Transcript Smart Battery Technology for Military Battery Charging and Management Rick Silva, Sr.

Smart Battery Technology for Military
Battery Charging and Management
Rick Silva, Sr. Systems Engineer
Advanced Concepts
Custom Manufacturing & Engineering, Inc.
May 4, 2005
Company Legacy
 CME was a 1997 spinout of Lockheed Martin. Owner and founder,
Dr. Nancy Crews. We originally supported Sandia and others with
technology development and transition dating back to 1957,
formerly GE Neutron Devices
 We successfully used the SBIR/STTR, research institutions, and
other grants to develop products and IP, especially in Sensors and
Electrical Power market areas
 First contracts with Government and primes were platform
integration, power distribution, power electronics for monitoring
and control, and battery management
 Core competencies included: Shelter integration, power
distribution, SCADA and embedded monitoring and control, data
networking, wireless, environmental sensors and monitoring
Power-Related Programs
Intelligent Power
Management System
(IPMS)
Specialized Battery
Applications
Advanced Power Control Improved Low-Power
Networks
for FCS & Objective Force
Magnetics
Power Source
Integration
Power Product Development &
Manufacturing Experience
Power Distribution Cart for
International Space Station
5-Year Army AC/DC Tactical
Power Supplies Contract
AC/DC Power
Control Module
I200 Advanced Power
Power Control
Distribution for Tactical Panel Assemblies
Operation Centers
for C2 Vehicles
Power Network
Gateway Module
SOF UUV Battery Box,
Power Distribution
Ongoing Power Research
Battery Research
CME is conducting applied research in the most recent
rechargeable battery cell technology for military
applications
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Developing improved uninterruptible power supplies (UPS’s)
weighing a fraction of the present CHS hardware while providing
three times the run time
Evaluating state-of the art LiS battery technology that can provide
nearly double the specific energy density, compared to other
Lithium technology
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Developing a “Smart Battery” which will be capable providing the
user with useful information
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Developing state of the art “Smart Charging” technology capable
of charging a large number of batteries in an optimized manner
ensuring the most efficient throughput
Smart Power Management for Military
Vehicles and Shelters
The Question
The Army Battery Usage
 Primary, Secondary, Chemistry
 Applications
The Problems
Smart Battery Technology
 What is it? What can it provide?
Possible Answers
Conclusions
The Question
“ Is there value in using Smart Battery
Technology in military batteries?”
“ I’m not sure it’s worth the $5 to put it in the
battery.”
More Questions
Are there problems in the military that Smart
Battery Technology can help solve?
Can Smart Battery Technology be utilized to
provide a benefit to the military?
Will the implementation be worth the cost?
The Army Battery Use
 The Army uses primary and secondary batteries
• Commercial AA, C, D, 9V and lantern batteries are
used in equipment, both non-rechargeable and
rechargeable.
• Non-rechargeable Army batteries include; BA-5316,
BA-5390, BA-5590, BA-5588, BA-5600, BA-5800, BA5847
• Rechargeable batteries include BB-388, BB-390, BB516, BB-2590, BB-2600, BB-2847, BB-2800
• Rechargeable Chemistries include; Nickel Cadmium,
Nickel Metal Hydride, Lithium Ion
The Army Battery Use
 They use a variety of shapes and sizes [1]
Battery Applications
 XX90
• SINGCARS radios
• AN/PSC-3, -5 SATCOM radios
• AN/MLQ-40 Prophet
• REMBASS Repeaters, SMS, SSS
• M22 ACADA
• Javelin Anti-Tank Missile
• TSEC/KY-57
• And more than 50 other types of equipment
Land Warrior Power
[2] Army Power Needs and Initiatives, Dr Robert Hamlen
OFW Capabilities Anticipated for
FY06 Experiments & Demos
Network Digital Radio
Helmet-Mounted Sensors
• Lightweight/low power JTRS Cluster V (SLICE
Soldier Radio Waveform (SRW))
• Helmet mounted sensors (IR, I2, fused)
• See-thru, color, monocular helmet mounted display
• Gel microphone with bio-sensory capability
• N Gas sensor (ICIDS, MILES capabilities)
• Digital ad hoc (self re-routing) networking
• Cross-domain solution (multiple security levels)
• Body conformal antenna
• Soldier-centric design
Personal Navigation
• Hybrid all-terrain nav; 3D, 3 meter accuracy
• GPS, DRM, TOA, IMU
• Kalman filter
Situational Awareness
Headgear Protection and Integration
