E NEERI RING BORATO Y

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/I!ill E NEERI RING B O R A T O Y

DEDICATED TO PROGRESS IN MARINE ENGINEERINGThe M a r i n e E n g i n e e r i n g L a b o r a t o r y i s c h a r g e d w i t hthe discovery of fundamental knowledge, t h ed e v e l o p m e n t o f new a n d u n i q u e e q u i p m e n t t o meeta n d a n t i c i p a t e new n a v a l r e q u i r e m e n t s ,,analysisof F l e e t machinery f a i l u r e s , and e v a l u a t i o n o fp r o t o t y p e s t o i n s u r e high performance and r e l i a b i l i t y i n the Fleet.Dedicated t o progress i nnaval e n g i n e e r i n g , t h e Marine E n g i n e e r i n g Laboratory contributes t o the technical excellenceand s u p e r i o r i t y o f t h e N a v y t o d a yANYTHISTHEMATTERSREPORTOFCOMMERCIAL-and FPROPRIETARYDUEINCLUDEDREGARDINTERESTS.THE I N F O R M A T I O N C O N T A I N E D H E R E I N S H A L LUSEDTHISANYFORADVERTISINGRFPORTPAGESHASARENOTa PURPOSES.BEEN MACHINEMISSINGINFORPLEASEASSEMBLED.REQUESTI FFROMMEL.

N i c k e 1- C a d m i u m B a t t e r yReconditionerA s s i g n m e n t 61 501MEL R&D R e p o r t 183/66A u g u s t 1966BYFloyd E, FordA p p r o v e d by:62-B.L UR. 3 , WYDEElectrical S y s t e m s D i v i s i o nD i s t . r i b u t i o n of t h i s d o c u m e n t i s u n l i m i t e d .

MEL Report183/66Distribution L i s tNAVSHIPS (SHIPS 051)NAVSHIPS ( S H I P S 2021)NAVSHIPS ( SHIPS O y U D ,INAVSEC (Code 6 6 6 0 )DTMBNAVSECPHI U D I VDDC ( 2 0 )NASA ( 3 )S c i e n t i f i c and TechnicalInformation C e n t e rC o l l e g e F 3 r L Md- 20740( A t t n , NASA, R e p r e s e n t a t i v e )NASA ( 2 )Washington, E, C ,20546( A t t n , RNW/E, M, Cohen;FC/A, M , Greg Andrus)NASAGoddard Space F l i g h t C e n t e rG r e e n b e l t , Md20771( A t t n : Joseph S h e r f e y ,Code 735)NASA ( 2 )Langley Research C e n t e rI n s t r u m e n t Research Di TTHampton, Tia23365( A t t n : John L o P a t t e r s o n ,MS-234: M , B o S e y f f e r t ,MS-112)NASA (3)L e w i s Research C e n t e r21000 Brookpark RdCleveland, Ohio 44135( A t t n : N, D, S a n d e r s , M S - 3 0 2 - 1 ;R , L , Cummings, MS-5OO-2Ol;R , R , M i l l e r , MS-500-202)NASA ( 2 )George C . M a r s h a l l SpaceFlight CenterH u n t s v i l l e , Ala35812( A t t n : P h i l i p Youngblood andRichard Roehme Bldg 4487- B)iiNASA(5)Manned S p a c e c r a f t C e n t e rHouston, Texas 77'058( A t t n : William R , Cusenbury,P r o p u l s i o n & Energy SystemsBranch, Bldg 61" S i t e 1;R o b e r t Cohen, G e m i n i P r o j e c tO f f i c e : Richard Perguson( E P - 5 ) ; Tames T , Kennedy( E E - 5 ) ; F o r r e s t E , Eastman(EE-4))NASA ( 2 )A m e s Research C e n t e rPioneer P r o j e c tMoffett Field, C a l i f .94035( A t t n : James R Swain andA , S o Hertzog; J o n R u b e n z e r ,Biosatellite Project)J e t Propulsion L a b4800 Oak Grove D rPasadena, C a l i f91103( A t t n : A i l i Uchiyama)U , S, A r m y E n g i n e e r R8cD LabsE l e c t r i c a l Power BranchF o r t B e l v o i r , Va, 22060( A t t n : Code SMOFB-EP)C O , U, S , army E l e c t r o n i c sRBGD Labs, Power S o u r c e s D i vF o r t Monmouth, N o J ,( A t t m : Code SELRA/PS)Research O f f i c eR&D D i r e c t o r a t eAmy Weapons CamnandRock I s l a n d , I l l , 61201( A t t n : M r . G o Riensmith,Chief)U, S, A r m y Research O f f i c eBox CM, Duke S t a t i o nDurham, N o C o 27706( A t t n : D r . Wilhelm J o r g e n s e n )

