Cell Matching.doc by handongqp

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									                 Air Force Research Laboratory                                   UN-PLN-12328
                 Space Vehicles Directorate                                      Revision: Draft
                                                                                 September 2001




                Battery Cell Acceptance Test Plan
                       University Batteries
                               University Nanosat Program




                              University Nanosat Program Office
                                   3550 Aberdeen Ave. SE
                                         Building 472
                               Kirtland AFB, NM 87117-5776




 The publication of this material does not constitute approval by the government of the findings or
conclusion herein. Wide distribution or announcement of this material shall not be made without the
                      specific approval of the sponsoring government activity.


               Distribution limited to US Government agencies and their contractors.
University Nanosat Program                                                                 AFRL/VSSV, SMC/TELH



1.    INTRODUCTION

A complete listing of batteries and their relative locations on Nanosat-1 are shown in Table 1-1 and
Figure 1-1. Similar information is provided for Nanosat-2 in Table 1-2 and Figure 1-2, respectively.
                      Table 1-1: Summary of Batteries/Battery Types on Nanosat-1
     Used On                 Cell Type              Number of Cells                Characteristics
                     NiCd rechargeable                                   Open Bus Voltage: 28-33V
MSDS                                                       22
                     Sanyo N4000DRL                                      Pack Capacity: 4 A-h
                     NiCd rechargeable                                   Open Bus Voltage: 12V
Orion                                                      10
                     Sanyo KR10000M                                      Pack Capacity: 10 A-h
Emerald (See         NiCd rechargeable                                   Open Bus Voltage: 12.6
                                                       10/satellite
Note 1)              Sanyo KR 5000DEL                                    Pack Capacity: 5 A-h
Notes for Table 1-1:
1.    Two battery packs are used on each Emerald satellite for a total of four battery packs. Characteristics shown in
      the table are for a typical satellite. Thus, the entire Emerald stack contains 20 NiCd cells.


                                                                                 Orion Battery
                                                                                 Sanyo NiCd KR10000M cell
                                                                                 10 cells, series
     Emerald Batteries                                                           12 V, 10A-h
     2 Batteries (identical)
     Sanyo NiCd KR-5000DEL cell                                                    MSDS Battery
     10 cells per satellite (2 packs per                                           Sanyo NiCd N4000DRL
     satellite), arranged in series                                                22 cells, series
     12.6 V, 5A-h                  z
                                                                                   28 V, 4A-h
                           x (AFT)


                                                                                      SHELS Interface Plane

                                  Figure 1-1: Battery Locations, Nanosat-1

                      Table 1-2: Summary of Batteries/Battery Types on Nanosat-2
     Used On                 Cell Type              Number of Cells                Characteristics
                     NiCd rechargeable                                   Open Bus Voltage: 28-33V
MSDS                                                       22
                     Sanyo N4000DRL                                      Pack Capacity: 4 A-h
                     NiMH rechargeable                                   Open Bus Voltage: 14-18 V
ION-F/USUSat                                               11
                     Sanyo HR-4/3FAUX                                    Pack Capacity: 4.5 A-h
                     NiCd rechargeable                                   Open Bus Voltage: 23 V
ION-F/Dawgstar                                             20
                     Sanyo KR-1100AE                                     Pack Capacity: 22 A-h
                     NiCd rechargeable                                   Open Bus Voltage: 16-25V
ION-F/HokieSat                                             15
                     Sanyo KR-1400AE                                     Pack Capacity: 21 A-h
                     NiCd rechargeable                                   Open Bus Voltage: 12 V
3CS (See Note 1)                                           10
                     Sanyo KR2300SCE                                     Pack Capacity: 2.3 A-h
Notes for Table 1-2
1.    Three batteries are used on the 3CS stack, one for each satellite. Each battery is identical. Characteristics
      shown in the table are for a typical battery. Thus, the entire 3CS stack contains 30 NiCd cells.



