USG and Quallion STTR Test Packs - NASA · 1 USG and Quallion STTR Test Packs. Demonstration Packs...
Transcript of USG and Quallion STTR Test Packs - NASA · 1 USG and Quallion STTR Test Packs. Demonstration Packs...
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USG and Quallion STTR Test Packs
Demonstration Packs in Support of MDA and USG Li-Ion LEOModeling and Cell Performance Programs
Harlan Lewis and Bruce Moore, NAVSEA Crane, INScott Verzwyvelt, USG, Washington, DC
Hisashi Tsukamoto, Quallion, Sylmar, CAEmail: [email protected]
2009 NASA Battery WorkshopHuntsville, AL
17-19 November 2009
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STTR Battery Packs
Outline:
•
STTR Battery Test–
Test Purpose and Plan
–
Hardware Setup–
Data Collection
–
Test Data–
Conclusions
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STTR Batteries
Purpose:
●
NAVSEA Crane Code GXSR has built and is testing two Li- ion batteries of 10 Ah USG and 15 Ah Quallion prismatic cells
in 3P8S configurations with eight “virtual”
cells of three, in support of an MDA Phase III contract. The MDA Phase III seeks to develop a physics-based first principles model for LEO cycling of Li-Ion batteries, and this testing is to provide performance data against which the model can be evaluated. The model is being developed by Dr. Ralph White (Univ. of South Carolina), in conjunction with the USG and Quallion LLC.
●
This test is not intended to be a life test, but a performance characterization of flight like battery configurations.
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STTR Batteries
Pack Description:Cells are USG Gen 1.0 design with LiCoO2
positive, and Quallion Gen 1.0 design with LiNiCoAlO2
, true prismatics. Both have MCMB negatives. The USG Gen 1.0 design has been subsequently modified to increase the anode/cathode ratio.
Design criteria are for 10 or 15 Ah; actual capacities are 14.35 Ah for the USG cells, 16.42 Ah for the Quallion cells, and we derate 5/6ths to 11.96 Ah and 13.68 name plate capacity, respectively.
Test Plan:Packs are being cycled for 500 LEO cycles at each of nine matrix conditions, with operational and standard capacity, impedance, and DC resistance measurements at the conclusion of each condition.
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Condition Number
Temperature (°C)
DoD (%/Ah) Peak Charge Rate@ Amps
Discharge Rate*
Amps1
15
30/10.76 11.91 ~C/3 18.45 ~C/2
2 40/14.35 15.88 ~C/2.25 24.60 ~C/1.5
3 50/17.94 19.85 ~C/1.8 30.75 ~C/1.2
4
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30/10.76 11.91 18.45
5 40/14.35 15.88 24.60
6 50/17.94 19.85 30.75
7
35
30/10.76 11.91 18.45
8 40/14.35 15.88 24.60
9 50/17.94 19.85 30.75
@
At peak charge rate (CC) to 4.0 V max and hold (CV) at 4.0 V for a total charge timeof 61 min
*
At discharge rate for a total discharge time of 35 min
Matrix Test Plan – USG Pack
STTR Batteries
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Condition Number
Temperature (°C)
DoD (%/Ah) Peak Charge Rate@ Amps
Discharge Rate*
Amps1
15
30/12.31 13.68 ~C/3 20.52 ~C/2
2 40/16.42 18.24 ~C/2.25 27.36~C/1.5
3 50/20.52 22.80 ~C/1.8 34.20 ~C/1.2
4
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30/12.31 13.68 20.52
5 40/16.42 18.24 27.36
6 50/20.52 22.80 34.20
7
35
30/12.31 13.68 20.52
8 40/16.42 18.24 27.36
9 50/20.52 22.80 34.20
@
At peak charge rate (CC) to 4.0 V max and hold (CV) at 4.0 V for a total charge timeof 61 min
*
At discharge rate for a total discharge time of 35 min
Matrix Test Plan – Quallion pack
STTR Batteries
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Thermal Grease
Top view(looking down on cold plate)
10 Ah OGA cell or15 Ah Quallion cell
Cold Plate
Restraining rod stockFasteners not shown
(at least 4 )
Side View (without rod stock)
Insulating Plate
Al plateL-Brackets
Kapton & thermal grease
+
- - -
+ + +
- - -
+ + +
- - -
+ + +
- - -
+ +
Total Length of Pack is 21.315”
V1
V2
V3
V4
V8
V7
V6
V5
Top and Side Views of Pack Assembly
STTR Batteries
All virtual cells are in thermal contact andwithin each virtual pack, as well.
