11

Conclusion of Conclusion of MFF Battery MFF Battery Development Development

Eugene MarquisEugene MarquisNSWCDDNSWCDD--G34G34Fuze BranchFuze Branch

22

““Lead is Dead”Lead is Dead”

ObjectiveObjectiveDevelop a replacement battery for the MK 44 Develop a replacement battery for the MK 44 LeadLead--Acid LiquidAcid Liquid--Reserve Battery for use in Reserve Battery for use in the Navy’s Multithe Navy’s Multi--Function Fuze, MK 419Function Fuze, MK 419

Lithium has more voltage per cell than LeadLithium has more voltage per cell than LeadLithium’s startup characteristics are different Lithium’s startup characteristics are different than Leadthan Lead

33

3 Battery Options3 Battery Options#1: Modify Alliant MOFA battery#1: Modify Alliant MOFA battery–– Increased voltage & current draw Increased voltage & current draw –– Larger diameter requires mechanical Larger diameter requires mechanical

modification to fuzemodification to fuze#2: Modify Thales UA#2: Modify Thales UA--6275 battery6275 battery–– Increased voltage & current draw Increased voltage & current draw –– Fits within MK 44 battery’s envelopeFits within MK 44 battery’s envelope–– Issue: Unknown susceptibility to rough Issue: Unknown susceptibility to rough

handling handling -- Not a safety concernNot a safety concern#3: Modify Diehl/EP Mod 597 battery#3: Modify Diehl/EP Mod 597 battery–– Increased voltage & current draw Increased voltage & current draw –– Fits within MK 44 battery’s envelopeFits within MK 44 battery’s envelope

44

Performance RequirementsPerformance Requirements

Requirements for MFF Battery

02468

101214161820222426

0 50 100 150 200 250 300 350 400 450 500

Time (msec)

Volta

ge (v

)

0

50

100

150

200

250

300

350

400

450

500

Cur

rent

(mA

)

Voltage Requirement

Current Requirement

Time (msec)

Voltage (v)

Current (mA)

0 0 050 12.5 60

99.9 12.5 60100 12.5 450

140 sec 12.5 450

Risetime was never an issue with lead acid batteries

55

Testing: MFF Load CircuitTesting: MFF Load CircuitVoltage is measured across the batteryVoltage is measured across the battery–– Voltage drop across diode steering circuit Voltage drop across diode steering circuit

Current is measure across 0.5 Ω resistorCurrent is measure across 0.5 Ω resistor

Constant current draw Constant current draw at 12.5V or moreat 12.5V or more–– Voltage regulator with a Voltage regulator with a

fixed resistor on outputfixed resistor on outputBattery comes up under Battery comes up under a 60 mA load a 60 mA load -- R3R3450 mA load is 450 mA load is switched in at 100ms switched in at 100ms --R2

Current

Voltage

R2

R3

VR

R2

66

1st Approach: ATK1st Approach: ATK

2 Electrolyte Studies were conducted to investigate 2 Electrolyte Studies were conducted to investigate ways to easily improve risetime ways to easily improve risetime –– Results showed MOFA electrolyte was best for risetimeResults showed MOFA electrolyte was best for risetime

Built 80 batteries with 5x2 configurationBuilt 80 batteries with 5x2 configuration–– Based on MOFA battery design (3x2 configuration)Based on MOFA battery design (3x2 configuration)

(-)

(+)

(-)

(+)

3x2 3x2 configurationconfiguration

5x2 5x2 configurationconfiguration

77

MOFA MOFA MFFMFFM782 M782 -- MOFAMOFA3x2 configuration3x2 configuration325mA current draw 325mA current draw 5.6V battery voltage

MK 419 MK 419 -- MFFMFF5x2 configuration5x2 configuration450mA current draw450mA current draw12.5V battery voltage12.5V battery voltage–– Added 2 more cells per Added 2 more cells per

parallel stackparallel stack

5.6V battery voltage

88

Fitting into MK 44Fitting into MK 44

Alliant

Ø 1.50”

0.86”

Ø 1.53”

MK 44

1.05”

Electronics flex print lays on top of flat

99

Typical ATK RisetimeTypical ATK Risetime 70°F

12msec/ division

Time zero pulse

Current draw (scale 0-500mA)

Battery voltage (scale -20 - +20v)

Current draw (scale 0-100mA)60mA

60mA 450mA

15.5v 13.9v

1010

Conclusion of 1Conclusion of 1stst Approach: ATKApproach: ATK

36 Alliant Batteries tested36 Alliant Batteries testedRisetime met in batteries that did not show signs of Risetime met in batteries that did not show signs of excessive inner cell shortingexcessive inner cell shortingTypical CVT Mission Life would be metTypical CVT Mission Life would be met

