Advanced Munitions Batteries - creb.umd.edu · 1 Center for Research in Extreme Batteries (CREB) The Future of Munitions Batteries Workshop Advanced Munitions Batteries 7 & 8 December

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Center for Research in Extreme Batteries (CREB)

The Future of Munitions Batteries Workshop

Advanced Munitions Batteries

7 & 8 December 2016

Paul SchisselbauerDirector of Engineering

EnerSys Advanced Systems

Horsham, Pennsylvania

(215) 773-5416

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Agenda

The Future of Munitions Batteries

• Munitions Batteries Overview

– Thermal Batteries

– Ambient Temperature Batteries

– Secondary Batteries

• Future Direction

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EnerSys Advanced Systems is the leading

producer of lithium reserve batteries in the

U.S. We have provided state-of-the-art

batteries to the U.S. Army for over 50 years

and have delivered over 30 million primary

batteries to the DoD and allied governments.

Munitions Batteries Overview

EnerSys provides high energy density “lithium/oxyhalide batteries”and high power density “thermal batteries” as well as secondary “lithium ion batteries”.


EnerSys (EAS’ parent company) is a $2.5 billion/year, publically traded, American

company. EnerSys operates 32 manufacturing facilities around the world. EAS is

comprised of 6 of those facilities, all dedicated to lithium batteries, and 2 of which

(located in the US) are focused on munitions batteries.

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Electrochemical Systems• Lithium Silicon/Cobalt Disulfide (LiSi/CoS2)

• Lithium Silicon/Iron Disulfide (LiSi/FeS2)

• Lithium/Thionyl Chloride (Li/SOCI2)

• Lithium/Sulfuryl Chloride (Li/SO2CI2)

• Lithium/Sulfur Dioxide (Li/SO2)

• Lithium/Vanadium Pentoxide (Li/V2O5)

• Lithium-Ion (various chemistries)

Long Shelf LifeLithium reserve batteries are unique in their ability

to last for over 20 years prior to activation. This

long shelf life is made possible by either storing the

active materials separately until activation or by

storing the active materials in a non-ionically

conductive state until activation.

Environmentally HardenedOur lithium reserve batteries are optimized for

operation in high acceleration environments (up to

100,000 g’s) and high spin rate (30,000 RPM),

applications that ordinary batteries cannot survive.

Lithium reserve batteries for smart weapons

and electronic fuzing applications.

Products Offered• Lithium Thermal Batteries

• Lithium Ambient Temperature Batteries

• Lithium-Ion Rechargeable Batteries



Automated Manufacturing• Multiple automated manufacturing lines are used to produce Ambient Temperature Batteries

and Thermal Batteries.

Why?

Temperature RangeCapable of operation across the full military

temperature range (-65˚F to +221˚F/-54˚C to

+105˚C).

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EnerSys automated battery manufacturing offers many benefits.



Automated Manufacturing• EnerSys automates manufacturing where it makes sense.

• High rate and high volume production

• Ambient Temperature Batteries

• Thermal Batteries

• Semi-automated production

• Machine assisted manufacturing

• Fully automated production

• Machine produced electrodes and assemblies

• Human support to equipment minimized

• Benefits of automation

• Improved battery performance

• Improved repeatability & consistency, i.e., tighter perf. groupings

• Zero defects/escapes

• Higher manufacturing throughput

• Lower cost – last but not least!

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Munitions Batteries Facilities

Pinellas Park, FL Facility

(formerly The ENSER Corp.)

Horsham, PA Facility


Features:

• Two Facilities: 112,500 ft2.

• 18,000 ft2 of Humidity Controlled Dry Rooms.

• Extensive Computer Modeling & Analysis Capabilities.

− Electrochemical, Thermal, & Structural

• Lithium Battery Development, Manufacturing &

Testing

− Lithium Oxyhalide Primary Reserve Batteries

− Lithium - Metal Disulfide Thermal Batteries

> LiSi / FeS2 and LiSi / CoS2

> Wide Range of Sizes, Voltages & Power

Levels

− Full Range of Non-Destructive & Destructive Test

Systems (static & dynamic environments)

> Digital X-Ray, Loads to 96 kW, High-g Shock,

Vibration, Acceleration, Temperature / Humidity

• Power Wide Range of Tactical, Strategic Defense &

Civil Space Systems

• Quality Management Systems Certified:

• ISO 9001:2008

• AS9100C

EAS has all of the physical assets and facilities required to:

design, develop, manufacture, test, and analyze lithium batteries.