Revision Draft              Use or disclosure of data contained on this sheet is subject           UN-PLN-12328
Issue Date: 9/01              to the restrictions on the title page of this document.                    Page 1
University Nanosat Program                                                                AFRL/VSSV, SMC/TELH


         ION-F / USUSat
         Sanyo NiMH HR-4/3FAUX                                                       3CS Batteries
         11 cells, series                                                            3 Batteries (identical)
         14-18 V, 4.5 A-h                                                            Sanyo NiCd KR2300SCE
                                                                                     @10 cells, series
     ION-F / Dawgstar                                                                12 V, 4A-h
     Sanyo NiCd KR-1100AE
     20 cells, series
     23 V, 22 A-h
        ION-F / Hokiesat                                                           MSDS Battery
        Sanyo NiCd KR-1400AE                                                       Sanyo NiCd N4000DRL
        15 cells, series                                                           22 cells, series
        16-25 V, 21 A-h  z                                                         28 V, 4A-h
                     x
                   (AFT)


                                                                                 SHELS Interface Plane


                                 Figure 1-2: Battery Locations, Nanosat-2
All Nanosat-1 and Nanosat-2 battery cells will be subjected to an acceptance test regime as described
below. This test regime applies to all battery cells used on individual nanosats (i.e., Emerald and Orion).
A separate test plan describes acceptance testing for the MSDS battery cells. Since there are different
cells used on each nanosat, this test plan includes parameters (P-1, P-2, etc) that represent test parameters
unique to each cell type. A summary of these test parameters may be found in Table A-1.

2.    ACCEPTANCE TESTING
2.1     Visual
All cells will be stripped of their insulating sleeves, and washed if necessary to remove traces of
electrolyte residue. All cells shall be visually inspected for defects and cells shall be rejected which have
damage exceeding the limits specified in Table 2-1.
2.2     Leak Check
Leaks shall be detected by applying phenolphthalein around the crimp seal and vent hole areas of each
cell. Leak check will occur at ambient temperature and pressure conditions
2.3     Open Circuit Voltage
The open circuit voltage of each cell shall be measured to verify that there are no internal defects,
including internal shorts within the cells. Any cell with an open circuit voltage of P-1 volts or less shall
be rejected. This is a go/no-go type of measurement. Actual voltage values, by cell serial number, are
not required.
Note: P-1 is the voltage of the depleted cell upon receipt of the cell from the manufacturer.




Revision Draft             Use or disclosure of data contained on this sheet is subject         UN-PLN-12328
Issue Date: 9/01             to the restrictions on the title page of this document.                  Page 2
University Nanosat Program                                                                 AFRL/VSSV, SMC/TELH


                                          Table 2-1: Cell Acceptance Test
          Cell Model       Initial OCV, Min (V)            Mass (g)           Height (in)        Diameter (in)
              P-2                   P-1                     P-3                  P-4                 P-5

3.   CELL MATCHING
Cell matching is recommended to increase the prospects for a successful nanosat mission. University
batteries are electrically inhibited at all times during which the nanosats have the ability to affect shuttle
safety. In addition, no charging or discharging of university batteries will occur during Shuttle Launch
and flight operations. Charging of university batteries will only occur after ejection from the payload bay.
Cell matching shall be accomplished by subjecting each individual cell (or battery assembly) through two
full charge/discharge cycles for each temperature 0C and 25C (a total of four charge/discharge cycles
per cell). Ambient temperature conditions may vary by  3C, but actual temperature must be recorded.
A single charge /discharge cycle is summarized in Table 3-1.
Voltage measurements will be made at regular intervals throughout each step in Table 3-1. If a battery
pack is being tested, then the voltage measurements will be made simultaneously for each individual cell
in the pack. Voltage of each cell shall not vary by more than 5% from the arithmetic mean of voltages for
cells used within a given pack.

                                      Table 3-1: Charge/Discharge Cycle

     Step             Type                   Current                       Duration                        Note
      1      Discharge                         P-6                   Until P-7 (volts) 5%                   1
             Rest cells on open circuit         -                            1 hour
                                                                                                             2
      2      Charge                            P-8                             P-9

             Rest cells on open circuit         -                          3-6 hours                         3
      3      Discharge                        P-10                   Until P-7 (volts)  5%
Notes for Table 3-1
1.   Step 1 of Table 3-1 can be omitted for any cell(s) having an OCV less than P-7 volts. For each cell, record
     discharge capacities for Step 1(if performed) and Step 3. If a battery pack is tested, then Step 1 can be omitted
     if each cell in the battery pack has an OCV less than P-7 volts. For each cell in the pack, record voltages at the
     end of Step 1 (simultaneous reading).
2.   The charge process of Step 2 must begin with the cells (or battery pack) soaked for at least 1 hour at the test
     temperature (0C or 25C) and be completed in a thermal environment convectively controlled to  2 C.
3.   After the completion of the initial charge step (Step 2), allow the cells (or battery pack) to rest on open circuit
     for 3 to 6 hours before proceeding with the next step. Again, this rest period should be conducted at the test
     temperature as in Note 2.