Rise Time to 12.5 Volts (msec)

Voltage@ 50ms

Voltageafter load

AVERAGE STAND. DEV Pass Fail Pass Fail

20°F 7 30.26 1.15 4 3 4 3

50°F 10 27.17 2.94 6 4 6 4

70°F 10 25.94 1.67 8 2 8 2130°F 9 18.31 1.18 5 4 5 4Total 36 25.35 4.47

Temp. (°F)

# of units tested

Batteries that exhibited shorting were not included in risetime average

1111

2nd Approach: Thales2nd Approach: Thales

Approach #2: Modified Thales batteryApproach #2: Modified Thales battery–– Modified UAModified UA--6275/8216275/821

4x2 configuration4x2 configuration

–– Built 80 batteries UABuilt 80 batteries UA--6295/5216295/5215x2 configuration5x2 configuration

–– Glass ampoule Glass ampoule Unknown susceptibility to breakage Unknown susceptibility to breakage Not a safety issue but affects long term reliabilityNot a safety issue but affects long term reliability

1212

Fitting into MK 44Fitting into MK 44

Thales&

Diehl/EP

Ø 21Ø 32

23

Ø 38.8

MK 44

26.7

1313

Conclusion of 2Conclusion of 2ndnd Approach: ThalesApproach: Thales

Meets Fit, Form, & Function of MK 44Meets Fit, Form, & Function of MK 44–– Very limited mechanical repackaging of fuzeVery limited mechanical repackaging of fuze–– Rise time is very close to MK 44 & consistent across Rise time is very close to MK 44 & consistent across

temperature rangetemperature range–– Meets mission life requirementMeets mission life requirement

Rise Time to 12.5 Volts (msec)

Voltage@ 50ms

Voltageafter load

AVERAGE STAND. DEV Pass Fail Pass Fail

20°F 10 20.55 1.38 10 0 10 0

50°F 10 16.08 2.00 10 0 10 0

70°F 10 13.97 1.87 9 1* 10 0130°F 10 9.83 0.68 10 0 10 0

TOTAL 40 15.11 4.28

Temp. (°F)

# of units tested

*missed by 1.6V

1414

3rd Approach: Diehl/EP3rd Approach: Diehl/EP

Diehl/EagleDiehl/Eagle--Picher 597Picher 597–– Recently enter US marketRecently enter US market–– Capable of 5x2 configurationCapable of 5x2 configuration

4x2 design tested4x2 design tested

–– Glass ampoule Glass ampoule It should not be susceptible to It should not be susceptible to breakage due to breaker breakage due to breaker designdesign

BattAnim_neu.mov

1515

1616

Conclusion of 3Conclusion of 3rdrd Approach: Approach: Diehl/Eagle PicherDiehl/Eagle Picher

Meets Fit, Form, & Function of MK 44Meets Fit, Form, & Function of MK 44–– Very limited mechanical repackaging of fuzeVery limited mechanical repackaging of fuze–– Rise time same as MK 44 Rise time same as MK 44 –– Scaling of 4x2 battery suggests that 5x2 would meet Scaling of 4x2 battery suggests that 5x2 would meet

risetime requirementsrisetime requirementsTesting of D/EP 5x2 for Mission Life RequirementTesting of D/EP 5x2 for Mission Life Requirement

Rise Time to 12.5 Volts (msec)

Voltage@ 50ms

Voltageafter load

AVERAGE STAND. DEV Pass Fail Pass Fail

20°F 4 7.46 0.27 4 0 4 0

50°F 0

70°F 5 16.11 6.21 5 0 5 0130°F 3 8.57 1.22 3 0 2 1TOTAL 12 11.34 5.67

Temp. (°F)

# of units tested

Pass/Fail scaled to 4x2 configuration

1717

ConclusionsConclusionsAlliant Alliant –– Typical CVT Mission Life metTypical CVT Mission Life met–– Investigate inner cell shorting on top stackInvestigate inner cell shorting on top stack

ThalesThales–– Good rise time and consistent across all temperaturesGood rise time and consistent across all temperatures–– Glass ampule susceptible to breakage Glass ampule susceptible to breakage

PastPast experience with glass ampules show reduced reliabilityexperience with glass ampules show reduced reliability

Diehl/EagleDiehl/Eagle--PicherPicher–– Testing of 4x2 battery suggests a 5x2 can perform as well Testing of 4x2 battery suggests a 5x2 can perform as well

as MK 44as MK 44–– 22ndnd source & potentially improved reliability against source & potentially improved reliability against

accidental activation during storage & handling accidental activation during storage & handling