• Improved weight, ergonomics and center of gravity
• Integrated/modular design compatible w/XM50
mask for respiratory protection
• Lightweight protection from fragments and 9mm
• Modular laser eye protection (3 lines)
• Hearing protection and sound localization
• Improved suspension liner
• Seamless integration of LW net with FCS
network and unattended or autonomous sensors
Warrior team collaborative planning and mapping
• Horizontal data fusion within squad
• Multiple I/Os (wrist, helmet mounted, tablet)
Direct & Area Fire Weapons
• XM-8, XM-29
• Lightweight machine gun w/caseless ammo
• Lightweight 5.56 ammo
Leveraged FCS Unmanned Systems
• Common Operator Control Unit (Goal:
Integrated soldier control unit
Robotic Mule
Fire Control Systems
• Load Carriage, power generation
• Mobile squad-based fusion station
• Laser pointer for rapid target acquisition
• Fused thermal/I2 on weapon
• Day sight for close quarters combat
Small Organic Unmanned Ground Vehicle
• Modular sensor suite payloads
Organic Supporting Fires and
Synchronization
Organic Unmanned Air Vehicle
• Inter-team target hand-off
• Software integration for near real time call for
FCS fires
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One man portable
0.5 – 2 lb payload
8 (T) – 16 (O) km range
Real time day/night video and comms
[3] Objective Force Warrior Program Update, Scot Feldman
OFW Capabilities Anticipated for
FY06 Experiments & Demos
Rechargeable Batteries
• Lithium polymer
Energy Source for Hybrid Power
• Metal-air (e.g. Zn, Al)
• Fuel cells
Power Architecture
• Semi-distributed on soldier
• Conformal designs
• FCS-compatible recharging station
Power Management
• Low power processing
• Efficient SW architectures
• Efficient DC/DC converters
• Automated/selective device powering
• Smart chargers
Training
Integrated Combat Suit
• Modular design
• Integrated body armor/load carriage chassis
with ltwt, high performance ballistic materials
• Integrated joint protection
• Multifunctional materials including:
• SPM for CB/wet protection
• Hybrid Electro-textile power/data PAN
• Novel signature mgmt (multienvironment visual and near/far IR)
• FR materials
Thermal Balance
• Passive thermal management via spacer materials
and highly wicking materials
• Personal Air Ventilation System (PAV)
Prompt Casualty Care
• Positionable tourniquets
• Improved trauma dressings
• Integrated pneumatic tourniquets
Sustenance
• Live, constructive, virtual links
• TTP recall; Manuals, reference access
• Leader training
• Collaborative en route planning and mission
rehearsal
• First Strike Ration
• Self-Hydrating Ration
• Nutritional supplements
Physiological Status Monitoring
• Sensor suite for PSM
• Remote triage
Human Performance
• System fightability (physical, cognitive)
• Physical/cognitive performance enhancement
• Multi-modal input/output devices
• Non-stimulant performance enhancers
Hydration
• On the move hydration w/CB protection and
water purification
[3] Objective Force Warrior Program Update, Scot Feldman
Observations
Primary batteries are preferred by the Army
 Last longer than rechargeable batteries
 Operate at higher temperatures
 More convenient for frontline use
 Less expensive to buy
But they
 Are more expensive to use
 Cause 150 ton disposal issue annually
 Have logistics issues as a consumable
The Event
The shortage of non-rechargeable batteries during the
Iraqi war became critical resulting in changes [4][5]
 Standard practices regarding replacement intervals
were modified
 Batteries were rationed, if you weren’t on the frontline
you might not get batteries
 Units had to learn to use rechargeables in the field
The result was that the rechargeable battery, for the
present, is the preferred power source for
communications, navigation, imaging, computation, and
sensor systems.
The Problems
Usage Issues
 Rechargeable batteries have State of Charge,
SOC, indicators but they are not accurate
• Poor design, shallow discharging, no battery
management can cause this
• A lack of a good SOC can cause shallow discharges
 The SOC provides 20% increments but the
soldier wants to know how long the battery will
last
The Problems
Usage Issues
 Rechargeable batteries have a life span but
there is no State of Health, SOH, indicator
• Soldiers have been using and continue to use
batteries that can’t hold charge due to age or failure
• Batteries can be prematurely aged due to operating
conditions, excessive charging, abuse, etc
• Expiration dates are implied but may not be readable
by the time it matters.
