Aeroflex 2012 SPW Presentation

7/30/2019 Aeroflex 2012 SPW Presentation

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www.aeroflex.com

Aeroflexs Battery ManagementElectronics for Lithium Ion Batteries

Achieves TRL 9 for Earth &

Inter-Planetary Orbital Missions

Joseph Castaldo

Global Director, Business Development

[email protected]

Space Power Workshop

April 16 19, 2012

1 Space Power Workshop 20121
mailto:[email protected]:[email protected]


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www.aeroflex.com

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.

Space Power Workshop 20122


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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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www.aeroflex.com

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




BEU Functional Block Diagram




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




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)


Primary Slice (R):Balancing & Telemetry

Center Slice:

Bypass Drivers

Redundant Slice (L):Balancing & Telemetry



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!




BEU On-Orbit Experience&

Ground Test Results




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


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


Government

FundedLEO Ground Test

24 Cell, Non-Redundant



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)


4mV



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




LEO Evaluation Cycling Summary


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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http://www.aeroflex.com/beuhttp://www.aeroflex.com/beu



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


Ideal for Short Missions where cell balancing is optional!



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


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


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


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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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

Aeroflex 2012 SPW Presentation

Documents

Transcript of Aeroflex 2012 SPW Presentation