Safety of Lithium Nickel Cobalt Aluminum Oxide Battery Packs in Transit Bus Applications

The future of mass transportation is clearly moving toward the increased efficiency and greenhouse gas reduction of hybrid and electric vehicles. With the introduction of high-power/high-energy storage devices such as lithium ion battery systems serving as a key element in the system, valid safety and security concerns emerge. This is especially true when the attractive high-specific-energy and power-chemistry lithium nickel cobalt aluminum oxide (NCA) is used. This chemistry provides great performance but presents a safety and security risk when used in large quantities, such as for a large passenger bus. If triggered, the cell can completely fuel its own fire, and this triggering event occurs more easily than one may think. To assist engineers and technicians in this transfer from the use of primarily fossil fuels to battery energy storage on passenger buses, the Battery Application Technology Testing and Energy Research Laboratory (BATTERY) of the Thomas D. Larson Pennsylvania Transportation Institute (LTI) in the College of Engineering at The Pennsylvania State University partnered with advanced chemistry battery and material manufacturers to study the safety concerns of an NCA battery chemistry for use in transit buses. The research team ran various experiments on cells and modules, studying rarely considered thermal events or venting events. Special considerations were made to gather supporting information to help better understand what happens, and most importantly how to best mitigate these events and/or manage them when they occur on a passenger bus. The research team found that the greatest safety concern when using such a high-energy chemistry is ensuring passenger safety when a cell’s electrolyte boils and causes the ventilation of high-temperature toxic material. A cell-venting event can be triggered by a variety of scenarios with differing levels of likelihood. Also, though the duration of a venting event is relatively short, on the order of just a few seconds, the temperature of the venting material and cell is extremely high. During a venting event, the high-pressure, burning gases tend to burn holes in nearby packaging materials. Most interestingly, the team discovered that following a venting event the large-format cells tested immediately reached and remained at extremely high external skin temperatures for very long periods, on the order of hours. The majority of this report covers the testing designed to better understand how high-energy cells of this chemistry fail and what materials can be used to manage these failures in a way that increases passenger survivability

Wear of conveyor chains with polymer rolls

Roller conveyor chains are common used to transport goods in production lines or assembly lines, such as pallets, cars or steel coils. They are sometimes used in severe environments, soiled with water, foreign particles, chemicals or other contaminants. Normal use will result in wear of the components of the chain which can lead to unexpected failure and costly production downtime. Today, few literature on the wear of conveyor chain is available and there are almost no reliable test-rigs to generate and measure chain wear in a reproducible manner. In this research the different components of conveyor chains and the loading conditions are described. Additionally, the applications and (dis)advantages of chains with polymer rollers are discussed. The chain wear mechanisms found in literature are listed. Abrasive and adhesive wear between pin, bushing, roller and track are discussed. From the contact mechanics of the chain and pressure-velocity limit of the roller materials, the design constraints for the laboratory test-rig were derived. The capabilities and working principles of the developed test-rig are explained in this paper

Atomic Oxygen Erosion Yield Predictive Tool for Spacecraft Polymers in Low Earth Orbit

A predictive tool was developed to estimate the low Earth orbit (LEO) atomic oxygen erosion yield of polymers based on the results of the Polymer Erosion and Contamination Experiment (PEACE) Polymers experiment flown as part of the Materials International Space Station Experiment 2 (MISSE 2). The MISSE 2 PEACE experiment accurately measured the erosion yield of a wide variety of polymers and pyrolytic graphite. The 40 different materials tested were selected specifically to represent a variety of polymers used in space as well as a wide variety of polymer chemical structures. The resulting erosion yield data was used to develop a predictive tool which utilizes chemical structure and physical properties of polymers that can be measured in ground laboratory testing to predict the in-space atomic oxygen erosion yield of a polymer. The properties include chemical structure, bonding information, density and ash content. The resulting predictive tool has a correlation coefficient of 0.914 when compared with actual MISSE 2 space data for 38 polymers and pyrolytic graphite. The intent of the predictive tool is to be able to make estimates of atomic oxygen erosion yields for new polymers without requiring expensive and time consumptive in-space testing

A mobile Magnetic Sensor Unit for the KATRIN Main Spectrometer

The KArlsruhe TRItium Neutrino experiment (KATRIN) aims to measure the electron neutrino mass with an unprecedented sensitivity of 0.2 eV/c2, using b decay electrons from tritium decay. For the control of magnetic field in the main spectrometer area of the KATRIN experiment a mobile magnetic sensor unit is constructed and tested at the KATRIN main spectrometer site. The unit moves on inner rails of the support structures of the low field shaping coils which are arranged along the the main spectrometer. The unit propagates on a caterpillar drive and contains an electro motor, battery pack, board electronics, 2 triaxial flux gate sensors and 2 inclination senors. During operation all relevant data are stored on board and transmitted to the master station after the docking station is reached.Comment: 11 pages, 14 figure

A Study of Dielectric Breakdown Along Insulators Surrounding Conductors in Liquid Argon

High voltage breakdown in liquid argon is an important concern in the design of liquid argon time projection chambers, which are often used as neutrino and dark matter detectors. We have made systematic measurements of breakdown voltages in liquid argon along insulators surrounding negative rod electrodes where the breakdown is initiated at the anode. The measurements were performed in an open cryostat filled with commercial grade liquid argon exposed to air, and not the ultra-pure argon required for electron drift. While not addressing all high voltage concerns in liquid argon, these measurements have direct relevance to the design of high voltage feedthroughs especially for averting the common problem of flash-over breakdown. The purpose of these tests is to understand the effects of materials, of breakdown path length, and of surface topology for this geometry and setup. We have found that the only material-specific effects are those due to their permittivity. We have found that the breakdown voltage has no dependence on the length of the exposed insulator. A model for the breakdown mechanism is presented that can help inform future designs.Comment: 15 pages, 12 figures. Accepted to JINS

Atomic Oxygen Erosion Yield Prediction for Spacecraft Polymers in Low Earth Orbit

The ability to predict the atomic oxygen erosion yield of polymers based on their chemistry and physical properties has been only partially successful because of a lack of reliable low Earth orbit (LEO) erosion yield data. Unfortunately, many of the early experiments did not utilize dehydrated mass loss measurements for erosion yield determination, and the resulting mass loss due to atomic oxygen exposure may have been compromised because samples were often not in consistent states of dehydration during the pre-flight and post-flight mass measurements. This is a particular problem for short duration mission exposures or low erosion yield materials. However, as a result of the retrieval of the Polymer Erosion and Contamination Experiment (PEACE) flown as part of the Materials International Space Station Experiment 2 (MISSE 2), the erosion yields of 38 polymers and pyrolytic graphite were accurately measured. The experiment was exposed to the LEO environment for 3.95 years from August 16, 2001 to July 30, 2005 and was successfully retrieved during a space walk on July 30, 2005 during Discovery s STS-114 Return to Flight mission. The 40 different materials tested (including Kapton H fluence witness samples) were selected specifically to represent a variety of polymers used in space as well as a wide variety of polymer chemical structures. The MISSE 2 PEACE Polymers experiment used carefully dehydrated mass measurements, as well as accurate density measurements to obtain accurate erosion yield data for high-fluence (8.43 1021 atoms/sq cm). The resulting data was used to develop an erosion yield predictive tool with a correlation coefficient of 0.895 and uncertainty of +/-6.3 10(exp -25)cu cm/atom. The predictive tool utilizes the chemical structures and physical properties of polymers to predict in-space atomic oxygen erosion yields. A predictive tool concept (September 2009 version) is presented which represents an improvement over an earlier (December 2008) version