SATPC0040138 Tab 04 4 SOW.pdf

LEMS SuperBrick Assembly & Test

1.0 Objective – Provide Li-ion Superbricks for use in LEMS-A3.

2.0 Scope – Using NASA provided parts and drawings, assemble, and perform acceptance testing on 1 Li-ion superbrick. The superbrick preserves the 14P-8S topology and 14P brick design used for Orion in 2017 and 2018. The repair of one (1) superbrick may, optionally, be required.

3.0 NASA Inputs – NASA will provide all parts on the BOM for the Superbrick to the contractor. All fabricated parts shall be of sufficient quantity to build up to one (1) superbrick. Cell design shall be Molicel M35A in a quantity of 100 passing screened cells for the Superbrick assembly.

All cell screening data shall be provided. Unlike the Orion superbrick, this design packages the 14P bricks in a different aspect ratio to achieve 5”x 17”x 3” as shown in Fig 1. Additionally, this design incorporates the thermal ground plane and gap pad installation. The thin aluminum sheet, gap pads, and redesigned Al and G10 window frames will be provided as part of the Bill of Materials. Suitable shipping containers will be provided for all superbricks and subassemblies, as applicable. The 0.005” Ni bus plates will be mated to the cell terminal during welding. NASA will also provide any necessary assembly process fixtures and any mating hardware needed for interfacing with the superbricks for acceptance testing. Suitable tabs for weld qualification and voltage sense tab repair activities will also be provided, if the superbrick repair option is pursued.

4.0 Contractor Tasks

4.1 Part Modification – Due to late identification of the necessary temperature sensing device, NASA-provided parts shall be modified by enlarging thermowells machined into the thermal ground plane to accommodate the NASA selected sensing device. Additionally, boring and reaming of NASA provided stand-offs is to be performed to ensure fit of the supplied fasteners. Due to the location of this modification and the lack of structural sensitivity to the loss of any one mounting fastener, the internal surfaces marred by the boring and reaming processes do not require conversion coat repair.

4.2 Cell Receipt for SuperBrick – NASA shall deliver 100 cells that have passed screening per EP-WI-037B and set at 30% SoC. As this value exceeds the 10% required measure, each cell used in battery assembly shall be discharged to 10% SOC in accordance with manufacture recommended discharge protocols.

4.3 Superbrick Assembly–A superbrick shall be assembled per Goddard Space Flight Center Part Number: 2356581.

4.4 Superbrick Acceptance Test – Mass, OCV, insulation resistance, dimensions, and capacity cycle with DCR shall be performed. Insulation resistance measurement can be taken with a high voltage measurement, or DMM as deemed appropriate, and dimensional measurements to be taken are overall maximum length, width, and height of the superbrick. Charge 6A to 32.8V with 300mA taper while monitoring the voltages of each virtual cell. Rest 10 minutes. Discharge at 6A to 24.0V with a DCR pulse at 50% SoC. Rest 30 minutes and recharge to 5% SoC. Insulation resistance shall be characterized for the first four modules to assess the degree of isolation between cell and module thermal ground plane using a meter capable of delivering a substantial current, this can be achieved using a combination of a DMM and power supply as deemed necessary. Once assessed, future modules can be assessed using a digital multimeter capable of measuring 1kOhm resistance or greater.

4.5 (OPTIONAL) Repair damaged SuperBrick #1 – Repair damaged SuperBrick #1 according to plan formulated after inspection of damaged SuperBrick. (Including but not limited to cleaning all debris and re-welding damaged voltage sense tabs)

4.5.1 If repair is pursued a formal weld qualification will need to be performed (see item 4.5.2 & 5.1.1).

4.5.2 Weld Schedule Verification – A welding procedure specification (WPS) shall be generated for the repair welds (freestanding tab to bus plate) to list the parameters used for each weld. The filled out WPS shall become the Procedure Qualification Record (PQR) for each weld.

5.0 Deliverables

5.1 Data –

5.1.1 (OPTIONAL – Pending Completion of task 4.5.2) A PQR for one voltage sense tab repair weld type along with a cross-section sample for the weld shall be shipped to NASA-JSC within 2 weeks after receipt of cells, bus plates, and tabs. Applicable document is PRC-0009 Process Specification for the Resistance Spot Welding of Battery and Electronic Assemblies.

5.1.2 Acceptance test results for the superbricks shall be emailed to martin.d.martinez@nasa.gov and melvin.s.abraham@nasa.gov and ruth.v.young@nasa.gov within 12 weeks of receipt of all parts.

5.2 Superbrick – The superbrick and the NASA provided container shall be made available for shipping by a suitable packaging and shipping agent of NASA’s choosing. Transfer to the shipping agent shall occur within 3 months after part receipt. Shipping the superbrick to the domestic recipient is beyond the scope of this contract.

5.3 (OPTIONAL) Repaired SuperBrick #1 – The superbrick and the NASA provided shipping container shall be made available for shipping by a suitable packaging and shipping agent of NASA’s choosing. Transfer to the shipping agent shall occur within 3 months after parts receipt. Shipping the superbrick to the domestic recipient is beyond the scope of this contract.

mailto:melvin.s.abraham@nasa.gov mailto:ruth.v.young@nasa.gov

5.4 Remaining parts and subassemblies – All remaining cells and/or subassemblies containing cells shall be made available for shipping by a suitable packaging and shipping agent of NASA’s choosing. All other remaining parts shall be shipped to NASA-

JSC.

Fig 1. Superbrick with rectangular aspect ratio.