Battery safety and design manual for payloads
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Battery Safety and Design Manual for Payloads. presented by Jerri S. Ling September 13, 2004. Background. Battery community suggests that the JSC battery handbook needs to be updated (June 2001). RMO submits a Code Q RTOP proposal to update the JSC battery handbook (Sept. 2001).

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Battery safety and design manual for payloads

Battery Safety and Design Manual for Payloads

  • presented by

  • Jerri S. Ling

  • September 13, 2004


Background

Background

  • Battery community suggests that the JSC battery handbook needs to be updated (June 2001).

  • RMO submits a Code Q RTOP proposal to update the JSC battery handbook (Sept. 2001).

  • RTOP is approved Oct. 2002 , however payload community recommendations for updates differ from PSRP recommendations (Jan. 2003 to March 2003).

  • Decision to make document internal to GRC (March 2003).

  • Initial information gathering (Best Practices, Lessons Learned, text books, graphics, vendor sites, etc) (March 2003 to Sept. 2003).

  • GRC-M8100-006 Battery Safety and Design Manual for Payloads completed (July 2004).


Overview

Overview

  • DOCUMENT PURPOSE - Provides a compendium of quality and safety-related best practices and reference information for design, and testing of cells and batteries used in space flight applications.

  • DOCUMENT SCOPE - Intended to provide project managers and design engineers with key elements of battery selection, factors to consider during the design/development phases, and clarification of the safety review process for batteries.

  • Used by payload designers in conjunction with the JSC Battery Handbook (JSC 20793).

  • Allows Project Management to more accurately map out required resources based on battery-related tasks that need to be performed.


Contents

Contents

  • CHAPTER 2 - REFERENCES

    • Applicable Documents

      • NSTS 1700.7B and it’s ISS Addendum - Safety Policy and Requirements for Payloads

      • NSTS/ISS 13830 - Payload Safety Review and Data Submittal Requirements

      • JSC 20793 - Manned Space Vehicle Battery Safety Handbook

      • GRC-0510-002 Space Assurance Requirements and Guidelines (SARG)

      • Others


Contents1

Contents

  • CHAPTER 3 - CELL/BATTERY DESIGN CONSIDERATIONS

    • Charging Batteries

    • Preventing Battery Short Circuits

    • Voltage Reversal

    • Thermal

    • Preventing Leakage

    • Preventing Improper Insertion


Contents2

Contents

  • CHAPTER 4.0 - FACTORS AFFECTING BATTERY PERFORMANCE

    • Voltage Level

      • Discharge load

      • Discharge mode (constant current, constant power, constant load, etc.)

    • Temperature during discharge

    • Service Life

    • Voltage Regulation

    • Charging Voltage

    • Battery Age/Storage Conditions

    • Battery Design


Contents3

Contents

  • CHAPTER 5.0 - BATTERY SELECTION AND APPLICATIONS

  • CHAPTER 6.0 - CELL/BATTERY TEST PLANS

    • Purpose of Test Plan

    • Test Plan Outline

    • Test Plan Checklist


Contents4

Contents

  • CHAPTER 7.0 - GROUND TEST CONSIDERATIONS

    • Hazards and Precautions for Battery usage

    • Battery Test Facility Checklist

    • Safe Handling Requirements

      • Lead-Acid Batteries

      • Nickel-Cadmium Batteries

      • Lithium Batteries

    • Emergency Procedures

      • Exposure to Electrolyte

      • Leakage/Venting/Temperature increase

      • Cell Rupture

      • Lithium Cell Fires

    • Disposal Procedures


Contents5

Contents

  • CHAPTER 8.0 - FLIGHT SAFETY REQUIREMENTS

    • Overview of Flight Safety Review Process/Requirements Summary

    • General Hazards and Controls

      • Structural

      • Gas Evolution

      • Elevated Pressure

      • Electrolyte Leakage

      • Short Circuits

      • Circulating Currents

      • High Temperature

      • Overcharging

    • Safety of Specific Battery Types

      • Lithium Ion, Nickel-Cadmium, Nickel Hydrogen, Silver-Zinc, et al.


Contents6

Contents

  • CHAPTER 9.0 - CELL SCREENING TESTS

    • Automated Testing Equipment

    • Coulombic Efficiency

    • Polarization Testing

    • Open Circuit Decay Test

    • Tailoring Screening Tests for Specific Cells

    • Thermal Tests


Contents7

Contents

  • CHAPTER 10.0 - BATTERY TEST PROGRAM

    • Engineering/Certification Tests

      • Battery Level Performance Testing

      • Abuse Tests

    • Qualification Testing

    • Flight Acceptance Testing

    • Payload vs. GSE Usage and Testing

    • Recommendations


Contents8

Contents

  • CHAPTER 11.0 - OTHER ENERGY STORAGE DEVICES

    • Fuel Cells (description of various types), Flywheels

  • APPENDIX A - LESSONS LEARNED

  • APPENDIX B - THEORETICAL VOLTAGE/CAPACITY TABLE

  • APPENDIX C - SUMMARY OF BATTERY BEST PRACTICES

  • Glossary of Terms/Acronym List


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