, 10S / Capacity step: 4P, 5P / 6P, 8P to cover

from 6S to 20 S with 4P to 60P> Other configurations possible on request


4P

5P

6P

8P

6S8S

10S

VES16 battery approach

Battery approach:> Mono-block battery: as many building as necessary in parallel, one interface> Multi-block battery: one interface per building block, to be spread in the

platform


Mono-bloc battery Multi-block battery

10S8P VES16 battery block


Block 10S8P VES16

Energy 1,300 Wh at C/3, 20°C

Power760 W for GEO under 70% DoD

520 W for LEO under 20% DoD

EoCV 40.5V (Recommended)

Min voltage 34V BoL, after 72 min under 760W

L x W x H 190 x 410 x 180 mm3

Mass 11.5 kg

10S8P VES16 thermal behavior (GEO cycle)

Thermalmathematical modelT° mapping at theend of discharge:

20

21

22

23

24

25

26

0 2 4 6 8 10 12 14 16 18 20 22 240

1

2

3

4

5

6

Max T° (cell #114)

Avg T°

Min T° (cell #249)

Max. gradientT° evolution during24h under 1.2hdischarge (20°Cwall):


10S8P VES16 mechanical design

1st EigenFrequency

Random levels

X axis 265 Hz 20.3 Grms

Y axis 570 Hz 20.3 Grms

Z axis 515 Hz 17.9 Grms


xy

z

Vibration tests:

Main modes:

y

xz

10S8P VES16 mechanical behavior


Mechanical mathematical modelcomposed of 76,000 elements and73,500 nodes:

Mode shape of the maineigen frequency at 256Hz

Y-axis

X-axis

Z-axis

Z-axis random load – 3σVon Mises stresses

Nanosat exemple: 4S3P VES16


Budgets Value

Energy 205 Wh

Capacity 13.5 Ah

Dimension (L x l x h) 174 x 114 x 75 mm3 max

Mass 1.8 kg

Launch date End 2012

Conclusion

29

3


Conclusion

Low capacity VES16 space cell is qualified for LEO and GEOmissions with typical NCA performances

Battery range qualification to cover from 6S to 12S and 3Pto 50P :

> 7 contracts on-going with configurations from 3P to 30P

First flight expected end 2012 or beginning 2013 (ISTSAT)

VES16 format has been selected to support the 250 Wh/kgcell development and qualification started with ESA/CNES


Saft Li-ion in orbit heritage84 satellites already in-orbit with Li-ion (GEO, MEO & LEO) : 76 operational

> More than 190 million of cell*hours, and a total around 1.07 MWh in-orbit

> 63 GEO satellites Launched today with VES technology (5 launch failures):• W3A launched 14th March 2004 with VES140• OPTUS-D3 launched 21st Aug 2009 with VES180• Last launches : ASTRA 2F launched 29th Sept 2012 and Yamal 300K launched the 3rd of November

> 5 MEO satellite flying with VES technology:• Giove-B flying since April 08• 4 Galileo IOV launched in Nov 2011 with VES180

> 16 LEO satellites are today in-orbit with VES or MPS Li-ion technologies:• 5 with VES technology: Calipso, Corot, Jason, SMOS, SRE1, Kompsat 3 (with ISIS electronic)• 11 with MPS technology: Agile, SSETI, Proba-2, NanoSat-1B, CanX-2, NTS, OG2 -1

31

SMOS Proba-2 Optus-D3


Acknowledgements

P. Tastet from CNES for its technical and financial supportE.Simon from ESA for supporting the characterization tests


Thank You

33 S3094-12 NASA Battery Workshop - Hunstville, Al : 6th to 8th November

ves16 cell and battery design · > one sbs in parallel of one ves16 cell > possibility to...

Documents