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V1
V2
V3
V4
V8
V6
V7
V5
A
B
C
A
A
A
A
A
A
A
B
B
B
B
B
B
B
C
C
C
C
C
C
C
TemTemperature Monitoring Locations –
Top View
STTR Batteries
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STTR Batteries
Location of Temperature Probes
STTR USG Battery
Assembled USG Pack Illustrating Virtual Cell Configuration with Wiring 10
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STTR Quallion Battery
Assembled Quallion Pack Illustrating Virtual Cell Configuration with Wiring11
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Data Collection:Twenty thermistors for temperature sensingVirtual cell and pack voltages as well as individual cell voltages in two virtual cells
Charge Control:Charge control and cell removal hardware for each virtual cellVoltage adjustable 2.80<V<4.60Voltage regulation ±0.002 VMaximum current capability 30 A
Shunt Bypass:One circuit per virtual cell (resistor + relay)Bypasses excessive current during taper chargeBalance rate C/20Voltage window specifies variable activate and release values, e.g. Activate 4.005, Release 3.995
STTR Batteries
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STTR USG Battery
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STTR USG Battery
Wider Spread at lower EoDV.
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STTR USG Battery
The separation of virtual cell capacity increased at the 15 Celsius 50% DoDmeasurement. The 50% DoD also saw the highest charge rate (C/1.8) for its matrix value of ~500 cycles.
Slight separationon recharge.
Increased spreadat lower EoDV.
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STTR USG Battery
Narrower spread andslightly higher EoDVthan at 15°C.
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STTR USG BatteryVoltage / Current Plot Cycle 2300 (25°C - 40% DOD)
3.7
3.7
3.8
3.8
3.9
3.9
4.0
4.0
4.1
0 20 40 60 80 100 120
Cycle Time (min))
Volta
ge
-30
-25
-20
-15
-10
-5
0
5
10
15
20
Cur
rent
(Am
ps)
Cell 01 VoltsCell 02 Volts
Cell 03 VoltsCell 04 Volts
Cell 05 VoltsCell 06 VoltsCell 07 Volts
Cell 08 VoltsCell 03a Volts
Cell 03b VoltsCell 03c VoltsCell 08a Volts
Cell 08b VoltsCell 08c Volts
Pack Current
Narrower spread andslightly higher EoDVthan at 15°C.
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Voltage / Current Plot Cycle 2825 (25°C - 50% DOD)
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
0 20 40 60 80 100 120
Cycle Time (min)
Volta
ge
-35
-25
-15
-5
5
15
25
Cur
rent
(Am
ps)
Cell 01 VoltsCell 02 Volts
Cell 03 VoltsCell 04 VoltsCell 05 VoltsCell 06 Volts
Cell 07 VoltsCell 08 VoltsCell 03a VoltsCell 03b Volts
Cell 03c VoltsCell 08a VoltsCell 08b VoltsCell 08c Volts
Pack Current
STTR USG Battery
Greater spread andlower EoDV thanprevious plots.
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STTR USG Battery
Note steep drop inCell #5 on discharge.
2.5
2.7
2.9
3.1
3.3
3.5
3.7
3.9
4.1
0 10 20 30 40 50 60 70 80 90 100
Cycle Time
Volts
-40
-20
0
20
40
60
80
100
120
140
Am
ps
Cell 01 Volts
Cell 02 Volts
Cell 03 Volts
Cell 04 Volts
Cell 05 Volts
Cell 06 Volts
Cell 07 Volts
Cell 08 Volts
Pack Current
Cycle 2927 Voltage/Current Plot - 25°C and 50% DoD
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STTR USG Battery
Voltage 25C 50% DOD
3.0
3.2
3.4
3.6
3.8
4.0
4.2
2650 2700 2750 2800 2850 2900 2950
Cycle Number
Volta
ge
Cell 01 Volts
Cell 02 Volts
Cell 03 Volts
Cell 04 Volts
Cell 05 Volts
Cell 06 Volts
Cell 07 Volts
Cell 08 Volts
All virtual cells show significant capacityloss, and especially #5, at 25°C, 50% DoD.