MEL Report183/66Distribution L i s t (cont)N a t i c k LabsC'l&Jiing and OrganicM a t e r i a l s DivN a t i c k , Mass,01760( A t t n : R o b e r t N. Walsh andG o A , Spano)H a r r y Diamond LabsRoom 300, Bldg 92Connecticut A v e . &V a n KESS S t . , N. W.Washington, D e C .20438( A t t n ; Nathan Kaplan)Army M a t e r i e l CommandResearch D i v , AMCRD-RSCM-T-7W a s h i n g t m , D. C .20315( A t t r ! : John W, C r e l l i n )Army M a t e r i e l CommandCevelopment Div, AMCRD-DE-MO-PWashington, D. C.20315( A t t n r Marshall D. Aiken)U, S. A r m y TRECOM ( 2 )F o r t E u s t i s , Va.23604( A t t n : D r , E. L , Echols(SMOPE-PSG) ; Leonard M.E?artor,e ( SMOFE-ASE) )'JDS , A m y M o b i l i t y CommandResearch DivC e n t e r L i n e , Mich. 48090( A t t n : 9, Renius (AMSMO-RR))ONR ( 2 )( A t t n : Head, P o w e r Branch,?"ode 429; H. W. Fox, Code 425)NEiL( A t t n : C r , J. C . White,Code 61.60)NAl'AIRkSCOM(2)( A t t n : W h i t e w e l l T . Beaton,Code RAAE-52; M i l t o n Knight,Code RAAE-50)Naval Ammunition Depot ( 6 )C r a n e , I n d , 47522( A t t n : E , B r e u s s andH, S c h u l t z )NOLCorona, C a l i f .91720( A t t n : W i l l i a m C. Spindler,Code 441)NOLS i l v e r S p r i n g , Md.20900( A t t n : P h i l i p B. C o l e ,Code WB)NAVSEC (Code 6660)( A t t n : C. F. V i g l o t t i )NAVSHIFS (SHIPS 034)( A t t n : Bernard B. Rosenbaum)Space Systems DivLos Angelos A F S t a t i o nLos Angelos, C a l i f .90045( A t t n : SSSD)F l i g h t V e h i c l e P o w e r BranchA e r o propulsion LabW r i g h t - P a t t e r s o n AFB, Ohio45433( A t t n : J a m e s E. Cooper)A i r F o r c e Cambridge Research LabL o G, Hanscom F i e l dBedford, Mass01731( A t t n : Commander, CRO)Rome A i r Development C e n t e r , ESDG r i f f i s AFB, N. Y. 13442(Attn: Frank J, M o l l u r a ,RASSM)N a t i o n a l E u r e a u of S t a n d a r d sWashington, D , C .20234( A t t n : Dr, W , J, H a m e r )Dept of Defense %E GroupThe PentagonWashington, D , C.20310( A t t n : G. B o Wareham)U, S , A t o m i c Energy CommissionA m y Reactors, DRDWashington, D. C .20545( A t t n : Donald B. Hoatson)iii

D i s t r i b u t i o n L i s t ( c o-.n t l1Chemical P r o d u c t s DivAero j e c t - G e n e r a l CorpAzusad C a l i f , 91702( A t t n : D r S o 0 , Rosenberg)Aeronutronic D i vPhilco C o r pFord R dNewport Beach, C a l i f . 92660( A t t n Library]Aerospace SorpP , o., BOX 95085Los Angelos , C a l i f90045A 1 lis-Chalmers Manufacturing eo1100 South 7 0 t h St.Milwaukee, W i s .53201( A t t n : D r P Joyner)American V n i vMassachusetts &Nebraska A v e O N m W,Washington, D , C ,20016( A t t n : Dr, R T , F o l e y ,Chemistry Dept)A r t h u r D, L i t t l e , I n cAcorn ParkCambridge, Mass. 02140( A t t n . Dr E l l e r y W S t o n e )Atomics I n t e r n a t i o n a l DivNorth American A v i a t i o n , I n c .8900 D e S o t ? Ave,Canoqa P a r k , C a l i f91304( A t t n : D r H , L Recht)B a t e l l e Memorial L n s t i t u t e505 King Ave,Columbus Ohio 43201( A t t n : D r C, L o F a u s t )B e l l LabsMurray H i l l , N, J, 07971( A t t n : U , B , Thomas andD o A , Feder)The Boeinq C O ,P . 0 , Box 98124S e a t t l e , Wash98124ivBorden Chemical C o sC e n t r a l Research LabP o 0 , Box 9524P h i l a d e l p h i a , Pa ,.19124Burgess B a t t e r y eo,Exchange S t .F r e e p o r t , 111. 61032( A t t n : D r Howard 2 - S t r a u s s )C & D BatteriesDiv of E l e c t r i c A u t o l i t e C o r nConshohocken, Pa,19428( A t t n : D r . Eugene W i l l i h n g a n z )Calvin CollegeGrand Rapids, Mich, 49506( A t t n : Prof, T , P o Dirkse)C a t a l y s t Research C o r p6101 F a l l s Rd,B a l t i m o r e , Md- 21209( A t t n : J, P o Wool'ey)ChemCell I n c .3 C e n t r a l Ave,E a s t Newark, N, J, 0'17029( A t t n : P e t e r D . Richman)Delco Remy DivGeneral Motors Corp2401 Columbus Ave.Anderson, I n d .46011( A t t n : D r . J, 2 , Lander)Douglas A i r c r a f t Go. I n c .Astropower Lab2121 Campus D r ,Newport Beach, C a l i f .92663( A t t n : D r . C a r l Berger)Dynatech Corp17 Tudor S t ,Cambridge, Mass,02138( A t t n : R , L, Wentworth)E a g l e -P i c h e r C oP o 0 , Box 47J o p l i n , Mo.64802( a t t n : E , M , Molise)aIIIIIII1

