Supercapacitors and Space Applications

Supercapacitors and space applications
Les supercapacits-CCT-CNES workshop First of July 2008 P. Mattesco

Contents
Who are we?

Customer
Organisation
Background on supercapacitors study
Test
Studies
Potential space applications
Satellites
Launchers
Others
Development and qualification needs
Qualification at component level
Qualification at equipment level
Conclusions
Page 2 CCT-CNES-Supercapacits-2008 July 1st
Contents
Who are we?

Customer
Organisation
Test
Studies
Satellites
Launchers
Others
Conclusions
Astrium: a 100% subsidiary of EADS
EADS
Airbus Military Eurocopter Astrium Defence
Transport & Security
Aircraft Systems

Astrium: the heritage and expertise of
the leading European space nations
Additional locations
France
Limeil-Brvannes (Sodern)
Houston (Texas) Stevenage Germany

Poynton Backnang (Tesat)
UK
Leiden
Colerne (Paradigm)
Portsmouth Bremen
Trauen Corsham (Paradigm)
Brest
Kourou Lampoldshausen Hawthorn (Paradigm)
Paris
(French Guiana) Farnborough (Infoterra)
Aquitaine Ottobrunn
Oakhanger (Paradigm)
Biscarrosse Friedrichshafen
Saudi Arabia
Ryadh (GPT)
Vlizy
Madrid
Toulouse Les Mureaux

Astriums activities are based in three key areas
Astrium Space Astrium Astrium

Transportation Satellites Services
The European A world leader At the forefront of
prime contractor in the design satellite services
for civil and and in the secure
military space manufacture of communications,
transportation satellite Earth
and manned systems observation and
navigation fields
space activities

ASG5 Electrical Engineering
Who are we?
Earth Space Navigation Telecom- Military Equipment &

Observation Science Galileo munication System Subsystems
e.g. e.g. e.g. e.g. e.g. e.g.
TerraSarX ROSETTA ANIK Early Warn. Solar Gene-
Demonstra. rator
Electrical Engineering (ASG5) Service Provider

Technology
Electrical Power Communication EMC / ESD I/F & Harness
Methodology
Systems Eng. Engineering Engineering Eng. & Test Engineering Innovations

Customer
External Internal
Customers Customers
Main Services:
ESA Prime BUs
- Earth Observation,
Navigation &
ASG5 Science
CNES Electrical - Telecom
Engineering
DLR Other Services:
- Equipment BDs
- Central AIT
- Supply Management
- Space Transportation
BNSC

Electrical Engineering in ASTRIUM
Electrical Engineering (ASG5)

Support to electrical architectural S/C design
Electrical
Digital S/C engineering
Systems Eng.
Modeling & analysis of electrical circuitries
EPS subsystem trade offs, analyses and simulations
Power
Engineering
Solar array, battery, power regulation & distribution definition, sizing and
performance assessment
Communication Communication subsystem trade offs, analyses, simulations and sizing

Engineering RF compatibility, antenna coupling & pattern analysis
EMC / ESD EMC-ESD design, modeling, analysis, requirement definition & tests
Eng. & Test Electrical laboratory & EMC test chamber
I/F & Harness Electrical I/F definition and characterization

Engineering Electrical harness definition
Technology New EE Methodologies & Tools

Methodology Innovative Technologies to enable S/C Architecture Innovation
Innovations Characterization of Key EPS components
Electrical Engineering in ASTRIUM
Power EPS subsystem trade offs and sizing

Engineering Solar array, battery, power regulation & distribution
definition, sizing and performance assessment
EPS simulations and analyses
Energy budget
Power Bus compatibility analyses
In orbit power performance prediction and correlation
Elaboration and verification of mathematical models
Definition and improvement of Power Engineering Tools
Power engineering expertise
Technology expertise in EPS equipments
Lab testing activities
Transnational Power Working Group established to build

up a strong power engineering expertise in on all Astrium
prime sites regularly know how exchange

Power Analysis Tool: Power Systema
Power-Systema allows to perform EPS trade offs, EPS

analysis and sizing
Uses Systema modules for S/C geometry, orbit, pointing and
thermal modelling
Used from phase A up to In-flight correlation
Based on a schematic approach & evolving component
library : Power-Systema can simulate any mission
Accurate component models allows to reduce the margins
Simulation duration reduced by 25% since 2000
Operational on all 3 Astrium prime sites

Research & Development
Technology
Methodology
Innovations
R&D
New EE Methodologies & Tools
Innovative Technologies to Enable

