NASA/Glenn Research Center, 21000 Brookpark Road, Cleveland, OH 44135

A -- LITHIUM-BASED POLYMER ELECTROLYTE BATTERY SOL RFO3-129006 DUE 032400 POC Gary A. Golinski, Contracting Officer, Phone (216) 433-2790, Fax (216) 433-2480, Email Gary.A.Golinski@grc.nasa.gov WEB: Click here for the latest information about this notice, http://nais.msfc.nasa.gov/cgi-bin/EPS/bizops.cgi?gr=D&pin=22#RFO3-1290 06. E-MAIL: Gary A. Golinski, Gary.A.Golinski@grc.nasa.gov. STATEMENT OF WORK LITHIUM-BASED POLYMER ELECTROLYTE BATTERY AND CONTROL SYSTEM: CONCEPT AND DEMONSTRATION UNIT Background The purpose of this project is to demonstrate the viability of a lithium-based (i.e., lithium metal or lithium-ion intercalation compound as negative electrode), polymer electrolyte regenerative battery system as the on-board energy source for reusable launch vehicle (RLV) systems. This project is part of a larger effort intended to demonstrate new, mission-enabling technologies for advanced RLV concepts. The advanced RLV is envisioned as an all-electric vehicle, with energy for all on-board requirements, including electromechanical flight control actuators, provided by the electrical energy source. Technology efforts under this project are intended to demonstrate that the lithium-based polymer electrolyte regenerative battery, plus the associated ground service equipment (GSE) required by these batteries for charge/discharge control and cell protection, can be designed AS A SYSTEMthat will contribute significantly to the ultimate RLV goal of reducing payload launch costs to hundreds, rather than thousands of dollars per pound. The development of cost-effective RLVs is currently of great interest to NASA, DOD and commercial launch providers. A significant market seems assured for a successful vehicle and its associated components and equipment. The anticipated operational life for such a vehicle is about one hundred flights over a four year span. Objective This project is intended to develop a lithium-based polymer electrolyte battery SYSTEM CONCEPT for a generic advanced RLV, involving the equipment and the operating protocols for in-flight battery operation and for ground-based charging, rebalancing, maintenance and testing of the batteries. It is expected that this concept will minimize the production and replacement cost for the batteries, the cost of the GSE and the expenses related to operations and ground servicing. The validity of the concept and the selection of lithium-based, polymer electrolyte batteries will be confirmed by fabrication and evaluation of a DEMONSTRATION UNIT. This required Demonstration Unit shall comprise: (1) A charge/discharge control and cell protection system that will demonstrate the economies available when virtually all the system electronics are ground-based and free of strict reliability and other flight requirements; (2) A set of lithium-based, polymer electrolyte batteries of sufficient size and number to adequately evaluate the performance of both the charge/discharge control and cell protection system and the batteries themselves; (3) A simulated flight vehicle main bus, including the battery unit discharge controller (if required), data acquisition for on-board battery unit health monitoring, and an electrical load controlling the Demonstration Unit discharge profile; and (4) A "universal" interface for the battery set that provides simple connection either to the ground-based control and protection system, or to the simulated flight vehicle mainbus. A final objective is to demonstrate, by flight qualification tests, a FLIGHT-QUALIFIED BATTERY structural design that is compatible with the rigors of multiple mission launches. Scope The program shall consist of the following principal parts: 1. Definition of RLV power and performance requirements. 2. Definition of integrated battery/control system concept. 3. Definition of Demonstration Unit components and performance requirements. 4. Evaluation of existing cell technology relative to Demonstration Unit requirements. 5. Design of Demonstration Unit battery. 6. Fabrication and evaluation of Demonstration Unit battery cell. 7. Design and preliminary evaluation of electronic charge/discharge control and cell protection system. 8. Design and preliminary evaluation of the simulated flight vehicle main bus. 9. Design and integration of battery system electrical interface. 10. Fabrication and evaluation of prototype Demonstration Unit battery. 11. Fabrication and characterization of Demonstration Unit battery set. 12. Performance evaluation of the Demonstration Unit. 13. Design and qualification of flight battery. 14. Reporting The contractor shall perform the following tasks in conjunction with their standard Quality Assurance practices. Task 1. Technology Survey 1.1 The Contractor shall arrange and attend a meeting with RLV Project personnel at the NASA Marshall Space Flight Center. Contractor shall acquire the most recent plans and goals that will influence RLV battery system design. This information shall be used (Task 3) to define, for subsequent evaluation, a sub-scale Demonstration Unit that will validly represent the Contractor's integrated battery/control system concept (Task 2). Task 2. Integrated Battery/Control System Concept Definition 2.1 Contractor shall develop a battery SYSTEM concept that will satisfy RLV mission requirements and focus upon the goal of low-cost multiple, rapid turnaround orbital launches per vehicle each year. Advantage shall be taken of the inherent characteristics of the lithium-based, polymer electrolyte battery: low weight and volume, high voltage per cell, design flexibility, safety and long life. The system concept shall stress the minimization of overall cost for cells and batteries, the ground service equipment, and for maintenance and operations.