MEL Report183/66Distribution L i s t (cont)E l g i n N a t i o n a l Watch CO.107 N a t i o n a l S t .E l g i n , I l l . 60120( A t t n : T. Boswell)E l e c t r i c Storage Battery Co.M i s s i l e B a t t e r y Div2510 Louisburg Rd.R a l e i g h , N, C .27604( A t t n : A , Chreitzberg)Electric Storage B a t t e r y Co.C a r l F. Norberg ResearchC e n t e r , 19 W e s t C o l l e g e A v e .Yardley, Pa.19068( A t t n : D r . R, A . S c h a e f e rand W, S. H e r b e r t )E l e c t r o c h i n i c a Corp1140 O ' B r i e n D r .Menlo Park, C a l i f . 94025( A t t n : D r . Morris Eisenberg)E l e c t r o - o p t i c a l Systems, I n c .300 North H a l s t e a dPasadena, C a l i f . 91107( A t t n : E. Findl)Emhart Manufacturing Co.sox 1620H a r t f o r d , Conn.06101( A t t n : W, P. Cadagon)Engelhard I n d u s t r i e s , I n c .49'3 DeLancy St,Newark, N, J, O T l O 5( A t t n : D r , J, G , Cohn)D r , Arthur F l e i s c h e r460 S o u t h C e n t e r St.Orange, N, 3, 07050G e n e r a l E l e c t r i c Co.S c h e n e c t a d y , N . Y o 12301( A t t n : : D r . R, C , O s t h o f f andD r , W. C a r s o n ; AdvancedTechnology Lab)General E l e c t r i c C o .M i s s i l e de Space D i vS p a c e c r a f t DeptP. 0. Box 8555P h i l a d e l p h i a , Pa.19101( A t t n : E , W. Kipp, Room T-2513)General E l e c t r i c C o oBattery Products SectionP o 0, B o x 114Gainsville, Fla.32601General E l e c t r i c C o ,Research LabsSchenectady, N, Y o 12301( A t t n : C r . H, L i e b h a f s k y )General MotorsDefense Research Labs6767 H o l l i s t e r S t .Santa B a r b a r a , C a l i f93105( A t t n t D r . J, S o Smatko andD r . C, R, R u s s e l l )Globe -UnionInc.900 E a s t Keefe Ave.Milwaukee, W i s .53201Gould-National B a t t e r i e s , dncEngrgo &; R e s - C e n t e r2630 U n i v e r s i t y A v eS. E .Minneapolis, Minn55418( A t t n : Z e F. Donahue)A l k a l i n e B a t t e r y DivGulton Industries212 Durham A v e .Metuchen. N o J. 08840( A t t n : D r . Robert S h a i r )Hughes A i r c r a f t CorpBldg 366, M,S, 524E l Segundo, C a l i f - 90245( A t t n : R , B , Robinson)Hughes Research Labs Corp3011 M a l i b u Canyon Rd,Malibu, C a l i f90265V

