NASA Battery Power Workshop 11/27/07 – 11/29/07 Managing the Health and Safety of Li-Ion Batteries using a Battery Electronics Unit (BEU) for Space Missions George Altemose Aeroflex Plainview, Inc. www.aeroflex.com/BEU 1 Introduction W Lithium-Ion batteries have become prominent in space applications, because of their lighter weight and lower cost than NiH2 batteries W Lithium-Ion batteries require electronic cell balancing to reduce the possibility of overcharging or deep discharging W Cell balancing is required to achieve the maximum possible mission life for a LithiumIon battery 2 BEU Development History W W W W The Aeroflex 8627 Battery Electronics Unit (BEU) was designed, fabricated and tested to meet Boeing specifications for use with Lithium-Ion batteries on the Boeing 702B and other satellites The basic approach for the BEU was developed by Boeing, and is described in Patent 6,873,134. This patent describes transformer-coupled DC-DC converters that transfer charge over a bidirectional Share Bus Aeroflex has completed the electrical and mechanical design of the BEU. Engineering Models (EM) and Engineering Qualification Models (EQM) have been fabricated and tested In addition to cell balancing, the BEU provides additional functions: – – – – – Cell voltage monitoring Battery voltage monitoring Telemetry (MIL-STD-1553) Bypass relay driver circuits Reconditioning load control 3 Benefits of Cell Balancing W W W W W W Cell balancing equalizes the charge among the cells in a battery Unlike other types of cells, Lithium-Ion cells do not exhibit natural cell-to-cell balancing mechanisms Lithium-Ion batteries may become unbalanced, leading to one cell becoming overcharged, causing cell damage If cells are balanced, no cell will reach overcharge if the battery is charged properly During discharge, balanced cells discharge equally For satellites with high power or long mission life, balancing provides: – Minimum battery size: no additional capacity is required to allow for imbalance – Protection from cell damage due to over-charge or over-discharge 4 Desirable Features of a Cell Balancing System W Autonomous operation W Balancing of all cells to within millivolts of each other W Balancing current directly proportional to voltage difference between cells W Operate continuously during charge, discharge and standby modes W Accurate cell voltage monitoring and telemetry W High reliability W Fault tolerant, for both cell faults and circuit faults W Negligible degradation due to temperature, life and radiation W Protection from Single Event Upset (SEU) faults W Low power W Light weight 5 Cell Balancing by Share Bus 6 Cell Balancing Characteristic Curve 7 Functional Description of Balancing Circuit W W W W W W W Active DC-DC Converters interconnect all cells, through a Share Bus Controlled impedance in each balancing circuit sets the Transfer Ratio to 1 ohm Each balancing circuit contains a 1 amp fuse, which opens if a cell shorts Balancing is continuous and autonomous Current flows from the higher voltage cells into the Share Bus Current flows into the lower voltage cells from the Share Bus Balancing does not utilize voltage measurements or computations 8 Cell Balancing Circuits 9 Cell Balancing Circuit Waveforms 10 BEU Functional Block Diagram 11 BEU Functional Block Diagram (Primary Side Only) 12 Circuit Description – Balancing Circuit W W W W W W Forward converter with resonant reset Resonant frequency is determined by parallel combination of transformer primary inductances and circuit capacitances Transformer secondaries are connected to the Share Bus by 1 ohm resistors and 1 amp fuses Balance Clock is generated by Phase Lock Loop (PLL), and provides zero-loss switching PLL also generates a Monitor Clock synchronous to the Balance Clock 1 amp fuses are designed to open in case of a shorted cell and allows proper balancing among the remaining cells 13 Circuit Description – Monitoring and High/Low Limits W W W W W Monitor Clock drives Sample-and-Hold (S/H) circuits to derive monitor voltages equal to the cell voltages Monitor voltages are connected through Multiplexer (MUX) to the 12-bit A/D Converter controlled by the ASIC processor. MUX inputs also include three battery voltage buffers and a precision 4.000 volt reference ASIC processor performs auto-calibration (slope and offset correction) using the precision 4.000 volt reference ASIC processor