AMS02 UPS Status

1
AMS-02 UPS Status

• C.K.Ho Y.P.Chang
• J.H.Yeh C.B.Huang
• Jan. 12, 2006

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Outline

• Modification of Box
• Structural Analysis
• Non-Structural Fastener Containment
• UPS SOW Rev B
• Phased Schedule
• Action Item Review
• JSC Shipping Document

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RIGHT ANGLE PRINTED BOARD MOUNT DB 25 CONNECTOR
SND25F100E2G
J6
J16

• SND25M100E2G

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BMS
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Modification of Box

• Provide CAD file so that it can be integrated
  into the payload model for evaluation
• Ross Harolds preliminary assessment is that
  increasing the height dimension 15 mm will not be
  a problem.
• Splitted inner bracket
• Stress analyses

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15mm increase in height

• 15 mm increase in the UPS side wall height.
• Move BMS 4mm up
• interior height of the box --- 180 mm,
• exterior height of the box ---196 mm.

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15mm increase in height
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UPS BOX
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Structural Analysis

• Y.P.Chang C.B.Huang
• UPS Box Engineering Diagram
• UPS Structural Analysis Report---ANSYS
• Bolt_Nut_Insert Stress Analysis Report--- MathCAD

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Structural Analysis

• Add 15mm in box height
• Splitted inner bracket

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Structural Analysis

• Margin of Safety of bracket structure is 6.72,
  and ultimate margin of safety is 5.13.
• All the margin of safety of the bolts are
  positive. And the minimum margin of safety is
  0.107 (Total Tension Yield) which occurred at
  Joint 1.

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Joint Assembly
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Non-Structural Fastener Containment

• The screws heads will be encapsulated with Epoxy
  for containment purposes.  
• This process has been approved by JSC Safety and
  Structure and Materials.

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Non-Structural Fastener Containment

• either of the following adhesives
• Scotch-Weld 2216 B/A (epoxy w/ amine catalyst)
• EPON 828 (epoxy) with Versamid 140 catalyst
  (polyamide)
• Any fasteners that are exposed to Atomic Oxygen
  (AO) place a piece of Teflon tape over the cured
  epoxy. 
• Please supply adhesive Teflon tape

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Means of Containment---Bruce Sommer

• Staked Fastener
• Not Acceptable

• Fully Potted Fastener
• Acceptable

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Verification Process--- Bruce Sommer

• Include the potting of the fasteners as a line on
  a TPS to be signed and stamped by appropriate
  quality control personnel.
• Verification photos of the potted fasteners can
  be taken where possible.
• Whats TPS?

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UPS SOW Rev B

• The AMS-02 project intends to release a Rev. B to
  the SOW to expand the battery level thermal
  testing temperature range, based upon the new
  thermal analysis results, to which you have
  already concurred.

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SOW 4.1.1.5  Electrical Interfaces

• The following interfaces are required between the
  battery/BMS and the CAB.
• Battery Charge Cabling
• Battery Discharge Cabling (to monitor electronics
  and to Quench Heaters via the CAB)
• There is a Charge Enable signal (AKA the
  Battery Safety Warning Signal), J2 Pins W and
  V, to allow charging under normal conditions, the
  signal is closed (shorted, resistance lt1Ohm) when
  charging is permitted, it is open (resistance
  gt1MOhm) when charging should not be permitted.

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Appendix B 4.3 Overvoltage

• The battery shall be charged to 35.0 V (40 .0 V,
  original) at C/10 rate, or until the
  resistance across J2 Pins W and V increases above
  1 MegaOhm, and held at 35.0 V for 6 hours??? 
• The battery electronics DO NOT inhibit the
  charging of the battery and DO NOT independently
  prevent overcharge. The electronics will ONLY
  open the Charge Enable signal. This signal MUST
  be monitored externally and charging MUST be
  stopped externally when this signal goes OFF
  (high impedance).  

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Appendix B 4.3 Overvoltage

• The test shall be considered successful when
  proper operation of the BMS  Charge Enable OPEN
  signal is verified.

21
Appendix B 4.3 Overvoltage
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Appendix B 4.4.2 External Short Circuit

• Load change from 90 amp to 72 amp
• But according to (HS-BEA301-001E)
• A current between 7A and 80A is permitted for
  approximately 800ms.
• Overcurrent greater than 80A is interrupted
  within 200?s maximum.
• Change to 85 amp???

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Appendix B 4.4.2 External Short Circuit

• ?Grant Kokoszka of Eaves Devices?The threshold
  for the immediate Protection Switch break is
  80A.  As I recall, 71A is the maximum attainable
  current under proper conditions, and the 80A
  selection was made to provide a very comfortable
  margin.  Our BEA301 test procedure provokes the
  break with an 82/83A minimum load current
  (imprecise due to use of resistive load, see note
  below for technical details).
• (Technical Note on 82/83A in ATP  Reading
  through it, the ATP may seem to suggest a
  verification at 84A min (stated 86A 2A), but
  this resistive setting is applied before the BMS
  is placed in circuit, thereby adding resistance
  and reducing current.)

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4.7 Thermal Vacuum Test and Figure A

• (Rob) The higher temperatures seem a bit extreme
  to me. I dont foresee a performance or safety
  issue with the tests as described (Qual at 61C
  and Acceptance at 51C), but it just seems a lot
  higher than the maximum expected temperature per
  Appendix D. Test is fine, but is it an over-test?
  