4.   MECHANICAL AND THERMAL VERIFICATION OF THE BATTERY ASSEMBLY
AFRL will be conducting system level tests, including random vibration and thermal vacuum testing.
These tests will be used to verify that the university battery assemblies do not develop a short when
subjected to environmental loads.
The universities are responsible for providing sensors for battery thermal and voltage data. The data may
be provided either through instrumentation that is installed specifically for the test, or through satellite
telemetry.
Revision Draft              Use or disclosure of data contained on this sheet is subject            UN-PLN-12328
Issue Date: 9/01              to the restrictions on the title page of this document.                     Page 3
University Nanosat Program                                                               AFRL/VSSV, SMC/TELH


Thermal data must be provided in at least two locations within the battery box. Each nanosat battery
assembly incorporates P-12 (no.) temperature sensors. Data from these sensors will be available real-time
during the execution of both thermal and random vibration testing. AFRL will provide a means of
recording this data.
Battery voltage data will be provided either real time or at the conclusion of the test. AFRL will provide
a means of recording this data.

5.   REFINISHING
Cells that have been selected for flight use shall be refinished with an insulating sleeve. This sleeve shall
consist of kapton tape, kynar, teflon tape, or other material that serves as an electrical insulator with low
flammability and outgassing characteristics.
The sleeve material used for these cells is P-13.

6.   TEST PARAMETERS
Test Parameters P-1 – P-13 described in Sections 1 through 5 are summarized in Table 6-1.




Revision Draft            Use or disclosure of data contained on this sheet is subject         UN-PLN-12328
Issue Date: 9/01            to the restrictions on the title page of this document.                  Page 4
University Nanosat Program                                                                                                                     AFRL/VSSV, SMC/TELH


                                                      Table 6-1: Summary of University Test Parameters

Parameter         Parameter                 Emerald                   Orion                   3CS                 ION-F                ION-F                ION-F
                 Description                                                                                      USUSat              Dawgstar             Hokiesat
     P-1        Minimum Initial              0.90 V                  0.90 V                  0.90 V               0.95 V               0.95 V               0.95 V
                   Voltage
     P-2          Cell Model              Sanyo NiCd               Sanyo NiCd             Sanyo NiCd           Sanyo NiMH            Sanyo NiCd           Sanyo NiCd
                                         KR-5000DEL               KR10000-M              KR-2300SCE             HR-4/3AUX            KR-1400AE            KR-1400AE
     P-3              Mass                   Note 1               400  TBD g             58  1.74 g             55  1 g             31  1 g             31  1 g
     P-4             Height              2.299  0.06 in          3.58  0.10 in         1.97  0.06 in         2.6  0.05 in      1.909  0.012 in     1.909  0.012 in
     P-5            Diameter             1.272  .04 in           1.69  0.10 in         0.91  0.02 in         0.7  0.05 in       0.65  0.008 in      0.65  0.008 in
     P-6           Discharge-1              1100 mA                 1000 mA                   1C                    C/10               700 mA                140mA
                                                                                                                (~ 450 mA)
     P-7           Duration-1         Until each cell 1.05     Until each cell <1.0    Until each cell at     Until each cell at   Until each cell at    Until each cell
                                               V                        V                1.1V (volts)              0.95 V                1.1V               at 1.0V
     P-8            Charge-2               1250 mA                  1000 mA                  C/10                   C/10               700 mA              140 mA
                                                                                                                (~ 450 mA)
     P-9           Duration-2         Until no thermal          15.0 hours  0.2         13 Hours  30       Until each cell at     Until detection     Until each cell
                                      change for 2                                          minutes          1.48 V                  of –V on          at 1.46 V
                                      minutes or a                                                                                    batteries
                                      decreasing                                                                                     (~2 hours)
                                      temperature for 30
                                      seconds (5-7 hours)
     P-10          Discharge-3              1100 mA                 1000 mA                    1C                   C/10                700 mA              140mA
                                                                                                                (~ 450 mA)
     P-12          Duration-3                  2                       2                      2                      2                    2                    2
     P-13          Cell Sleeve            Kapton Tape             Kapton Tape            Kapton Tape            Kapton Tape          Kapton Tape          Kapton Tape
                    Material
Notes for Table 6-1
1.     Individual cell mass will not be recorded due to the fact that Emerald batteries have already been assembled. Other performance measures will be used to
       determine acceptability of these cells.




Revision: Draft                                 Revision Draft
                        Use or disclosure of data contained on this sheet is subject to the restrictions on the title page of this document.            UN-PLN-12328
Issue Date: 9/01                                                                                                                                              Page 5

								
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