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THAAD

Aegis

Ashore

SM-3 Block IB TDACS

SM-3 Block IIA TDACS (Multiple)

EKV

Sea-Based

Navy

Army

Aegis Ballistic Missile Defense

– Standard Missile - 3

Future Development

Ground-Based Terminal Systems

Ground-

Based

Patriot Advanced

Capability - 3

Ballistic Missile Defense

EnerSys Powers Multiple Mid-Course & Terminal Phase Systems

https://www.youtube.com/watch?v=4HvAuIi02AE

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Examples of Tactical & Strategic

Defense Applications

Multiple Batteries per Missile

Multi-Function Battery

Air-to-Air

Guided Projectile Batteries

Civil Space

Multiple Batteries per Missile

Multiple Batteries

per Missile

Air-to-Ground

http://en.wikipedia.org/wiki/File:AGM-154_03.jpg

http://en.wikipedia.org/wiki/File:AGM-154_03.jpg

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LiSi/FeS2 Thermal Battery

(Device No. G3202A1)

Φ1.000 X 1.436

Precision Extended Range Munition

(PERM)



Φ1.500 X 1.880

Artillery Fuze 155 mm Projectile



Φ1.110 X 2.850

AC130 Spectre 105 mm

Projectile

Selected Thermal BatteriesThermal Batteries can be Activated Electrically

or by the Conditions of Ballistic Launch.

Thermal Batteries

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Performance

Voltage (V): 24 to 35

Current (mA): 800, 1.8A 2s Pulse

Rated Capacity (mAh): 730

Activation Time (ms): < 1000

Initiation Approach: Electric IgniterOperating Temp. Range (°F): -58⁰ to +178⁰Storage Temp. Range (°F): -65⁰ to +221⁰

Physical Characteristics

Chemistry: LiSi/FeS2

Size: 3.00” Dia. by 3.50” Length

Weight (lbs): 3 Max

11 Pin Terminal Plate

3 Redundant Voltage Connections

Robust Bracket Design

Environmental

MIL-STD-331 Environments

NAVSEA 9310 Lithium Battery Safety

RCC319-10 Battery Requirements

LiSi/FeS2 FTS Thermal Battery


The G3206A1 LiSi/FeS2 Thermal Battery provides an active life greater than 35 minutes across the full temperature range (-58 ⁰F to +178 ⁰F).

Thermal Batteries

High-speed

Anti-Radiation

Missile

(HARM)

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(Device No. G3190B2)

Performance

Voltage (V): 22 to 32.0

Current (mA): 700



Initiation Approach: Electric Igniter

Operating Temp. Range (°F): -65 to +221

Storage Temp. Range (°F): -65 to +221


Chemistry: LiSi/FeS2

Size: 1.50” Dia. by 2.38” Length

Weight (g): 250

Environmental


NAVSEA 9310 Lithium Battery Safety

The EnerSys G3190B2 Lithium Silicon/Iron Disulfide (LiSi/FeS2) Thermal Battery

powers the DSU-33 Proximity Sensor used on the Joint Direct Attack Munition

(JDAM) bombs.

F-15 drops JDAM-equipped

bombs in Afghanistan.

(U.S. Air Force photo by

Staff Sgt. Michael B. Keller)

Thermal Batteries

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G3168B1 Cell

(SDF)

Φ.220 x .215

Self-Destruct

Fuzing

G3201A1 Cell

(LW30)

Φ.275 x .325

30 mm

Projectile

Munitions

G3198B1 Cell

(ANLM)

Φ.319 x .359

40 mm

Air-bursting

Non-Lethal

Munitions

G3165D1 Cell

(BMF)

Φ.350 x .435

20 mm

Projectile

Fuzing & 84mm Rockets

G3207A1 Cell

(SAGM)

Φ.450 x .395”

40 mm

Grenade

Munitions

G2666B1

(HED)

Φ.500 x .840

Barrier

Munitions

G3147A1 Cell

(M767)

Φ.500 x .840

Artillery

Fuzing

Projectile Fuzing

EnerSys offers a wide range of state-of-the-art Reserve Lithium/Oxyhalide Cells

for medium and large caliber projectile fuzing.