• (Tim) The higher temperatures are based upon
  thermal analysis performed here at Jacobs
  Sverdrup.
• (HS-BEA301-001E) These sensors are Elmwood 3200
  series thermostats, specified to close at a
  temperature of 60C and open again at a
  temperature of 55C.

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4.7 Thermal Vacuum and Figure A

• ?Rob? The thermostats
• OPEN at 50 2.8C
• CLOSE at 60 2.8C
• ?Rob?NOTE I STRONGLY recommend NOT testing the
  battery at 60C. This will put quite a stress on
  the chemistry of the cells
• high temperature exposure is not good, leads to
  life and performance limiting degradation of the
  cell materials.
• The thermostats and electronics are tested here,
  independent of the cells. There is little reason
  to be concerned that they have failed during
  transit or battery assembly. If its a real
  concern, we may be able to come up with some
  other test to verify operation.

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UPS Thermal Vacuum Test Profile
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Appendix B 4.2 Thermal Environment Test

• Battery shall undergo ten charge/discharge cycles
  at the following temperatures. The temperatures
  tested shall be 25 ºC, 0 ºC, 20 ºC and 51 ºC (40
  ºC, original). signal goes OFF (high impedance).
   

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Appendix B 4.5 Thermal Cycle

• Place battery in a thermal chamber and raise the
  temperature of the chamber to 61 ºC (50ºC
  ,original) in one hour .

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Appendix B 5.6 Thermal Cycle---omit ???

• Place battery in a thermal chamber and raise the
  temperature of the chamber to 50ºC in one hour .
• Judith 4.7 Thermal Vacuum Test, was ADDED. But
  since thermal cycling is being performed, I would
  recommend doing just vacuum leak checks.

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4.6 Vibration

• The fully charged batteries vibrate for 15
  minutes in each of the x, y and z axes. Moniter
  OCV.
• One D/C/D cycle. 2nd D capacity within ?5 of the
  capacity in the 2nd discharge test of 3.3

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Vibration Test

• Since the UPS boxes (qty. 2) are to be vibration
  tested attached to their mounting brackets, the
  plan is as follows
• Qualification test 1 QM 1 EM
• Acceptance test 2 FMs
• Acceptance test 1 FSM (1 QM)

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Vibration Fixture Assembly
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Main Adapter Plate
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Left Adapter Plate
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Right Adapter Plate
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Completion Phased Schedule

• Rob My schedule would be to ship
  theelectronics and battery modules out on
  1/27/06.

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UPS Milestone Schedule
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UPS Battery Test

• Physical, electrochemical characteristics,
  charge/disch. cycle, vacuum leak test --- 22days
• EDU TESTS---56days
• Qualification Tests---64days
• thermal enviroment---32days
• performance test, overvoltage, discharge
  reversal, external short circuit, thermal cycle,
  vibration---24days
• Thermal Vacuum Test---8days
• FAT---30days 8days TVT

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Action Item Review

• 25.1 UPS TVT test at NSPO
• when?
• QU 09/13 to 09/22
• FU 11/3 to 11/15
• Test fixtures? Procedures?
• CH Lin will make the request.
• 25.2 Portable UPS tester
• Y.T.Ting, 1-Apr

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5.5 Thermal Vacuum Test

• UPS should provide formal request to NSPO. 
• Test schedule, interface (electrical, mechanical,
  thermal), scenario should be described.
• NSPO needs to go through internal reviewing
  process after we get the formal request.
• The available window is after May 2006.

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Action Item Review

• 25.2 Portable UPS tester
• Y.T.Ting, 1-Apr

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JSC Shipping Document
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Updated UPS Weight Data
Misc. Hardware J1J2 230g Intercell Connector
200g Screw Nut 20g Adhesive 50g Flux
100g RTV566 200g Wire 100g (6.4g8m29.3g1.4m)
Total900g X 21.8kg
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Module Assembly

• Module 001 10.194 in.
• Module 002 10.193 in.
• Module 003 10.195 in.
• Module 004 10.196 in.
• Module 005 10.192 in.
• Nominal 10.194 0.002 in.

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bondpath

• Per Mike The ChoTherm goes under the complete
  cell/flange footprint. Hence we need some sort of
  bondpath to the cell brackets and cell walls (or
  are the cell walls totally floating?).---copper
  sheet

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Cell Module / MCB to J1/ J2 Connector
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UPS mounting on Upper Trunnion Bridge

• UPS will be mounted on Vacuum Case Joint Upper
  Trunnion Bridge of USS-02 via Outer Inner
  Bracket.
• Inner Bracket has 13 NUT, SELF-LKG,
  PLATE(NAS1789C4M)fastened with 26
  RIVET(MS20426AD3-7A).
• Inner Outer Bracket will be fastened with 13
  15 sets of NASA provided 1/4 inch
  bolts,NAS1954CX length is TBD by NASA

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UPS mounting on Trunnion Bridge

• Outer bracket
• (NAS1291C4M nut NAS1587-4 washer) installed
  on the inside of the USS beam.  
• The screws that pass thru the outer bracket
  thread into regular nuts (NAS1291 or similar)
  not nut plates.

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The Installation of the UPS

• Per Ross Harold
• a. Attach the Outer UPS Bracket to the USS
• b. Attach the Inner bracket to the UPS
• c. Lift and hold the UPS Inner Bracket in
  place
• d. Install screws thru USS into Inner
  Bracket
• e. Install screws thru Outer Bracket into
  UPS boxes
• Note It might be a good idea to have an
  installation bracket to hold the boxes together
  during installation. Another option would be to
  split the inner bracket so each box could be
  installed separately since they are fairly heavy
  Roberts arms might get tired otherwise.