Architecture Innovations
Characterisation of Key EPS components

Current R&D subjects: Power
Super Capacitors
evaluation/characterisation of new products
applicability to various missions/function
Kinetic storage (flywheels)
"lobbying" at agencies with the objective to initiate a preliminary
design exercise to assess actual potentialities
Li Ion battery cells
Small capacity commercial Li Ion cells characterization.
SAFT and MELCO Li Ion cell Batteries characterization and life
tests.
Solar arrays and solar cells
full scale development of an EOL performance prediction tool
New PSS architectures
Fuel Cells survey

Electrical Laboratory : Main activities
PROGRAMS ACTIVITIES:
Electrical EGSE development:
battery test bench, battery simulator, electrical/EMC set-up
SATCOM Battery (Electrical) Acceptance Tests
SATCOM TB-TV Thermal Test Benches
EMC Qualification tests : Equipments, Instruments, -S/L
Electrical I/F bread boarding and validation
On call SERVICES : Bread boarding, tests and failure
investigations / reproduction
EGSE CE: EMC & Low Voltage Marking tests
R&D ACTIVITIES:
Battery cells, super capacitors, solar cells characterization
Wireless data link

Contents
Who are we?

Customer
Organisation
Tests
Studies
Satellites
Launchers
Others
Conclusions
SUPERCAPACITORS CHARACTERISATIONS since
1997
10 characterisation campaigns for
internal and external R&D (ARIANE
5, EADS-LV)
Capacity: between 0.3F and 3600F
Manufacturers: BOLLORE, CAPXX,
MAXWELL, POLYSTOR, EPCOS,
MONTENA, PRI, ELNA,SAFT
2 dedicated test benches

Several studies since 1997but still no concrete
project..
Voltage balancing in series connected Astrium 10th DLC 2000

supercapacitors seminar in Florida
Supercapacitor specification Astrium, ESA contract 2001
Requirement for supercapacitor ESA contract 2001

validation testing
Application of supercapacitors to Astrium AAAF 2003

pyrotechnics firing onboard ARIANE5 Avignon

Lessons learnt and main concern
Exhaustive characterisation and qualification campaign have to be undertaken

with focus on ageing and specific space environment (radiation, vacuum)
In several cases, electrical performances were not really in line with the required
specification
For applications requiring high energy density and high power, hybrid solutions
= possible solutions but higher complexity and cost
Low voltage devices series connection is mandatory with reliable

balancing device to cope with higher self discharge current than batteries.
Space heritage is very low with only one or two very specific space applications
with Maxwell PC5 & PC 10 qualified components.

Survey on supercapacitors still on going in the
space community
Industrial
Astrium (ASG52) is currently testing commercial supercapacitors
Development and evaluation of supercapacitors for space applications

done by BATSCAP in 2006-2007 (ESA TRP contract 16514/02/NL/ND)

Survey on supercapacitors still on going in the
space community
Agencies
in 2008 ESA Invitation to tender: High Power battery-Supercapacitor study

Identification of potential space applications
Impact at system and EPS system level
Trade-off between high power lithium battery
Baseline testing of supercapacitors project by NASA for the Next Generation

Launch Technology (NGLT)

Key success for the use of new or improved energy
storage technologies at spacecraft level
The performance and design of the spacecraft, mainly in term of mass,

power and size shall be significantly improved with advanced technologies
Ex: Lithium battery implementation on GEO satellites
500 3500 10
450 9
3000
400 8
350 2500 7
300 6
Ni/Cd 2000
250 Ni/Cd 5 Ni/Cd
Ni/H2 1500 Ni/H2
200 Ni/H2 4
LiIon LiIon
150 1000 LiIon 3
2
100 500 1
50
0 0
0 Selfdischarge
Weight (kg) Thermal
dissipation (Wh) (%/day)
More than 50% Much lower thermal About 2 decades less

weight saving stress and reduced than NiH2 makes
versus NiH2 thermal constraints ground management
Page 21 easy
CCT-CNES-Supercapacits-2008 July 1st
Time frame of development, maturity, perceived risk shall be accepted
Technology Readiness Levels

TRL 9 : Actual system flight proven through successful
mission operations
TRL 8 : Actual system completed and flight qualified
through test and demonstration (ground or space)
TRL 7 : System prototype demonstration in a space
environment
TRL 6 : System/subsystem model or prototype
demonstration in a relevant environment (ground or space)
TRL 5 : Component and/or elegant breadboard validation
in relevant environment
TRL 4 : Component and/or breadboard validation in
laboratory environment
TRL 3 : Analytical and experimental critical function
and/or characteristic proof-of concept
TRL 2 : Technology concept and/or application
formulated
TRL 1 : Basic principles observed and reported

