Lesson Info:

• Lesson Number: 0714
• Lesson Date: 1999-02-01
• Submitting Organization: MSFC
• Submitted by: Wil Harkins

Subject:

Description of Driving Event:

This Lesson Learned is based on Reliability Practice No. PD-ED-1221; from NASA Technical Memorandum 4322A, NASA Reliability Preferred Practices for Design and Test.

Benefit:

Selection of the optimum battery for space flight applications results in a safe, effective, efficient, and economical power storage capability. The optimum battery also enhances launch operations, minimizes impacts to resources, supports contingency operations, and meets demand loads.

Implementation Method:

Primary batteries, those which are not recharged are and useful for short duration, are used principally for providing electrical power for launch vehicles. These batteries must have high energy density, high current capabilities, and good reliability. MSFC has had experience with Lithium/Monoflouride (Li/CF), Lithium/Thionyl Chloride (Li/SOCl₂), and Silver/Zinc (Ag/Zn) primary batteries.

Secondary batteries, those which are discharged and then recharged numerous times, are principally used for spacecraft, satellite, and other long-term space-oriented applications. In space applications, reliability, costs, producibility, responsiveness, risks, safety, and maintainability are more important than high current content. MSFC has had experience with Silver/Zinc (Ag/Zn), Nickel/Hydrogen (Ni/H₂), Nickel/Cadmium (Ni/Cd), Nickel/Metal Hydride (Ni/MH), and Bi Polar-Lead Acid (Bi-Pb/Acid).

[D]

Battery types are selected for specific applications based on a number of factors including specific energy and energy density (see Figures 1 and 2), lifetime, number of cycles, discharge rate, charge retention, shelf life, ruggedness, operating temperature, and other factors. Figure 3 presents these factors for various battery types. Figure 3 should be used by the designer as an initial tool for selecting the required battery type. The design of batteries for space flight should be accompanied by battery level electrical, mechanical and thermal analysis.

[D]

A typical battery selection flow chart is shown on Figure 4. After the program is identified and electrical power requirements are established, a trade study should be performed to determine the actual battery (primary or secondary) that will fulfill the requirements at a reasonable cost. Cell selection includes charge voltage, discharge capacity, and discharge voltage after cycling. Establishing the battery size is determined by the number of cells required to provide the required electrical power, i.e., a 24-volt battery using a 1.5 volt cell will require 16 cells. Mechanical packaging of the cells into a battery requires such parameters as cell type, number of cells, weight, length, height, temperature requirements, mounting method, vibration environment, electrical feed through, and venting requirements to ensure proper functioning of the battery. Perhaps the most important part of selecting a battery is the selection of a reliable cell/battery manufacturer. Preferably one that has consistently produced high quality and reliable batteries. Manufacturing engineers should critique the design for producibility and testability early in the design process and make corrective suggestions when problems are discovered.

[D]

Accelerated life testing of batteries is extremely difficult due to the nature of the chemical reaction between the electrolyte and the positive and negative electrodes. Therefore, preferred type and configuration of the battery should be selected early in the program to allow for lifetime testing.

Performance testing of the selected battery can be accomplished in parallel with life testing. Performance testing should be accomplished in an environment to which the battery is expected to be exposed during operation. The battery should demonstrate during testing that it will deliver the required electrical power and will charge and discharge as designed.

Technical Rationale:

MSFC's aerospace flight battery experience comes from a combination of its own in-house laboratory experience on numerous programs; from coordination with battery manufacturers, prime contractors, and subcontractors for a number of launch vehicles, space vehicles, and experiments; and from many years of participation in NASA/industry aerospace battery workshops. Two such workshops, hosted by the Marshall Space Flight Center in Huntsville, Alabama, were attended by approximately 200 persons each, representing both Government and industry. Credit must be given to the interdisciplinary efforts of Goddard Space Flight Center, NASA Headquarters, Jet Propulsion Laboratory, Johnson Space Center, Kennedy Space Center, Ames Research Center, Langley Research Center, Lewis Research Center, and their suppliers and contractors, as well as to many academic and nonprofit organizations who have contributed to the battery research leading to this body of knowledge.

References:

1. Bykat, Alex, "Design of an Expert System for Diagnosis of a Space Borne Battery Based Electric Power System," University of Tennessee at Chattanooga, IECEC, Vol. I Aerospace Power Systems Conference, August 1990.
2. Dunlop, J. D., "NASA Handbook for Nickel-Hydrogen Batteries," Preliminary Draft, Goddard Space Flight Center, June 1991.
3. Glover, D.G., "Aerospace Energy Systems Laboratory: Requirements and Design Approach," Ames Research Center, Dryden Flight Research Facility, Edwards AFB, CA, NASA Technical Memorandum 100423, 1988.
4. Guthals, D.L. and Olbert, Phil, "CRRES Battery Workshop," Ball Space Systems Division, letters dated March 11 and 16, 1992.
5. Halper, G., Subbarao, S., and Rowlette, J.J., "The NASA Aerospace Battery Safety Handbook," JPL Publication 86-14, July 15, 1986.
6. Jones, Dr. G.M., "ATM Electrical Power System Post Mission Design and Performance Review," George C. Marshall Space Flight Center Report No. 40M22430, February 6, 1975.
7. Kennedy, L. M., "1990 NASA Aerospace Battery Workshop," 1991, NASA Conference Publication 3119, Marshall Space Flight Center, December 4-6, 1990.
8. Linden, David, Handbook of Batteries and Fuel Cells, McGraw Hill Inc., 1984.
9. Manned Space Vehicle Battery Safety Handbook, NASA, Johnson Space Center, JSC 20793, September 1985.
10. MIL-B-81502B(AS), "Battery, Silver-Zinc-Alkali, General Specification for," February 26, 1980.
11. MIL-B-82117D, "Battery, Storage, Silver-Zinc, Rechargeable, General Specification for," July 25, 1983.
12. NASA SP-172, "Batteries for Space Power Systems," NASA 1968.

Lesson(s) Learned:

Failure to adhere to proven battery selection practices could cause shortened mission life, premature cessation of component or experiment operation, mission failure, and in extreme cases, loss of mission or life. All phases of battery use, from battery selection to installation in the launch vehicle or orbiting spacecraft, must adhere to the proven design and safe battery practice.

Recommendation(s):

When selecting batteries for space flight applications, the following requirements should be considered: ampere-hour capacity, rechargeability, depth of discharge (DOD), lifetime, temperature environments, ruggedness, and weight. Many batteries have been qualified and used for space flight, enhancing the ease of selecting the right battery.

Evidence of Recurrence Control Effectiveness:

This practice has been used on Space Shuttle Solid Rocket Booster (SRB); Space Shuttle External Tank (ET); Materials Experiment Assembly (MEA); Inertial Upper Stage (IUS); Tethered Satellite System (TSS); Transfer Orbit Stage (TOS); Saturn IB Launch Vehicle; Saturn V Launch Vehicle; Skylab; High Energy Astronomy Observatory (HEAO); Lunar Roving Vehicle (LRV); and Hubble Space Telescope (HST).

Documents Related to Lesson:

Mission Directorate(s):

• Exploration Systems
• Science
• Space Operations
• Aeronautics Research

Additional Key Phrase(s):

• Energy
• Flight Equipment
• Hardware
• Launch Vehicle
• Payloads
• Spacecraft

Additional Info:

Approval Info:

• Approval Date: 2000-03-16
• Approval Name: Eric Raynor
• Approval Organization: QS
• Approval Phone Number: 202-358-4738