Discharge Voltage Cycle Plot, 2650-2927, at 25°C and 50% DoD
Cycle Number
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STTR USG BatteryVC5 Voltage Current at end of C2 discharge
3.70000
3.75000
3.80000
3.85000
3.90000
3.95000
4.00000
4.05000
3/11/09 6:28 3/11/09 6:43 3/11/09 6:57 3/11/09 7:12 3/11/09 7:26 3/11/09 7:40 3/11/09 7:55
Voltage
Tim
e
-20.00
0.00
20.00
40.00
60.00
80.00
100.00
Cell 01 Volts
Cell 02 VoltsCell 03 Volts
Cell 04 Volts
Cell 05 VoltsCell 06 Volts
Cell 07 Volts
Cell 08 VoltsPack Current
End of VC5 CC charge earlier,due to higher impedance.
Unsure sure if it is only impedance related; could have lithium plated out such that the cathode is shifted to greater voltages also.
Charge Voltage Cycle 2927, at 25°C and 50% DoD
Vol
tage
Time
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STTR USG Battery
STTR Cell Voltage- Capacity Cycles- Cell 5
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
0 100 200 300 400 500 600 700 800 900
Cycle Time (min)
Volta
ge
Cell Impedance measured at C Rate Pulse 5a (SN53) = .0118 5b (SN86) = .0150 5c (SN88) = .0106
Cell Capacities (AmpHr)
Cell 5A Const Curr Chg 7.436 Taper Chg 11.642 Hi Rate Dis 10.050 Lo Rate Dis 11.564 Cell 5B Const Curr Chg 4.897 Taper Chg 9.803 Hi Rate Dis 6.824 Lo Rate Dis 9.490 Cell 5C Const Curr Chg 6.673 Taper Chg 10.833 Hi Rate Dis 8.568 Lo Rate Dis 10.636
Middle cell reached highcurrent discharge of 3.0 Vfirst. So more residual capacity at C/30.
Note that the middle cell tapers earliest on charge, and completes discharge last, at C/30.
Individual Cell Voltages on Charge, Virtual Cell #5
Vol
tage
Cycle Time
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STTR USG BatteryEnd of Charge/Discharge Cycling Voltage Trend
STTR - AH Trend Plot
-20
-15
-10
-5
0
5
10
15
20
0 500 1000 1500 2000 2500 3000 3500 4000
Cycle
Ahr
Cell 01 AmpHrCell 02 AmpHrCell 03 AmpHrCell 04 AmpHrCell 05 AmpHrCell 06 AmpHrCell 07 AmpHrCell 08 AmpHr
30% DOD15°C
40% DOD15°C
50% DOD15°C
30% DOD25°C
40% DOD25°C
50% DOD25°C
30% DOD35°C
End of Charge Voltage
End of CC Charge Voltage
End of Discharge Voltage
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End of Charge/Discharge Voltage Trend
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3.2
3.4
3.6
3.8
4
0 500 1000 1500 2000 2500 3000 3500 4000
Cycle
Volts
BTSV_01
BTSV_02
BTSV_03
BTSV_04
BTSV_05
BTSV_06
BTSV_07
BTSV_08
30% DOD15°C
40% DOD15°C 50% DOD
15°C
30% DOD25°C 40% DOD
25°C
50% DOD25°C
30% DOD35°C
End of Discharge Voltage
End of Charge Voltage
STTR USG BatteryEnd of Charge/Discharge Cycling Voltage Trend
Resumption ofcycling with onlysix of eight virtualcells.
Cell #4&5removed.
At 35°C and40% DoD, allthe cells failed.
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V1
V2
V3
V4
V8
V6
V7
V5
A
B
C
A
A
A
A
A
A
A
B
B
B
B
B
B
B
C
C
C
C
C
C
C
TemTemperature Monitoring Locations –
Top View
STTR Batteries
Two end cellsremoved.