MEL Report183166Distribution L i s t (cont)Hughes A i r c r a f t CorpCentinda Ave, 86 T e a l e S t ,Culver C i t y , C a l i f , 90230( A t t n : T , V , Carvey)I T T Research I n s t i t u t e10 West 3 5 t h S t ,Chicago, I l l .60616( A t t n : D r . H, T, Francis)R e s . & Engrgo Support DivI n s t i t u t e f o r Defense Analyses400 Amy-Navy D rA r l i n g t o n , Va22202( A t t n : M r , R. Hamilton andD r , Szego)Idaho S t a t e UnivDept of ChemistryP o c a t e l l o , Idaho 83201( A t t n : D r G,, Myron Areand)I n s t i t u t e o f Gas TechnologyS t a t e and 3 4 t h S t ,Chicago, Ill60616( A t t n : B o S , Baker!J o h n s Hopkins UnivApplied F h y s i c s Lab8621 Georgia AveS i l v e r S p r i n g , Md.23910( A t t n : Richard Cole)Johns -Manvil l e R e s 8r; EngrgC e n t e r , P m 0 , Box 159M a n v i l l e , N, J , 08835( A t t n , J o S , Parkinson)Leesona Moos LabsLake S u c c e s s FarkCommunity D r ,G r e a t Neck, N, Y o 11021( A t t n : D r . H, O s w i n )L i v i n g s t o n E l e c t r o n i c CorpR o u t e 309Montgomcryvillc, F a18936( A t t n . William F, Meyers).viLockheed M i s s i l e s & Space C o o3251 Hanover S t Palo A l t o , C a l i f . 93404( A t t n : Library)Mallory B a t t e r y Co.60 E l m S tNorth T a r r y t o n , N o 1 " 10593( A t t n : R, R, c l u n e )P , R , Mallory & C o o , Tnc.Yorthwest I n d u s t r i a l ParkB u r l i n g t o n , Masso 02103( A t t n : D r , P e r Bro)F , R , Mallory 8s C o , , Tnc3029 E , Washington S tI n d i a n a p o l i s Ind , 46206(Attn, Technical L i b r a r i a n )MelparTechnical Information Center3000 A r l i n g t o n Blvd,Falls Church, V a 22046M e t a l s and C o n t r o l s DivTexas I n s t r u m e n t s , I n c ,34 F o r e s t S t ,A t t l e b o r o , Mass. 02703( A t t n : D r , E , M, J o s t )Midwest Research I n s t i t u t e425 Volker Blvd.Kansas C i t y , Mo,64110( A t t n : D r , B o W , Beadle)Monsanto Research CorpE v e r e t t I M a s s . 02149( A t t n : D r , & I Q 0 , Smith)Rocketdyne D i vNorth American A v i a t i o n , I n c .6633 Canoga A v e .Canoga P a r k , C a l i f 91303( A t t n: Library)North A m e r i c a n A v i a t i an, I n c12214 Lakewood Blvd.Downey, C a l i f , 90241( A t t n : Burton M O t z i n g e r ).

MEL R e p o r t183/66D i s t r i b u t i o n L i s t (cont)Zohn OwenP, 0 , B o x 87Bloomfield, N , J. 07003P o w e r Information CenterUniv of P a .Moore School Bldg200 South 33rd S t .Phil3delphia, Pa.Power Sources DivWhittaker C o r p9601 Canoga Ave.Chatsworth, C a l i f . 91311( A t t n : D r . M. Shaw)P h i l c o CorpDiv of t h e Ford Motor C o .3 1 u e B e l l , P a . 19422( A t t n : 3r. P h i l l i p C h o l e t )Radiation Applicafions, Inc.36-40 3 7 t h S t .Long Xsland C i t y , N , Y. 11101Astro DivRadio Corp of A m e r i c aHightstown, N, J p 08520j A t t n : Seymour W i n k l e r )Radio Corp o f AmericaP - 0 , B o x 800P r i n c e t o n , N, J - 08540( A t t n : I . Schulman)Xddio Corp o f A m e r i c aS o m e r v i l l e , N. J, 08873( A t t n : D r , H, S, L o z i e r )Sokthwest Research I n s t i t u t e8500 C n l e b r a Rd,S m Antonio, Texas 78206( A t t n : D r , Jan A l )Sonotone CorpS a w M i l l R i v e r Rd.E l n s f o r d . N, Y, 10523( A t t n : A , Mundel)Dr.Texas I n s t r u m e n t s , Inc.13500 North C e n t r a l ExpresswayD a l l a s , Texas 75222(Attn: D r , Isaac Trachtenberg)Thomas A . Edison Research LabMcGraw Edison C o .Watchung Ave.W e s t Orange, N. J, 07052( A t t n : 3 r o P o F. Groeger)TRW Systems, I n c . ( 2 )One Space ParkRedondo Beach, C a l i f 90278( A t t n : D r . A . K r a u s z , Bldg 60,Rm 929; D r . H e r b e r t P . ilveman)-TRW,Inc,23555 Eucbid Ave.Cleveland, Ohio 44117( A t t n : Librarian)Tyco Labs, Inc.Bear H i l lHickory D r .Waltham, Mass.02154( A t t n : W , W, B u r n e t t )'Jnion Carbide CorpDevelopment L a b L i b r a r yP o 0 , B o x 6056Cleveland. 3 h i o 44101Union Carbide C o r pParma Research C e n t e rP o 0, B o x 6116Cleveland" Ohio 44101( A t t n : Library)Space S c i e n c e L a bUniv of C a l i fBerkeley, C a l i f .94720( A t t n : Gr, C , W. Tobias)Electrochemistry LabVniv of P a Philadelphia, P a ,19104cvii

MEL R e p o r t183/66Distribution List (cont)Western Electric C o oS u i t e 802, RCA B l d gWashington, D o C ,20006( A t t n : R, T, F i s k e )Westinghouse E l e c t r i c C o r pR e s e a r c h and D e v e l o p m e n t C e n t e rC h u r c h i l l BoroughP i t t s b u r g h , Pa,15235Whittaker C o r p3850 O l i v e S t .D e n v e r , Colo.80237( A t t n : B o r c h Wendir)Whittaker C o r pP. 0 , Box 337N e w b u r y P a r k , C a l i f . 91320( A t t n : M r . John R h y n e )Yardney E l e c t r i c Corp40-50 Leonard S t ,N e w Y o r k , N o Y, 10013(Attn: Dr. George D a l i n )A d d r e s s e e (12)viii