checks each cell voltage against preset limits, which are stored in the PROM. Typical limits are as follows: – Low Cell: 3.2 volts – High Cell: 4.2 volts – Overvoltage Protection: 4.4 volts 14 Circuit Description: Custom ASIC W Fully synchronous design W PLL and PWM (for power supply clock) circuits run at 24 MHz W All other logic runs at 12 MHz W State machine architecture with no undefined states W Guaranteed recovery from single event upsets W RHA Designator R: 100 Krad (Si) W Process: Aeroflex UT 0.6 µ CRH Commercial RadHard Gate Array 15 Circuit Description – SµMMIT 1553 Bus Controller W Proven technology: has been used on many previous programs W Rad hard to 100 Krad (Si) 16 Circuit Description – Bypass Relay Drivers W Provides 2 amp pulses, compatible with NEA Battery Cell Isolation Switches (referred to as “relays”) W Requires three separate and independent 1553 commands to activate a bypass relay. W Two-fault tolerant with respect to accidental contact closure W OR’ed inputs can operate from two redundant Control Cards 17 Circuit Description – Reconditioning Load Control W Switches 5 amp battery reconditioning load (load resistor is located with battery) W Immune to single-point failures (2 series FET switches with transformer-coupled drive circuits) W Requires two separate and independent 1553 commands to turn on the reconditioning load W OR’ed inputs can operate from two redundant Control Cards 18 Circuit Description – Internal DC-DC Voltage Converter W Input Voltage Range of 20-36 VDC W Provides output voltages of +5 VDC (+ 1%) and + 12 VDC W Flyback topology with linear post-regulators on every output W Immune to spurious SEU outputs to protect ASIC and SµMMIT from SEU transients W Fully compliant with MIL-STD-461C EMC requirements 19 Redundancy & Other Reliability Enhancements W Redundant balancing circuits (Balancing Card and Control Card) may be used simultaneously or individually W Bypass Relay Driver circuits are two-fault tolerant, with respect to unwanted turn-on of bypass relay W Reconditioning Load control circuit is one-fault tolerant, with respect to unwanted turn-on of the reconditioning load W Triple battery voltage monitoring circuits are provided on each Control Card – Measured battery voltages may be compared to verify accuracy of measurement circuits 20 Test Results W Cell balancing tests were performed using capacitors in place of battery cells W Monitor voltages were sent by telemetry over the 1553 bus W The 1 ampere load was provided on one cell by placing a 3 ohm resistor across the cell 21 25°C, No Load Cell Number 22 +25°C, 1 Amp Load Cell Number 23 +75°C, No Load Cell Number 24 +75°C, 1 Amp Load Cell Number 25 -35°C, No Load Cell Number 26 -35°C, 1 Amp Load Cell Number 27 Mechanical Design W Height: 5.25 inches W Width: 5.25 inches W Length: 11.5 inches W Weight: 3.75 Kg W Analyzed and tested for pyroshock, vibration and thermal vacuum W 3 machined housings (slices), fastened with 12 10-32 bolts W Housings made of nickel-plated aluminum, painted black for emissivity 28 Battery Electronics Unit W 2 Balancing Cards W 2 Control Cards W 1 Bypass Relay Driver Card 29 Balancing Card W 24 Cell Balancing Circuits 30 Control Card W W W W W ASIC, with PROM and POR SµMMIT 1553 Interface A/D, 4.000V Reference, MUX, 3 Battery Voltage Buffers Power Supply On/Off Controls 31 By Pass Relay Driver Card W 24 Relay Driver Circuits W Reconditioning Load Control Circuit 32 BEU Performance Characteristics W Cell Voltage Balancing: – 10 mv BOL (Beginning of Life) – 20 mv EOL (End of Life) W Cell Balancing Current (continuous): 1 ampere W Cell Voltage Monitoring Accuracy: – 10 mv BOL – 20 mv EOL W Battery Voltage Monitoring Accuracy: – 0.3% of full scale W Temperature Range: -34°C to +71°C W Power (from +30 VDC bus): 9.5 watts 33 Currents Drawn by BEU 34 Summary W Cell balancing has been shown to significantly enhance the mission life of Lithium-Ion batteries W The Aeroflex BEU meets the specified design goals, including autonomous and continuous cell balancing while operating in a space environment 35 Acknowledgement W The conceptual design of the BEU was performed by Boeing Space Systems, and is described in patent US 6,873,134 B2. The inventors are Stanley Canter, Winnie Choy and Robert Martinelli W Aeroflex designed and developed the original BEU in accordance with Boeing Space Systems specifications 36 Action Space Guy 37