Development of the MFF Battery. Eugene Marquis (Code G34 Phone
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1 Development of the MFF Battery Eugene Marquis (Code G34 Phone
2 Program Background Objective: Develop a replacement battery for the MK 44 lead acid liquid reserve battery Development started in 1996 to replace the lead acid liquid reserve MK 44 battery MOFA battery with extra cells This effort concluded in 1999 with little success but many lessons learned Improvements to testing by switching loads & using voltage regulator & fixed resistor Improvements to the design of the battery Desire to improve electrolyte risetime 2
3 Program Overview 2 Prong Approach #1: Modify the Army s MOFA liquid reserve battery for use in the Navy s Multi-Function Fuze Task began in 2001 Increase voltage from MOFA s 5.6V to 12.5V Increase current draw from MOFA s 325mA to 450mA Issues Requires mechanical modification to fuze Rise time issue #2: Modify Thales s liquid reserve battery Task added in 2002 Same Fit & Form of MK 44 battery Issue 5 foot drop may fracture glass ampule 3
4 1st Approach: ATK 1st Electrolyte Study 2nd Electrolyte Study: High Rate Electrolyte Study Build 80 batteries with 5x2 configuration Performance test 4
5 1st Electrolyte Study 1st Approach: ATK Objective: Identify an electrolyte with a faster risetime than MOFA electrolyte NSWC-Carderock & ATK investigated several electrolytes Electrolyte required to work with current MOFA cells Conclusion: No potential candidates identified 5
6 2nd Electrolyte Study 1st Approach: ATK High Rate Electrolyte (HRE) Study Objective: Identify an electrolyte with a faster risetime than MOFA electrolyte Testing a different class of electrolytes than the 1st electrolyte study to improve risetime over MOFA Identified two electrolytes that could have better rise time Based on the capacity No ability to test risetime in the lab w/o building batteries Used MOFA batteries filled with the two HREs Control MOFA batteries with MOFA electrolyte Railgun test: Risetime Airgun test: Mission life / capacity Improvements to airgun may activate batteries better & thus could test risetime 6
7 1st Approach: ATK HRE Study: MFF Load Circuit Battery voltage is measured across the battery Battery current is measure by the voltage drop across a 0.5 Ω resistor A voltage regulator is used with a fixed resistor on the output side so that the current draw from the battery is constant after the minimum voltage even as the voltage increases Battery comes up under a light 60 ma load At 100ms, the heavy load is switched in Designed to pull 450mA from the battery when the battery voltage is 7.5V or more 7.5v on a 3 cell MOFA battery is equivalent to a 12.5v on a 5 cell MFF battery 7
8 1st Approach: ATK HRE Study: MFF Load Circuit Similar MFF Load Circuit designs used in railgun and airgun testing Airgun version Unknown battery orientation is rectified using diode steering circuit Voltage drop across diodes accounted for Railgun version Ruggedized to survive gunfiring environment T 0 sensed by G-switch Data recorded by On-Board-Recorder 8
9 HRE Study: Railgun 1st Approach: ATK Risetime Results HRE Total Temp. Met 7.5V Met 7.5V Met 7.5V Met 7.5V Met 7.5V Met 7.5V Test ( 50ms before load after 10sec #2 5 20ºF 0% 100% 0% 20% 20% 100% #2 4 50ºF 0% 25% 0% 25% 25% 100% #2 4 70ºF 50% 100% 0% 25% 100% 100% # ºF 100% 100% 100% 100% 100% 100% #7 5 20ºF 0% 100% 20% 20% 40% 100% #7 4 50ºF 0% 0% 0% 0% 0% 100% #7 4 70ºF 0% 100% 0% 0% 0% 100% # ºF 0% 20% 0% 20% 40% 100% MOFA 2 20ºF 50% 100% 0% 50% 50% 100% MOFA 1 130ºF 100% 100% 100% 100% 100% 100% *The load of 450 ma was switched in at 100 msec 9
10 HRE Study: Airgun 1st Approach: ATK Mission Life Results HRE Total Test Temp. ( F) Met 50ms Met 7.5V before load* Met 7.5V after load Met 200ms Met 300ms Met 10sec Met 140sec #2 3 20ºF 0% 100% 0% 0% 67% 100% 100% #2 3 50ºF 100% 100% 0% 67% 100% 100% 100% #2 3 70ºF 100% 100% 0% 67% 100% 100% 100% # ºF 100% 100% 100% 100% 100% 100% 100% #7 3 20ºF 0% 67% 0% 0% 0% 100% 100% #7 3 50ºF 0% 100% 0% 100% 100% 100% 100% #7 3 70ºF 0% 100% 0% 67% 100% 100% 100% # ºF 67% 100% 67% 67% 67% 100% 67% MOFA 5 20ºF 100% 100% 100% 100% 100% 100% 0% MOFA 6 50ºF 100% 100% 83% 100% 100% 100% 0% MOFA 7 70ºF 100% 100% 100% 100% 100% 100% 29% MOFA 6 130ºF 100% 100% 100% 100% 100% 100% 33% *The load of 450 ma was switched in at 100 msec 10
11 HRE Study: Combine Results 1st Approach: ATK HRE Total Met 7.5V Met 7.5V Met 7.5V Met 7.5V Met 7.5V Temp. 50ms before load* after 300ms # ºF 0% 100% 0% 13% 25% # ºF 43% 86% 0% 43% 57% # ºF 71% 100% 0% 43% 100% # ºF 100% 100% 83% 100% 100% # ºF 0% 100% 0% 13% 25% # ºF 0% 42% 0% 43% 43% # ºF 0% 100% 0% 29% 43% # ºF 25% 50% 25% 38% 50% MOFA 7 20 ºF 86% 100% 71% 86% 86% MOFA 6 50 ºF 100% 100% 83% 100% 100% MOFA 7 70 ºF 100% 100% 100% 100% 100% MOFA ºF 100% 100% 100% 100% 100% Conclusion: Stay with MOFA electrolyte 11
12 2nd Approach: Thales Approach #2: modified European battery Used in DM52A2 & DM84 fuzes 2 Sources Thales Built 80 batteries (5x2 configuration) Glass ampoule Susceptible to breakage and thus battery activation Should not be a serious safety issue Affects long term reliability Diehl/Eagle-Picher Recently enter US market Capable of 5x2 configuration Build prototype designs for testing & for fuze integration 12
13 2nd Approach: Thales Thales became interested in modifying their design from a max of 9 cells to a max of 10 cells for a 5x2 battery capable of 450mA Preliminary performance testing on 4x2 battery configuration was inconclusive due to test hardware malfunction Preliminary safety testing on 4x2 battery configuration was conducted & identified typical issues with glass ampule which could cause noteworthy concern with Lithium battery in extremely rare case Thales delivered 80 5x2 batteries Batteries to be tested along side ATK 80 5x2 Mod-MOFA-2 batteries 13
14 Conclusion Risetime performance data for the MOFA battery can be obtained using ARL s upgraded airgun Airgun produces enough G-force verses time to activate the MOFA battery Awaiting delivery of 80 Mod-MOFA-2 batteries so that side-by-side testing can be conducted on both ATK & Thales 14
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