Aeroflexs Battery Management Electronics for Lithium Ion Batteries Achieves TRL 9 for Earth & Inter-Planetary Orbital

Missions
Joseph Castaldo Global Director, Business Development
joe.castaldo@aeroflex.com

Space Power Workshop April 16 19, 2012

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Abstract

Currently the Aeroflex Lithium-Ion battery cell balancing electronic units are flying on three spacecraft. More units are in manufacturing and are slated to be launched over the next two years. Additionally, a set of cell voltage monitoring and over voltage protection units is scheduled to be launched on Commercial Orbit Transportation System later this year. This paper briefly summarizes the development history, design highlights and features of these products in addition to documenting the flight experience, describing the on-going ground test efforts and finally provides information on future product development efforts.

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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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Aeroflex at a Glance

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
Flip Chip Packaging Rad Hard ASICs Rad Hard PWM Space Grade Voltage Regulators Heritage Chip On Board Battery Electronics Unit

Quad, Rad Hard Voltage Supervisor

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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 require electronic cell balancing to reduce the possibility of overcharging or deep discharging Cell balancing is required to achieve 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 on the Boeing HS-702B and other satellites Basic approach for BEU developed by Boeing, and described in Patent 6,873,134. This patent describes transformer-coupled DC-AC converters 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 the original BEU plus multiple derivatives. Engineering Models (EM) and Engineering Qualification Models (EQM) have been fabricated and tested 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 Switches
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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
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BEU Functional Block Diagram

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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 pyroshock, vibration and thermal vacuum

3 machined housings (slices), fastened with twelve 10-32 bolts

Housings made of nickel-plated aluminum, painted black for emissivity

Balancing Card

Includes 2 Balancing Cards, 2 Control Cards, 1 Bypass Device Driver Card

Fully redundant for balancing / telemetry
Control Card

Bypass Device Driver Card

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BEU Physical Construction & Environments

Temperature Range
Operational -24oC to 61oC Qualification -34oC to 71oC 2500G SRS Peak Spectrum 28G2/Hz X, 17G2/Hz Y & Z ~50 to 400Hz CE01, CE02, CS01, CS02, RE02, RS03 (5V/m and 20V/m)
Primary Slice (R):
Balancing & Telemetry

Pyro-shock

Random Vibration

Compliant with MIL-STD-461E

FMECA Reliability (Excludes Bypass Slice)

Failure Rate: 186.79 FITS MTBF: 5,353,605 hours Probability of Success: 0.999158, (18 years, GEO) Power Supply Balancing Circuits 12 Bit A/D Conversion Monitoring Accuracy +/-10mV BOL, (+/-20mV 18 years, GEO)
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Center Slice: Bypass Drivers

Redundant Slice (L):
Balancing & Telemetry

More than 100 WCAs performed

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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)

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!

Balancing / Monitoring accuracy: +/-5.0mV BOL +/-20.0mV EOL (18 years, GEO)

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BEU On-Orbit Experience & Ground Test Results

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BEU On-orbit Experience & Future Launches

GEO
24 Cell Dual Redundant HS-702HP HS-702MP SkyTerra 1 Intelsat Flight 22 Launched Nov. 2010 Launched Mar. 2012 HS-702MP Intelsat Flight 21 Launch Fall 2012 HS-702HP Mexsat-1 Launch 2013

INTER- PLANETARY

8 Cell Dual Redundant

JUNO - 28V BUS Launched Aug 5, 2011

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BEU Ground Testing & Evaluation

8 Cell Balancer Lab Unit with the same Aeroflex Autonomous Balancing Technology used in Flight
Organization
Aerospace Corp

Government Funded LEO Ground Test 24 Cell, Non-Redundant

Test
Cycle Life

Test Duration
Multiple Years

Status
Anticipated

Remarks
Unit on Order

Boeing
NASA Glenn NASA JPL Naval Surface Warfare Center Northrop Grumman Space Systems/Loral
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Cycle Life
Rover Study, 2 units installed Planetary Cycle Life Comparison of 3 cell balancing designs LEO Cycle Life GEO Cycle Life

On going, >6 years to date

Multiple Years Multiple Years Multiple Years 910 Cycles 3 years to date

BEU performing as expected

Assembled & in cue Anticipated In progress Concluded BEU performing as expected

Identical BEUs for LEO & GEO

Yet to commence Under Discussion NSWC will present in 2013 Results presented herein Results presented herein www.aeroflex.com

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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

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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
* BEU is also known as CME (Cell Management Electronics) at NGC
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LEO Evaluation Cycling Summary

End of Discharge Voltage (EODV) as a Function of Cycle Number and Test Article Configuration
3.600

Cell-to-cell voltage dispersion With BEU balancing during LEO cycling

3.595 3.590
3.585 3.580

12s Pack Test - CME Evaluation

12-Cell Average EODV Cell 6 EODV

EODV (volts)

3.575 3.570 3.565 3.560

CME ON

CME OFF 1 k R across cell 6

CME OFF "natural" cell divergance taking place

CME OFF 1 k R remains across Cell 6

CME ON 233 R across Cell 6

CME ON 1 k R remains across Cell 6

CME OFF 1k R across Cell 6 replaced with 500 R

3.555 3.550 3.545

CME ON 500 R remains across Cell 6

3.540
0 100 200 300 400 500 600 700 800 900 1000

Cycle Number

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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Battery Interface Electronics (BIE)

The Aeroflex BIE was designed, fabricated and tested to meet specifications provided by Orbital Sciences Corp. for use with Lithium-Ion batteries in the Commercial Orbital Transportation System (COTS) to deliver 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 cell temperatures 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!

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BIE Functional Block Diagram & External Interfaces

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Battery Interface Electronics (BIE) Application

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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Orbital Sciences Cygnus Spacecraft, 28V Bus Commercial Orbit Transportation System Expected Launch 2013, Multiple Units
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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)

BIE

Analyzed and tested for pyro-shock, vibration and thermal vacuum

Fastened to Battery Assembly with eight bolts, 8-32 size

Over Voltage Protection Slice

Housing made of nickel-plated aluminum, painted black for emissivity

Voltage Temp Analog Conditioning Slice

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NPP Satellite Launch

October 28th, 2011

Contributed two Chip-On-Board Power Supplies to CrIS Instrument: 8621 Digital and 8622 Quiet Power Supplies

AEROFLEX launches its latest Chip-On-Board Product

DIGITAL FLIGHT PWB

QUIET FLIGHT PWB

Digital Power PWB SMT Side

6.4L x 5.5W x 0.97 H 28V Input with Outputs: +3.3V, +5.0V, +/-12.0V 125W

Quiet Power PWB Encapsulated Side

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 Regulator Module Isolated Point of Load Module

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

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

Adaptive Loop feedback ZVS buck-boost regulator

Total dose: 100 krads (Si)

SEL: immune up to 80 MeV-cm2/mg

Over-temperature protection ZVS / ZCS Resonant Converter topology Total dose: 100 krads (Si) SEL: immune up to 80 MeV-cm2/mg www.aeroflex.com

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Summary

The Battery Electronics Unit (BEU) is an elegant, fully autonomous and 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-Ion battery 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 supplied at 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 thanks to the following organizations who contributed to this presentation
Aerospace Corporation Boeing

Northrop Grumman
Orbital Sciences Space Systems/Loral NASA Naval Surface Warfare Center

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