MEL Report183/66ABSTRACTA d e v i c e h a s been d e s i g n e d f o r a u t o m a t i c a l l y r e c o n d i t i o n i n g a nickel-cadmium b a t t e r y .I n d i v i d u a l c e l l v o l t a g e d e t e c t o r s and/or ab a t t e r y terminal voltage are u t i l i z e d t od e t e r m i n e when r e c o n d i t i o n i n g i s n e c e s s a r y ,R e c o n d i t i o n i n g i s accomplished by d i s c h a r g i n geach c e l l t o n e a r l y 0 v o l t s , then rechargingControlledt h e b a t t e r y a t a small c u r r e n t .d i s c h a r g e of t h e b a t t e r y is accomplished byi n d i v i d u a l c e l l s h u n t i n g t r a n s i s t o r s and ab a t t e r y c u r r e n t shunt t r a n s i s t o r .Cellr e v e r s a l i s p r e v e n t e d by c u t t i n g o f f t h eb a t t e r y dump c u r r e n t when a c e l l v o l t a g ereaches a l o w l i m i t .ix

MEL Report183/66REFERENCE(a)P o t t e r , Nelson and Richard Morrison, "Two Level 'VoltageL i m i t e r , " Goddard Space F l i g h t C e n t e r Rep- X-716-66-7,J a n 1966i

MEL Report183/66TABLE O F CONTENTSPage3 1 S T R I R L T T I O N LISTASSTRACTREFERENCE1LXTR 3 t U C 'II ONDevelopment TaskProblem BackgroundOPERATIONFunctional DescriptionKESULTSC DNCLUS I O NLTST 3F F I G U R E SF i g u r e 1 - Drawing, Nickel-Cadmium B a t t e r y R e c o n d i t i o n e rSystemF i g u r e 2 - C u r v e , C h a r a c t e r i s t i c s of 5 - C e l l B a t t e r yBeing Discharged by R e c o n d i t i b n e rF i g u r e 3 - Photograph, Nickel-Cadmium B a t t e r yReconditioner, Front V i e wF i g u r e 4 - Photograph, Nickel-Cadmium B a t t e r yR e c o n d i t i o n e r , Top-Rear V i e wF i g u r e 5 - Photograph, Nickel-Cadmium B a t t e r yR e c o n d i t i o n e r , Bottom V i e wAFPENZTXESAppendix A - O p e r a t o r s Guide f o r Nickel-Cadmium B a t t e r yR e c o n d i t i o n e r ( 1 2 pages)iiixX1122244I;Jxi

MEL Report183/66N ICKEL -CADMIUM BATTERY W C OND I T I ONE RThe U, S , Navy Marine Engineering L a b o r a t o r y was r e q u e s t e dby NASA (Goddard Space F l i g h t C e n t e r (GSFC)) a s p a r t ofC o n t r a c t S-12730-G. Amendment 5 of 20 A p r i l 1965, t o d e s i g n andd e v e l pa d e v i c e o p e r a t i n g w i t h i n a b a t t e r y t e s t system f o ra u t o m a t i c a l l y r e c o n d i t i o n i n g nickel-cadmium c e l l s . T h i s r e p o r tp r e s e n t s a d e s c r i p t i o n of t h e d e v i c e d e s i g n e d t o perform t h i stask,1.1 Development Task.When a nickel-cadmium b a t t e r y i s s u b j e c t e d t o e x t e n s i v e c y c l i n g , d e g r a d a t i o n i n t h e ampere-hourDegradation t a k e s p l a c e i n t h ec a p a c i t y of e a c h c e l l o c c u r s .form of a "memory e f f e c t : i , e . a f t e r r e p e t i t i v e c y c l i n g of anickel-cadmium t o a g i v e n d e p t h o f d i s c h a r g e , t h e c e l l11r e m e m b e r s " t h i s d e p t h and w i l l d e l i v e r o n l y t h a t amount ofampere-hour c a p a c i t y , i n s t e a d of its r a t e d c a p a c i t y .Then-umber of c y c l e s t o which a b a t t e r y may be s u b j e c t e d b e f o r et h e loss i n ampere-hour c a p a c i t y i s c r i t i c a l v a r i e s amongb a t t e r i e s of t h e same c a p a c i t y , and w i t h environment andd e p t h of d i s c h a r g e .When t h e memory e f f e c t h a s t a k e n p l a c e ,it i s i n d i c a t e d by a low b a t t e r y v o l t a g e and/or a low c e l lv o l t a g e n e a r t h e end of t h e d i s c h a r g e c y c l e , P r e v i o u s t e s t son nickel-cadmium c e l l s have i n d i c a t e d t h a t t h e ampere-hourc a p a c i t y of a b a t t e r y can be r e s t o r e d b y " b l e e d i n g " each c e l ldown t o a p p r o x i m a t e l y 0 v o l t s and t h e n r e c h a r g i n g t h e b a t t e r yz t a c u r r e n t ' t h a t i s v e r y low ( a p p r o x i m a t e l y C/10 c u r r e n t % ) .Thc "memory e f f e c t " on each c e l l v a r i e s from c e l l t o c e l land r e s u l t s i n c e l l unbalance i n a b a t t e r yReconditioningremoves t h i s c a p a c i t y unbalance by p r o v i d i n g t h e c e l l s w i t h ac mnorir e f e r e n c e c o n d i t i o n f o r r e c h a r g i n g I t i s e v i d e n t t h a t r e c o n d i t i o n i n g a b a t t e r y pack of n i c k e l cadmium c e l l s r e s u l t s i n an extended l i f e f o r t h e b a t t e r y andp r o v i d e s f o r g r e a t e r u t i l i z a t i o n of a b a t t e r y ' s ampere-hourc a p a c i t y . . T h i s g r e a t e r e f f i c i e n c y would p e r m i t t h e u s e of 3s m a l l e r ampere-hour b a t t e r y pack f o r a given s a t e l l i t e p a y l o a dReferred t o a s reconditioningc e l l c a p a c i t y i n ampere-hours;charging"C 10 : number of h o u r s f o r