Ambient Temperature Batteries

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Performance

Voltage (V): 2.5 to 3.6

Current (mA): 0.5



Initiation Approach: Stab Initiation

Operating Temp. Range (F): -25⁰ to +160⁰

Storage Temp. Range (F): -60⁰ to +160⁰


Chemistry: Li/SOCl2Size: 0.50” Diameter by 0.84” Length

Weight (g): 6.2

Environmental


Acceleration (G): 30,000 max.

Spin (RPM): 30,000 max.Artillery Fuze Battery(Device No. G3147A1)

The G3147A1 Li/SOCl2 Artillery Fuze Cell offers high energy in a robust

design capable of withstanding the extreme conditions of ballistic launch.


M767 Artillery Fuze,

155 mm & 105 mm

Projectiles

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Performance


Current (mA): 36


Activation Time (s): 2.0

Initiation Approach: Dual Electric Primers




Chemistry: Li/SOCl2

Size: 1.516” Width by 2.40” Length

Weight (g): 80

Environmental


Acceleration (G): 12,600 max.Data Hold Battery(Device No. G3177A1)

The G3177A1 Li/SOCl2 Data Hold Battery utilizes a 2S2P configuration to

support essential data hold functions in guided projectiles.


Extended Range

Guided Munition

(ERGM)

5” Projectile

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Performance


Current (mA): 350


Activation Time (s): ≤ 100

Initiation Approach: Setback Initiation




Chemistry: Li/SOCl2Size: 1.50” Diameter by 0.67” Length

Weight (g): 71

Environmental


Acceleration (G): 30,000 max.

Spin (RPM): 30,000 max.

The G3158B3 Li/SOCl2 Artillery Fuze Battery can sit in the dormant state for in

excess of 20 years and then be activated by the conditions of ballistic launch.

Artillery Fuze Battery(Device No. G3158B3)


Multi-Option Fuze

for Artillery (MOFA)

155 mm & 105 mm

Projectiles

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The G3203B1 Flight Termination Systems (FTS) Battery uses an

8S1P configuration of standard lithium-ion 18650 cells

Performance

Voltage (V): 24 to 33.6

Current (A): 5 Discharge

1.0 Charge

Rated Capacity (Ah): 2.8 at 77⁰F (25 ⁰C)

Internal Heater: Yes

Operating Temp. Range (F):

Charge: 32⁰ to +113⁰

Discharge: -4⁰ to +160⁰

Storage Temp. Range (F): <95⁰


Chemistry: Li-Ion

Size: 6.26” x 3.56” x 1.34”

Weight (lb.): 2.05

Environmental

RCC319-10 FTS Battery RequirementsLi-Ion FTS Battery(Device No. G3203B1)

Secondary Batteries

Joint Air-to-Surface

Standoff Missile

(JASSM)

Cruise Missile

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Performance

Section:

Voltage (V):

Current (A):

Rated Capacity:

Op. Temp. (F):

Stor. Temp. (F):


Chemistry: Lithium Ion Polymer

Size: 4.150” Diameter X 4.00” Length

Weight (Lb): 8.4

Environmental

Ballistic Conditions of Gun Launch.

ERGM Instrumentation Battery


1, TM 2, FTS 3, FTS

25 – 35 25 – 35 25 – 35

1.2 0.2 0.2

0.813 Ah 0.325 Ah 0.325 Ah

20 to 110 10 to 120 10 to 120

20 to 85 20 to 85 20 to 85

Extended

Range

Guided

Munition

(ERGM)

Secondary Batteries

The G3174A3 Instrumentation Battery provides a telemetry section

and two fully redundant flight termination systems sections.

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• Future Enhancements:

Thermal Batteries

» Longer Mission Life

» Higher Deliverable Energy

» Smaller Size


» Faster Activation at Cold Temperature

» Higher Power at Cold

Secondary Batteries

» Improved Performance at Cold Temperature

Thank You for Your Attention!

Future Direction


Documents

Advanced Munitions Batteries - creb.umd.edu · 1 Center for Research in Extreme Batteries (CREB) The Future of Munitions Batteries Workshop Advanced Munitions Batteries 7 & 8 December