Maturity is achieved for terrestrial applications
Home market
Back-up energy on CPU boards (small size capacitors)
Industry
Back-up energy on CPU boards (small size capacitors)
Space
Minor NASA applications on ISS (electrical tools)
Some predevelopment in BATSCAP (Bollor) under ESA funding
Evaluations in lab but no complete qualification on any product (TRL4)

Minor impacts on other subsystems and on operational requirements
Increase of supercapacitors performances
Lifetime shall be demonstrated
Involvement of supercapacitors manufacturers in space market

facing very low volume
Cost
Specific payloads, specific mission or extended mission or new

applications could required new storage technologies such as
supercapacitors.

Contents
Who are we?

Customer
Organisation
Test
Studies
Satellites
Launchers
Others
Specific space requirements
Example of qualification sequence
Conclusions
Potential spacecraft applications
Two main spacecraft applications for high power storage technologies yet identified
Satellites
Pyrotechnical system
Signal filtering applications
High pulse payload such as radar and Lidar
Actuator, like wheel, motor and CMG for AOCS purpose,
..
Launchers
Trust vector controls

Pyrotechnical system
.

Potential spacecraft applications
And two ranges of requirements associated to these applications
filtering applications
capacitance between several farads and several hundreds of farad,

time constant around 10 ms.
storage applications
capacitance between several hundred to several thousand of farads

time constant around 1 s

Potential space applications : future mission needs
New power sources
fuel cell or flywheel

Supercapacitor can be used as an intermediate storage device needed to
deliver fast power response time
Robotic and exploration mission (ex NASA Athlete rover)

Potential space applications : future mission needs
Increase in the demand and sizing of the on board power system
radar applications
High to very high peak power demand (up to several kilowatts)
variable operation time (few seconds to several minutes)
In some case significant orbit duty cycles.
lidar applications.
Extension of the mission duration
higher cycles number, higher duration : pulse power of secondary batteries could
be increased by combining them with supercapacitors

Potential space applications : architecture
Example of typical satellite electrical power subsystem main

architecture
User
User
S3R BCR BDR

User
S3R
User
Battery
Battery
Solar
array
Solar
array
Non Regulated bus Regulated bus

Potential space applications : possible architecture
for pulse load
Peak current
Average current (> 100A)
A pulsed power of 5000W during 1s requires less than 1Kg of supercapacitors
no high power bundle (0.5Kg/m)

Possibility of line protection
Low battery cycling
Representative test at unit level

Contents
Who are we?

Customer
Organisation
Test
Studies
Satellites
Launchers
Others
Conclusions
Qualification
Qualification could be a long story and a strong non recurring cost
Qualification shall be achieved on frozen product definition,
Qualification means not only product qualified but also process and
operators qualified,
Any change on qualified product or manufacturing line need delta

qualification
BOL qualification can be achieved in around 6 month, but life test

or accelerated life can take several years

Qualification can be specific depending on mission
requirements
Power bus
Applications Pyro function Actuator drive Radar
decoupling
Targeted technology Super cap Super cap Super cap Super cap
Electrical needs
Power range
Mean power (W) N/A 0 20 1500
Max Power (W) N/A 150 200 5000
Energy & Capacity

Electrical requirements
Total energy (Wh) 27 0.05 0.3 10
close to terrestrial applications
Total capacity (Ah) 0.27 NA (< 0.1) NA (< 0.1) 0.1
Voltage range & Intensity
Min Voltage (V) 100 5 22 22
Max Voltage (V) 100 20 100 100

Mean discharge current
N/A NA 5 50
(A)
Max discharge current
20 7 10 200
(A)
Charging current (A) 20 <1 1 15
Cycling
1000 (incl
Number of cycles >10000000 3000000 7000000
ground)
SOC max (% of total
100 100 100 100
capacity)
SOC min (% of total
100 80 25 25
capacity)

Qualification can be specific depending on mission
requirements
Power bus
Applications Pyro function Actuator drive Radar
decoupling
Targeted technology Super cap Super cap Super cap Super cap
Environments
Climatic
Cold -40 -40 -40 -40
Dry heat N/A N/A N/A N/A
Moist heat N/A N/A N/A N/A

Thermal cycles in moist
N/A N/A N/A N/A
Some environments requirements
air
Thermal shock N/A N/A N/A N/A
are specific
-9 -9 -9 -9
Vacuum 10 TORR 10 TORR 10 TORR 10 TORR
Thermal vacuum YES YES YES YES