MEL Report 183166c a p a b i l i t y , The u l t i m a t e g o a l i n developing t h i s n i c k e l cadmium b a t t e r y r e c o n d i t i o n e r , o r i g i n a l l y d e s i g n e d t o o p e r a t ei n a l a b o r a t o r y b a t t e r y t e s t system, i s a d a p t a t i o n t o s a t e l l i t epower s y s t e m s .1 . 2 Problem Background. The method p r e s e n t l y used t o recon-,d i t i o n nickel-cadmium b a t t e r i e s i s d e s i g n e d t o c o u n t t h e numberof c y c l e s t o which a b a t t e r y h a s been s u b j e c t e d and t h e n a u t o m a t i c a l l y t o d i s c h a r g e t h e b a t t e r y by p l a c i n g a l o a d r e s i s t o ra c r o s s each cell’.IIThe d i s a d v a n t a g e of t h i s method i s t w o f o l d , F i r s t , s i n c e t h enumber of c y c l e s , and n o t a l o w v o l t a g e c o n d i t i o n , , i s usedt o determine when r e c o n d i t i o n i n g i s t o t a k e p l a c e , t h e b a t t e r yw i l l be r e c o n d i t i o n e d i r r e s p e c t i v e of t h e s t a t e of d e g r a d a t i o nof t h e c e l l s , Secondly, t o p r e v e n t r e v e r s e c h a r g i n g of a c e l l ,r e l a y s switch i n d i v i d u a l load r e s i s t o r s a c r o s s each c e l l t odischarge the b a t t e r y .This r e q u i r e s r e l a y c o n t a c t s i n seriesw i t h each c e l l of t h e b a t t e r y , The new nickel-cadmium b a t t e r yreconditioner i s a voltage d e t e c t i o n device t h a t u t i l i z e s alow v o l t a g e c o n d i t i o n on t h e b a t t e r y t e r m i n a l s o r on a c e l l t oi n d i c a t e when d e g r a d a t i o n of t h e b a t t e r y i s such t h a t recon-.S i n c e t h e number of c y c l e s t o which ad i t i o n i n g i s necessary.b a t t e r y can be s u b j e c t e d b e f o r e s e v e r e d e g r a d a t i o n o c c u r sv a r i e s widely w i t h environment, t h e v o l t a g e d e t e c t i o n method i ss u p e r i o r t o t h e method of c o u n t i n g c y c l e s .The u s e of t r a n s i s t o r s as a s h u n t l o a d f o r e a c h c e l l e l i m i n a t e s t h e need f o rr e l a y s and a s s o c i a t e d c o n t a c t s t o s w i t c h l o a d r e s i s t o r s a c r o s seach c e l l ,2.0OPERATIONThe f o l l o w i n g s e c t i o n p r o v i d e s a g e n e r a l d e s c r i p t i o n of t h eo p e r a t i o n of t h e n i c k e l -cadmium b a t t e r y r e c o n d i t i o n e r and t h eb a t t e r y t e s t system i t i s used w i t h .A d e t a i l e d d e s c r i p t i o n ofeach c i r c u i t and i t s o p e r a t i o n may be found i n S e c t i o n 1 ofS e c t i o n I1 of Appendix A i s a d e t a i l e d d e s c r i p t i o nAppendix Aof component.S e c t i o n 111 c o n t a i n s t h e recommended a d j u s t m e n tand c a l i b r a t i o n p r o c e d u r e .2 - 1 F u n c t i o n a l D e s c r i p t i o n . The nickel-cadmium b a t t e r y r e c o n d i t i o n e r can b e s t be d e s c r i b e d by t h e f u n c t i o n a l diagram showni n F i g u r e 1, These f u n c t i o n a l u n i t s a r e : (1) b a t t e r y underv o l t a g e d e t e c t o r and t i m e r c o n t r o l , ( 2 ) c e l l v o l t a g e d e t e c t o r2