The Problems
Usage Issues
 Charging and Charging Logistics for batteries
can come with their own set of issues
• Battery Sitter or Soldier
• Battery Management
• The variety of batteries to be charged
• Available power limitation
The Problems
Additional Issues
 New chemistries can’t be addressed without
new chargers
• BB-2590 required a new charger
 Innovation stops at the release of the charger
• New charging algorithms can’t be implemented
• New conditioning or diagnostic technique can’t be
added
The Problems
Summary of Issues
 Inaccurate, uninformative SOC
 No SOH
 Charging process in not optimum
 No battery management practiced
 No power management
 New chemistries can’t be easily supported
 Innovation is stops at point of deployment
Smart Battery Technology
 By 1993 Duracell and Intel were developing
Smart Battery System
 Specifications 1.0 were released in February
1995
• Smart Battery Data Specification [6]
• System Management Bus Specification [7]
• System Management Bus BIOS Interface
Specification
Smart Battery Technology
 In 1996, 1.0 Releases
• Smart Battery Charger Specification
• Smart Battery Selector Specification
 In 1998, 1.0 Releases
• Smart Battery System Manager Specification
• Smart Battery Data Accuracy Testing Guideline
 Released 2.0 Specifications
• System Management Bus Specification, 2000
• Smart Battery Data Accuracy Testing Guideline,
2001
Smart Battery Data
 Smart Battery Data Specification defines
• Information a battery can convey to a charger
• The message format
• Data: battery chemistry, capacity, voltage, charge
and discharge information
• Messages include the current status of the battery's
charge and number charge-recharge cycles the
battery has endured
Smart Battery Data
Smart Battery SBData
SBS Parameters
 At Rate, Time To Full and Time To Empty
• Possible use in the approach to manage the
charging of large quantities of batteries
 Relative and Absolute State Of Charge (SOC)
• An accurate SOC is essential to users whose life
may depend on the battery in the equipment they
carry
• The difference between the relative and absolute
SOC could provide a State Of Health
SBS Parameters
 Run Time To Empty
• Possible use in the determining the State Of Charge
 Cycle Count
• A possible means for determining State Of Health
• A possible mechanism for initiating relearning
 Chemistry
• A mechanism for the altering charging algorithm
• Could be combined with manufacturer data for
optimized charging
Possible Answers
What would help the soldier
 A Smarter Battery
• A useful State of Charge
• A State of Health
 A Smarter Charger
• Programmable
• Upgrade Diagnostic Capability
• Embedded Battery Management
• Embedded Power Management
Possible Answers
Smart Battery Implementation
 Useful Smart Battery Data parameters
• Relative State of Charge
• Run Time to Empty
• Absolute State of Charge (State of Health)
 LCD Display Upgrade
• Seven segment
• Sequenced Display
Possible Answers
Smart Battery Implementation
 Conceptual LCD Display
• State of Charge
• Run Time Remaining
• State of Health
 Usage dependent display
Possible Answers
Smart Charger Implementation
 Smart Charger Operation
• Test and Charge legacy and Smart Batteries
• Similar in operation to existing chargers
• Multiple batteries, multiple chemistries
 Charger System Operation
• Multiple chargers communicate and coordinate
charging and power consumption
Possible Answers
Smart Charger Standalone Implementation
 Useful Smart Battery Data parameters
• Relative an Absolute State of Charge
• At Rate, Time To Fill and Time to Empty
• Cycle Count
• Chemistry
 Charger controlled battery display
Possible Answers
Smart Charger Group Implementation
 Uses the same set of Smart Battery Data
parameters as standalone
• The parameters are used to modify the individual
charger behavior based on group efficiency or
available power
 Charger groups of all sizes will coordinate their
operation to maximize throughput without
soldier intervention
Conclusions
A benefit of this approach is that battery life
could be extended or, more accurately, realized
for what are relatively expensive batteries
Another benefit is the trust the soldier could
have for the batteries used in his equipment
Smart Chargers with embedded capabilities
could possibly reduce the number of chargers
required for a specific throughput
Conclusions
Smart Battery Technology can be applied to
Army batteries and chargers to provide a benefit
to the Warfighter
A Smart Battery with an informative display
bypasses the need to upgrade fielded equipment
Smart Chargers with embedded capabilities
relieves the soldier of battery management and
analysis, letting them focus on their mission
How to Contact CME
Custom Manufacturing & Engineering, Inc.
2904 44th Avenue, North
St. Petersburg, FL 33714
www.custom-mfg-eng.com
Rick Silva
Advance Concepts
(727) 548-0522 Ext. 1765
FAX (727) 541-8822
email: [email protected]
Bibliography
[1] US Army Rechargeable Battery Program, CECOM Ft Monmouth , NJ
https://lrcteams.monmouth.army.mil/QuickPlace/ipm/PageLibrary85256A2B0062
C0F7.nsf/h_Toc/f8ded136ff17831985256b3e006cf4e0/?OpenDocument
[2] Hamlen, Dr Robert P, “Army Power Needs and Initiatives”, 4th Annual Electric
Power Conference, April 22-23 2004
[3] Feldman, Scott, “Objective Force Warrior Program Update”, OFW Technology
Program Office, US Army Natick Soldier Center, Tactical Power Sources, January
30, 2004
[4] Fein, Geoff S., “Battery Supplies Ran Dangerously Low in Iraq”, National
Defense Magazine, September 2003, Last accessed April 19, 2005,
http://www.nationaldefensemagazine.org/issues/2003/Sep/Battery_Supplies.htm
[5] “Logistics Lessons Learned in Operation Iraqi Freedom 2003”, Defense
Update, Year 2004 Issue 1, http://www.defense-update.com/features/du-104/batteries-lessons-iraq.htm
[6] Smart Battery Specifications, Last accessed April 24, 2005,
http://www.sbs-forum.org/specs/
[7] System Management Bus, SMBus, Last accessed, April 24, 2005
http://www.smbus.org/specs/