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STTR USG BatterySTTR Cycles 3484 to 3490
2.5
2.7
2.9
3.1
3.3
3.5
3.7
3.9
4.1
4.3
6/23/09 14:24 6/23/09 16:48 6/23/09 19:12 6/23/09 21:36 6/24/09 0:00 6/24/09 2:24 6/24/09 4:48
Time/Date
Volts
-80
20
120
220
320
420
Am
ps
Cell 01 VoltsCell 02 VoltsCell 03 VoltsCell 06 VoltsCell 07 VoltsCell 08 VoltsPack Current
Last Seven Cycles of USG STTR Pack at 35°C and 40% DoD
STTR Cycles 3484 to 3490
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STTR USG Battery
STTR Cycle 3490
2.5
2.7
2.9
3.1
3.3
3.5
3.7
3.9
4.1
4.3
6/24/09 0:57 6/24/09 1:26 6/24/09 1:55 6/24/09 2:24 6/24/09 2:52 6/24/09 3:21Time/Date
Volts
-80
20
120
220
320
420
Am
psCell 01 VoltsCell 02 VoltsCell 03 VoltsCell 06 VoltsCell 07 VoltsCell 08 VoltsPack Current
Last Cycle of USG STTR Pack at 35°C and 40% DoD
STTR Cycle 3490
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Pack Capacity Cycles
-45.0
-40.0
-35.0
-30.0
-25.0
-20.0
-15.0
-10.0
-5.0
0.0
0 500 1000 1500 2000 2500 3000 3500 4000
Cycle Number
Am
p H
rs
Cell 01 AmpHr
Cell 02 AmpHr
Cell 03 AmpHr
Cell 04 AmpHr
Cell 05 AmpHr
Cell 06 AmpHr
Cell 07 AmpHr
Cell 08 AmpHr
25°C35°C
15°C
25°C
15°C
25°C
15°C25°C15°C15°C15°C
Post50% DOD / 25°C
RegimeCapacity Results
Post30% DOD / 35°C
RegimeCapacity Results
STTR USG BatteryPost Matrix Value Capacities
The chart shows decreasing capacity after each matrix interval. Capacities wereremeasured at 15°C after each measurement at the higher matrix temperatures.
ConclusionsThis program of matrix cycling to provide cycle life data at three temperatures and
three DoD’s at each temperature completed the 15°C matrix DoD’s and two of the 25°C DoD’s. At those matrix values, there did not appear to be significant cell voltage divergence.
At the third 25°C matrix value of 50% DoD, problems with cell #5 caused us to discontinue that matrix value. The cycling was then resumed at 35°C at 30% DoD, when cell #5 immediately lost capacity and fell below the cutoff voltage, so it and a companion cell were removed, to balance the pack at six cells. Cycling continued at that matrix value to the completion of the 500 cycle interval. This was followed by the regular capacity evaluations. Then the next matrix value of 40% DoD was begun, at which time all the cells failed.
A review of the capacity data at 15°C and 50% DoD showed an indication of capacity divergence in the measurements, although subsequent open circuit
stand measurements did not indicate higher or divergent self discharge issues among
the virtual cells.We now believe that the 15°C, 50% DoD cycling with its higher charge rates caused
lithium plating during recharge, which became evident in the performance at 25°C and 50% DoD. Although the entire pack had been reconditioned with a C/2
charge followed by a C/100 discharge at cycle 2927, in an attempt to remove the Li plate on the anode, the subsequent cycling showed no recovery.
