Tab 04 SOW.pdf
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- Solicitation number
- 80NSSC900495Q
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This Statement of Work (SOW) details NASA's requirement for Li-ion Superbrick Assembly and Test for the LEMS-A3 project. The document outlines the contractor's tasks to assemble two Li-ion superbricks and one spare brick using NASA-provided components, preserving the 14P-8S topology and 14P brick design from the Orion project. NASA will supply 300 screened Molicel M35A cells, fabrication parts, and necessary assembly fixtures, with the contractor responsible for cell receipt, weld schedule verification, superbrick assembly, and comprehensive acceptance testing.
Key deliverables include generating Procedure Qualification Records (PQRs) for welds, submitting cross-section samples, and completing acceptance test results within specified timeframes. The superbricks must be assembled to precise specifications, including a unique rectangular aspect ratio of 5"x17"x3", incorporating a thermal ground plane and gap pad installation. The contractor must perform detailed testing including mass measurements, open circuit voltage (OCV), insulation resistance, dimensional checks, and capacity cycling with discharge capacity resistance (DCR) pulse testing. Upon completion, the superbricks and remaining parts will be prepared for shipping according to NASA's instructions.
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| File | Type | Posted |
|---|---|---|
| Tab 07 Capability Statement SAM.pdf |
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Li-ion Superbrick Assembly & Test
SOW rev 2 Dec 2024
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 2 Li-ion superbricks and 1 spare brick. The superbrick preserves the 14P-8S topology and 14P brick design used for Orion in 2017 and 2018.
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 three (3) superbricks. Cell design shall be Molicel M35A in a quantity of 300 screened cells in a Zarges Shipping Container. 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. The 0.020” Ni bus plates will be chemical etched to 0.005” to allow non-etched surfaces to mate 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.
4.0 Contractor Tasks
4.1 Cell Receipt – NASA shall deliver 300 cells that have passed screening and set at 10% SoC per
EP-WI-037B. NASA shall also deliver 100 rejected cells for use in weld development, qualification, and verification.
4.2 Weld Schedule Verification – A welding procedure specification (WPS) shall be generated for each of the 3 welds (tab to positive cell terminal, tab to negative cell terminal, and positive 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.
4.3 Superbrick Assembly – Two superbricks shall be assembled per TBD dwg.
4.4 Superbrick Acceptance Test – Mass, OCV, insulation resistance, dimensions, and capacity cycle with DCR shall be performed. Specifics of insulation resistance and dimensional measurements to be taken are TBD. 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. For this build, insulation resistance can be performed using a digital multimeter capable of measuring 1kOhm resistance or greater.
5.0 Deliverables
5.1 Data –
5.1.1 PQRs for all 2 welds along with a cross-section sample for each 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 within 12 weeks of receipt of all parts.
5.2 Superbricks – The pair of superbricks and the container that NASA used to deliver the cells 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 superbricks to the domestic recipient is beyond the scope of this contract.
5.3 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.
File details come from the government source that posted it. Updated .