MFIReport183/66and c o n t r o l c i r c u i t , ( 3 ) b a t t e r y c u r r e n t dump t r a n s i s t o r ,( 4 ) i n d i v i d u a l c e l l - s h u n t t r a n s i s t o r s , and (i.5) a c y c l e numberc o n t r o l . The o r b i t t i m e c o n t r o l , s h u n t r e g u l a t o r , c h a r g e r , ands p a c e c r a f t l o a d a r e shown t o i l l u s t r a t e t h e r e l a t i o n s h i p of t h eb a t t e r y r e c o n d i t i o n e r t o t h e r e s t of t h e b a t t e r y t e s t system,The c h a r g e r , s p a c e c r a f t l o a d , and s h u n t r e g u l a t o r a r e connectedi n p a r a l l e l , Normally, t h e power from t h e c h a r g e r i s s u p p l i e dt o t h e b a t t e r y and l o a d d u r i n g t h e d a y l i g h t p e r i o d of o r b i t . I nt h e d a r k p e r i o d , t h e b a t t e r y s u p p l i e s t h e power demands of t h eI f d e g r a d a t i o n of t h e b a t t e r y h a s t a k e n p l a c e (loss ofload,ampere-hour c a p a c i t y ) , a l o w v o l t a g e c o n d i t i o n on a c e l l o r t h eIfb a t t e r y w i l l e x i s t n e a r t h e end of t h e d i s c h a r g e p e r i o d .the v o l t a g e of a c e l l o r t h e b a t t e r y f a l l s below t h e r e s p e c t i v ep r e s e t l i m i t , t h e b a t t e r y i s switched from t h e l o a d t o cont r o l l e d discharge,In c o n t r o l l e d d i s c h a r g e , t h e b a t t e r y - c u r r e n t dump t r a n s i s t o rdiscAiarqes the b a t t e r y , and t h e c e l l - s h u n t t r a n s i s t o r s a r eb i a s e d "on" t o d i s c h a r g e e a c h c e l l . The c u r r e n t i n t h e dumpt r a n s i s t o r i s c o n t r o l l e d b y t h e v o l t a g e of the l o w e s t c e l l ofthe battery,Cutoff i s o b t a i n e d when a c e l l r e a c h e s a p r e s e l e c t e d lower l i m i t ,T h i s c u t o f f p r e v e n t s r e v e r s e c h a r g i n g oft h a t cell, The s h u n t t r a n s i s t o r s c o n t i n u e t o d e p l e t e each c e l lo f t h c remaining ampere-hour c a p a c i t y , t h e r e b y a s s u r i n g t h a t t h ev o l t a g e c f a l l c e l l s w i l l be reduced t o n e a r z e r o .&-en t h e L i m e c o n t r o l n o t e s t h a t s u f f i c i e n t t i m e h a s e l a p s e df J r a11 c e l l a t o d i s c h a r g e , t h e t i m e r removes t h e b i a s f r m t h ecell s h m t t r a n s i s t o r s , opens t h e s p a c e c r a f t l o a d c i r c u i t , andpLBces the b a t t e r y i n p a r a l l e l w i t h t h e c h a r g e r and s h u n t regul a t o r , The c h a r g e r p r o v i d e s a c o n s t a n t c u r r e n t t o r e c h a r g et h e b a t t e r y t o a v o l t a g e l e v e l determined by t h e s h u n t r e g u l a t o r , r e f e r e n c e (a). S u f f i c i e n t time f o r c h a r g i n g i s p r e s e t i n t othe t i m e r c o n t r o l . When t h e b a t t e r y i s c o m p l e t e l y charged, t h elo3d i s r e t u r n e d t o t h e b a t t e r y and c h a r g e r .Normal c y c l i n g oft h e b a t t e r y i s resumed by t h e 'orbit t i m e c o n t r o l w i t h t h eb a t t e r y r e c o n d i t i o n e r remaining i n s t a n d b y s t a t u s , The c y c l ec u m b e r c o n t r o l c o u n t s t h e number of c y c l e s campleted on t h ebs.tr.csl,. w k n a l o w v o l t a g e c o n d i t i o n i s r e a c h e d ,If desired,t h i s d e v i c e may a l s o be used t o s w i t c h t h e b a t t e r y t o c o n t r o i l e dd i s c h a r g e a f t e r a p r e s e l e c t e d number of c y c l e s h a s beenc 0m.p le t e dI3