STTR USG Battery
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STTR Quallion Battery
Virtual Cell 3P8S Voltage/Current Plot - Cycle 300 (25°C, 30%DOD)
3.4
3.5
3.6
3.7
3.8
3.9
4
0 10 20 30 40 50 60 70 80 90 100
Cycle Time (Min)
Cel
l Vol
tage
-30
-20
-10
0
10
20
Pack
Cur
rent
(Am
ps)
Cell 01 Volts
Cell 02 Volts
Cell 03 Volts
Cell 04 Volts
Cell 05 Volts
Cell 06 Volts
Cell 07 Volts
Cell 08 Volts
Cell 03a Volts
Cell 03b Volts
Cell 03c Volts
Cell 08a Volts
Cell 08b Volts
Cell 08c Volts
Pack Current
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STTR Quallion BatteryVirtual Cell 3P8S Temperature Plot - Cycle 300 (25°C, 30%DOD)
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21
22
23
24
25
26
27
28
29
30
0 10 20 30 40 50 60 70 80 90 100
Cycle Time (Min)
Tem
pera
ture
(°C
)
Amb Temp
Temp Cell 01b T-Mid
Temp Cell 02b T-Mid
Temp Cooloing Sleeve
Temp Cell 03b T-Mid
Temp Cell 03a B-Bot
Temp Cell 03c T-Mid
Temp Cell 03b B-Mid
Temp Cell 03c B-Top
Temp Cell 03b T-Term
Temp Cell 04b T-Mid
Temp Cell 05b T-Mid
Temp Cell 06b T-Mid
Temp Cell 07b T-Mid
Temp Cell 08b T-Mid
Temp Cell 08a B-Bot
Temp Cell 08c T-Mid
Temp Cell 08b B-Mid
Temp Cell 08b T-Term
Temp Cell 08c B-Top
Temp Cold Plate
Discharge Charge
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STTR Quallion BatteryVirtual Cell 3P8S Voltage/Current Plot - Cycle 800 (25°C, 40%DOD)
3.4
3.5
3.6
3.7
3.8
3.9
4
0 10 20 30 40 50 60 70 80 90 100
Cycle Time (Min)
Cel
l Vol
tage
-35
-25
-15
-5
5
15
25
Pack
Cur
rent
(Am
ps)
Cell 01 Volts
Cell 02 Volts
Cell 03 Volts
Cell 04 Volts
Cell 05 Volts
Cell 06 Volts
Cell 07 Volts
Cell 08 Volts
Cell 03a Volts
Cell 03b Volts
Cell 03c Volts
Cell 08a Volts
Cell 08b Volts
Cell 08c Volts
Pack Current
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STTR Quallion Battery
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Virtual Cell 3P8S Temperature Plot - Cycle 800 (25°C, 40%DOD)
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21
22
23
24
25
26
27
28
29
30
0 10 20 30 40 50 60 70 80 90 100
Cycle Time (Min)
Tem
pera
ture
(°C
)
Amb TempCell 03a VoltsCell 03b VoltsCell 03c VoltsCell 08a VoltsCell 08b VoltsCell 08c VoltsTemp Cell 01b T-MidTemp Cell 02b T-MidTemp Cooloing SleeveTemp Cell 03b T-MidTemp Cell 03a B-BotTemp Cell 03c T-MidTemp Cell 03b B-MidTemp Cell 03c B-TopTemp Cell 03b T-TermTemp Cell 04b T-MidTemp Cell 05b T-MidTemp Cell 06b T-MidTemp Cell 07b T-MidTemp Cell 08b T-MidTemp Cell 08a B-BotTemp Cell 08c T-MidTemp Cell 08b B-MidTemp Cell 08b T-TermTemp Cell 08c B-TopTemp Cold Plate
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STTR Quallion Battery
X1GL1 Voltage Trend Plot
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STTR Quallion Battery
Virtual Cell Amp hr Trend
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STTR Quallion Battery
Conclusions
For the 3P8S pack built with the Quallion 15 Ah cells, it was decided to begin the cycling at 25°C for the three DoD values, then proceed to 35°C
for the next three DoD values, and finally, to complete the matrix at 15°C. This is intended to hold off any low temperature and high recharge rate effects on the virtual cell pack performance until completion of the higher temperature matrix values, in order to accumulate a complete data set for the matrix.
To date, we have completed the first two matrix values of 30% and 40% DoD at 25°C, and the data do not show any untoward trends thus far.
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AcknowledgementsThe STTR work is being performed with the support of the Missile Defense Agency under a Phase III Contract HQ0006-06-C-7381, between Quallion LLC and the Univ. of South Carolina, with supplementary MDA funding for the battery pack testing at NAVSEA Crane.
The authors gratefully acknowledge the work of William Sylvester and James Wood in constructing the packs and performing the electrical wiring, and Evan Hand and Jason Leonard for the Charge Control and Cell Removal hardware design and construction, as well as the software/hardware interface.
STTR Battery Packs