Attachment J2 - DTBM Battery Schematics.pdf

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Batteries for Digital Talking Book Machines
Solicitation number
030ADV26R0055
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This document is a technical specification and engineering drawing for a battery pack intended for the National Library Service for the Blind and Physically Handicapped under contract GS23F0011L. The battery pack consists of six matched capacity and safety-vented AA-sized NiMH cells configured with specific electrical and safety components, including a JST connector (PAP-04V-S), 22 AWG stranded wire leads, a polyswitch rated for 2.5 Amps maximum at 60°C, a 100K thermistor with β of 4250, and a thermostat designed to open at 70°C. The assembled pack must not exceed 15mm at the ends including shrink-wrap, must weigh no more than 200 grams, and must measure no thicker than 16mm when placed on a flat surface.

The battery pack must deliver a minimum capacity of 2000 mA-Hrs when new, tested at 0.2C rate to 1.00 volts per cell. After 500 charge-discharge cycles, capacity must remain at least 70% of initial capacity with internal resistance not exceeding 450 milliohms. The pack must retain at least 50% charge after 90-day storage at 23±5°C and operate over discharge temperatures of 0 to 50°C and charging temperatures of 10 to 35°C. The specification includes four abuse tests per UL2054 (short circuit, abusive charging, abusive overcharge, and forced discharge), plus vibration testing at 0.35mm amplitude over 10-55 Hz frequency range for 30 minutes, and cable pull-test resistance verified by gradually increasing force from 0 to 20 pounds over 5-10 seconds. All dimensions are specified in inches per ASME Y14.5M-1994, with tolerances of ±0.032 inches for single decimal places and ±0.015 inches for double decimal places.

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Text version

15MM MAX. ENDS

INCLUDING SHINK-WRAP

FOR THE BLIND AND PHYSICALLY HANDICAPPED

THE LIBRARY OF CONGRESS

NATIONAL LIBRARY SERVICE

INTERPRET DIM AND TOL PER ASME Y14.5M-1994

THIRD ANGLE PROJECTION

ENGINEER

CHECKED

DRAWN

DATEAPPROVAL

CONTRACT NO.

SIZE

OF

TITLE

SHEET SCALE

REV DWG NO

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES, TOLERANCES ARE

1 2

.X .032 .XX .015 .XXX .005

ANGLES 1/2

S MADLAND

12-JUN-06

GS23F0011L

BATTERY PACK

B 4824591310 1.4

DO NOT SCALE DRAWING1:1

REV APPROVEDDATEDESCRIPTION

REVISION HISTORY

SHEET REV DWG NO

4824591310 1.41

D

RA

W

IN

G

M O

DE

L

P

DM

V

ER

1.

P

DM

V

ER

1.

F

ILE

NA

M

E:

F

ILE

NA

M

E:

B

B

A 3

LEAD WIRES 5

0.75 TO 1.00 INCHES EXPOSED

LENGTH TO CONNECTOR

VIEW SHOWN

WITHOUT SHRINK WRAP

2.12 MAX

NOTES:

INTERPRET DIMENSIONS AND TOLERANCES PER ASME 14.5M-19941.

2. POLYSWITCH

3. THERMISTOR

4. THERMOSTAT.

5. 22 AWG STRANDED (7 X 30) WIRE, STYLE 1007

6. JST CONNECTOR: PAP-04V-S (LF) (SN). PIN NUMBERING IN ACCORDANCE WITH JST CONNECTION SPECIFICATION.

7. THICKNESS OF THE BATTERY SHALL NOT EXCEED 16MM WHEN PLACED ON A FLAT SURFACE.

PIN WIRE DESCRIPTION

1 RED POSITIVE

2 BLACK NEGATIVE

3 WHITE THERMISTOR -

4 WHITE THERMISTOR +

B

B

A

D

RA

W

IN

G

M O

DE

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P

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ER

1.

P

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ER

1.