MEL Report183/662.2Discussion,S i n c e t h e i n i t i a l purpose of t h e d e s i g n oft h e nickel-cadmium b a t t e r y r e c o n d i t i o n e r was t o determine i t sf e a s i b i l i t y t h r o u g h u s e i n a b a t t e r y t e s t system, a number ofparameters and o p e r a t i n g c o n d i t i o n s w e r e made s e l e c t i v e s o t h a toptimum c o n d i t i o n s f o r system o p e r a t i o n c o u l d be determined,Thebe i n c l u d e t h e v a r i a b l e p a r a m e t e r a d j u s t m e n t s which a r e :(1) b a t t e r y low-voltage t r i p l e v e l ( 3 t o 6 v o l t s ) , ( 2 ) minimumc e l l v o l t a g e f o r z e r o - b a t t e r y dump c u r r e n t ( 2 5 t o 500 m i l l i v o l t s ) , ( 3 ; t r a n s i s t o r - d u m p c u r r e n t (0-1t o 0 . 5 amperes),( 4 ) c e l l s h u n t t r a n s i s t o r c u r r e n t ( 5 0 t o 750 m i l l i a m p e r e s a t1 v o l t ) , and ( 5 ) s e n s i t i v i t y of dump t r a n s i s t o r t o c o n t r o lc i r c u i t . The f o l l o w i n g s e l e c t f v e methods of s w i t c h i n g t o cont r o l l e d d i s c h a r g e a r e p r o v i d e d : (1) low c e l l v o l t a g e , ( 2 ) lowb a t t e r y v o l t a g e , ( 3 ) c y c l e number l i m i t , (4) low c e l l v o l t a g eo r cycle-number l i m i t , and ( 5 ) e i t h e r low c e l l v o l t a g e , lowb a t t e r y v o l t a g e , 3r cycle-number l i m i t .A means f o r b y p a s s i n gt h e dump t r a n s i s t a r , and u s i n g o n l y t h e c e l l s h u n t t r a n s i s t o r st o d i s c h a r g e t h e b a t t e r y , i s also p r o v i d e d ,The added v e r s a t i l i t y o b t a i n e d from t h e s e f l e x i b l e c h a r a c t e r i s t i c s allows t h i s d e v i c e t o be used t o o b t a i n i t s own optimumo p e r a t i n g c o n d i t i o n s , a s w e l l a s t h o s e f o r t h e b a t t e r y pack.Although t h i s i n s t r u m e n t i s d e s i g n e d f o r a 5 - c e l l b a t t e r y , t h econcept can be expanded t o o p e r a t e w i t h any number of c e l l s . .3.0RESULTSThe c h a r a c t e r i s t i c s o b t a i n e d from a t y p i c a l b a t t e r y r e c o n d i t i o n i n g o p e r a t i o n a r e i l l u s t r a t e d i n F i g u r e 2.(1) A 5 - c e l l ,6 ampere-hour nickel-cadmium b a t t e r y was b e i n g c y c l e d i n ab a t t e r y t e s t systemThe c e l l v o l t a g e of f o u r of t h e f i v ec e l l s was r e c o r d e d . A low c e l l v o l t a g e on cell N o . 1 i s n o t e dd u r i n g d i s c h a r g e of t h e b a t t e r y .A t t i m e T c- 15 m i n u t e s on t h eg r a p h , t h e r e c o n b i t i o n e r s w i t c h e d t h e b a t t e r y t o t h e dumpt r a n s i s t o r (a,) of F i g u r e l C The b a t t e r y c u r r e n t t h r o u g h t h edump t r a n s i s t o r i s reduced t o a p p r o x i m a t e l y 0 a s t h e v o l t a g eof c e l l N o . 1 i s reduced t o a p r e s e t low l i m i t .The remainingc e l l s have t h e i r r e s i d u a l ampere-hour c a p a c i t y removed by t h ei n d i v i d u a l c e l l s h u n t t r a n s i s t o r s (a, of F i g u r e 1 ) . The a r e aunder t h e c u r v e s f o r each c e l l p r o v i d e s a g r a p h i c i l l u s t r a t i o nof c e l l unbalance w i t h i n t h e ' b a t t e r y .1Data o b t a i n e d from G S F C , E r e enbe 1t , Maryland4

MEL R e p o r t183/66Two p r o t o t y p e s of t h e nickel-cadmium battery r e c o n d i t i o n e rhave been b u i l t and d e l i v e r e d t o NASA, GSFC, G r e e n b e l t , MarylandoThe f i r s t p r o t o t y p e Gas used to determine t h e f e a s i

Chemical Products Div -. 1 Aero ject-General Corp Azusad Calif, 91702 (Attn: Dr So 0, Rosenberg) Aeronutronic Div Philco Corp Ford Rd Newport Beach, Calif. 92660 (Attn Library] P, o., BOX 95085 Los Angelos , Calif 90045 A1 lis-Chalmers Manufacturing eo 1100 South 70th St. Milw

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