Vacuum
Salt spray N/A N/A N/A N/A
Radiation
Rain N/A N/A N/A N/A
Rapid depressurisation YES YES YES YES
Mechanical
20g RMS 20g RMS 20g RMS 20g RMS

Random vibration
[20 - 2000Hz] [20 - 2000Hz] [20 - 2000Hz] [20 - 2000Hz]
20g 20g 20g 20g
Sinusoidal vibration
[5 - 100Hz] [5 - 100Hz] [5 - 100Hz] [5 - 100Hz]
Acoustic vibration N/A N/A N/A N/A
Constant acceleration 20g 20g 20g 20g
Average shock N/A N/A N/A N/A
Pyrotechnic shock 800g @ 10kHz 800g @ 10kHz 800g @ 10kHz 800g @ 10kHz
EMC
80dBA RMS 80dBA RMS 80dBA RMS 80dBA RMS

Conducted emission
@ 100kHz @ 100kHz @ 100kHz @ 100kHz
Radiated emission 50dBV/m 50dBV/m 50dBV/m 50dBV/m
Contents
Who are we?

Customer
Organisation
Test
Studies
Satellites
Launchers
Others
Conclusions
Conclusions
Performances of supercapacitors are increasing,
Maturity is today achieved,
New space applications are coming with high power requirements,
Astium still involved in survey and characterisation of

supercapacitors to improve their spacecraft design and system
First space application will be the main driver for a qualification.
Need to be supported by Agencies and supercapacitor suppliers

even if the market is low and the qualification hard.

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Supercapacitors and space applications

Les supercapacits-CCT-CNES workshop First of July 2008 P. Mattesco

Who are we?

Who are we?

Page 4 CCT-CNES-Supercapacits-2008 July 1st

Houston (Texas) Stevenage Germany

Page 5 CCT-CNES-Supercapacits-2008 July 1st

Astrium Space Astrium Astrium

Page 6 CCT-CNES-Supercapacits-2008 July 1st

Earth Space Navigation Telecom- Military Equipment &

Electrical Engineering (ASG5) Service Provider

Page 7 CCT-CNES-Supercapacits-2008 July 1st

Page 8 CCT-CNES-Supercapacits-2008 July 1st

Electrical Engineering (ASG5)

Communication Communication subsystem trade offs, analyses, simulations and sizing

I/F & Harness Electrical I/F definition and characterization

Technology New EE Methodologies & Tools

Power EPS subsystem trade offs and sizing

Transnational Power Working Group established to build

Page 10 CCT-CNES-Supercapacits-2008 July 1st

Power-Systema allows to perform EPS trade offs, EPS

Page 11 CCT-CNES-Supercapacits-2008 July 1st

New EE Methodologies & Tools

Innovative Technologies to Enable

Characterisation of Key EPS components

Page 12 CCT-CNES-Supercapacits-2008 July 1st

Page 13 CCT-CNES-Supercapacits-2008 July 1st

Page 14 CCT-CNES-Supercapacits-2008 July 1st

Who are we?

Page 16 CCT-CNES-Supercapacits-2008 July 1st

Voltage balancing in series connected Astrium 10th DLC 2000

Supercapacitor specification Astrium, ESA contract 2001

Requirement for supercapacitor ESA contract 2001

Application of supercapacitors to Astrium AAAF 2003

Page 17 CCT-CNES-Supercapacits-2008 July 1st

Exhaustive characterisation and qualification campaign have to be undertaken

Low voltage devices series connection is mandatory with reliable

Page 18 CCT-CNES-Supercapacits-2008 July 1st

Astrium (ASG52) is currently testing commercial supercapacitors

Development and evaluation of supercapacitors for space applications

Page 19 CCT-CNES-Supercapacits-2008 July 1st

in 2008 ESA Invitation to tender: High Power battery-Supercapacitor study

Baseline testing of supercapacitors project by NASA for the Next Generation

Page 20 CCT-CNES-Supercapacits-2008 July 1st

The performance and design of the spacecraft, mainly in term of mass,

Ex: Lithium battery implementation on GEO satellites

More than 50% Much lower thermal About 2 decades less

Time frame of development, maturity, perceived risk shall be accepted

Technology Readiness Levels

Page 22 CCT-CNES-Supercapacits-2008 July 1st

Maturity is achieved for terrestrial applications

Page 23 CCT-CNES-Supercapacits-2008 July 1st

Minor impacts on other subsystems and on operational requirements

Increase of supercapacitors performances

Lifetime shall be demonstrated

Involvement of supercapacitors manufacturers in space market

Specific payloads, specific mission or extended mission or new