F

ILE

NA

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E:

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E:

SHEET REV DWG NO

4824591310 1.42

FOR THE BLIND AND PHYSICALLY HANDICAPPED

THE LIBRARY OF CONGRESS

OF

NATIONAL LIBRARY SERVICE

SHEET SCALE

REV DWG NO SIZE

TITLE

2 2

BATTERY PACK

B 4824591310 1.4

DO NOT SCALE DRAWING1:1

Requirement Verification Method The battery pack shall meet the mechanical dimensions as shown on page 1 of this drawing. Calipers and other measurement tools as appropriate for the measurement.

The battery pack shall weigh no more than 200 grams (7 oz). Analytical balance Components - Battery Pack shall consist of 6 matched capacity and safety vented AA-sized NIMH cells arranged as shown on page 1 of this drawing.

Examination of sample battery pack and comparison to drawing. Examination of vendor material certifications.

The battery pack shall contain a connector and cable as shown on page 1 of this drawing. Examination of sample battery pack and comparison to drawing. Connector, wire colors, connector pin numbers.

The battery pack shall contain a polyswitch that is sized to allow no more than 2.5 Amps to flow at 60 °C (140 °F).

Examination of vendor certification and part specifications. Examine the actual component in a battery pack.

The battery pack shall contain a 100 K thermistor with a β of 4250. Placed as shown in the Battery Pack Drawing.

Examination of vendor certification and part specifications. Examine the actual component and position in a battery pack.

The battery pack shall contain a thermostat that is designed to open at 70 °C (158 °F). Examination of vendor certification and part specifications. Examine the actual component in a battery pack.

Capacity - The battery pack capacity, when new, shall be 2000 mA-Hrs or greater when tested as described.

Capacity measured by discharge at a .2C rate to 1.00 volts/cell at an ambient temperature of 23 +/- 5 °C (73.4 +/- 9 °F).

Life - Battery capacity after 500 cycles shall be at least 70% of its initial capacity when tested as described. Internal resistance of the pack at the end of testing shall be no more than 450 milliohms (measured at DC).

Testing shall be done in sets of 25 charge/discharge cycles where the first 24 cycles consist of discharges at C/6 for 90 minutes and the 25th cycle is a capacity test at .5C until discharged to 1.00 volts/cell. Charging for all cycles shall be done at .5Cuntil either 1° C/min rise is achieved or -8mV/cell deltaV occurs. Testing shall be done at 23 +/-5°C (73.4 +/-9°F) ambient temperature

Self Discharge - The battery pack shall retain at least 50% of its fully charged capacity after storage at 23 +/- 5 °C (73.4 +/- 9 °F) for a minimum of 90 days.

Capacity measured as described in Capacity requirement.

Operating Temperatures - The battery pack shall be designed to operate over a temperature range of 0 to 50 °C (32 to 122 °F) while discharging at .2C rate.

Examination of vendor certification

Operating Temperatures - The battery pack shall be designed to operate over a temperature range of 10 to 35 °C (50 to 95 °F) while charging at a .5C rate.

Examination of vendor certification

Operating Temperatures - The battery pack shall be designed to operate after storage for 24 hours at each temperature extreme of -45 and +60 °C (-49 and +140 °F).

Examination of vendor certification

Abuse Testing - The battery pack shall comply with the short circuit test as described. Test is as described in Clause 9.7 of UL2054 dated September 21, 2005.

Abuse Testing - The battery pack shall comply with the abusive charging test as described. Test is as described in Clause 10.10 of UL2054 dated September 21, 2005.

Abuse Testing - The battery pack shall comply with the abusive overcharge test as described. Test is as described in Clause 11 of UL2054 dated September 21, 2005.

Abuse Testing - The battery pack shall comply with the forced discharge test as described. Test is as described in Clause 12 of UL2054 dated September 21, 2005.

The direction of vibration is vertical, and the severity is:

– Duration 30 min

– Amplitude 0.35 mm

– Frequency range 10 Hz...55 Hz...10 Hz

– Sweep range approximately 1 octave/min.

The cable shall resist being pulled out of the battery pack. The cable shall be pulled away from the pack with a force that gradually increases from 0 to 20 pounds over 5 to 10 seconds and maintained for 1 minute. The connector shall not be used to grasp the cable for this test.

The battery pack shall meet capacity requirements and mechanical dimensions after exposure to the vibration test as described. In addition, the connector shall still be operable.

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