(See Footnote (1)) Footnote (1) Things to be considered shall include use of commercial off-the-shelf components for ground-based equipment; battery design incorporating cells replaceable in situ; cells and batteries without built-in electronics; and centralization of all electronic control and protection components with the GSE. Task 3. Demonstration Unit Definition 3.1 Consistent with the data acquired in Task 1.1, Contractor shall define a Demonstration Unit of sufficient size and complexity to provide a meaningful evaluation of the battery/control system concept defined in 2.1.(See FootNote 2) The definition shall include an appropriate mission power profile that will stress Demonstration Unit batteries to the same degree as would be actual flight batteries. Footnote (2) Factors to be considered shall include reliability/redundancy requirements, which may dictate battery system configuration, redundancy and series-parallel arrangements. To the extent that such considerations may affect battery performance or the design and operation of the electronic control and protection system, they shall be incorporated into the Demonstration Unit definition. Task 4. Existing Battery Cell Technology Evaluation 4.1 Based on the requirements defined in 3.1, Contractor shall experimentally evaluate its existing cell technology relative to the Demonstration Unit requirements. Factors to be considered shall include power profile, thermal environment during simulated operation in flight or standby on the ground, cycle life, stand life, etc. Minor adjustments may be made to electrolyte chemistry and/or electrode composition to bring performance into conformance with the requirements. The changes shall be validated by further testing. Task 5. Demonstration Unit Battery and Battery Cell Design 5.1 Battery design shall conform to the capacity and performance requirements of 3.1, the performance capability of the existing cell technology evaluated in 4.1, and the requirements imposed by 2.1, the overall system concept.(See FootNote 3) Other design considerations shall include thermal control at the cell and battery levels, proper containment and support of cells, and structural integrity. In addition, each battery shall have a wiring harness for plug-in connection to an electrical interface providing access to either the ground-based electronic control and protection system or a simulated flight vehicle main bus and data acquisition /health monitoring system (see Task 9). Footnote (3) For example, consider a decision that there would be no response taken to a cell failure during flight as long as the cell did not actually reverse; the affected battery would remain on-line, and the faulty cell would be replaced after landing. This would require a battery design allowing easy (non-destructive) access to cells, and simple in situ cell replacement. Task 6. Battery Cell Fabrication and Evaluation 6.1 Based on the battery design of 5.1, battery cells shall be fabricated and placed on test. In addition to conventional characterization tests, cells shall be cycled according to the Demonstration Unit power profile. They shall also be evaluated in the thermal environments they are expected to encounter. Task 7. Battery Control Unit Design and Preliminary Evaluation 7.1 Based upon the integrated battery/control system concept of 2.1, the Demonstration Unit requirements of 3.1 and the RLV goal of significant cost reduction for equipment, operations and maintenance, Contractor shall design the electronic charge/discharge control and cell protection equipment for the Demonstration Unit.(See Footnote (4)) The system control unit concept and design shall be validated with sub-scale tests, as needed. The full-scale system shall then be assembled and undergo function and continuity tests prior to incorporation in the Demonstration Unit. Footnote (4) The design shall reflect a detailed understanding of the safety and performance requirements and vulnerabilities of the particular lithium-based technology to be used: some technologies require very precise and complex control at the single-cell level; others are quite "forgiving" and are controllable at the battery level. The design shall reflect the cost reduction possibilities available if the battery charge/discharge control and cell protection unit is ground-based: commercial off-the-shelf components can be used; control concepts need not be rejected because they require heavy components; similarly, components need not be compactly packaged, thus allowing simple repair and parts replacement in the GSE. Task 8. Simulated Flight Vehicle Main Bus Design and Preliminary Evaluation 8.1 Based on the RLV definitions of 1.1, the integrated battery/control system concept of 2.1 and the Demonstration Unit power profile of 3.1, Contractor shall design a simulated RLV main bus for the Demonstration Unit. This simulation shall include battery system data recording for system health monitoring, any necessary on-board cell discharge protection, and an electrical load to reproduce the Demonstration Unit power profile. This simulated main bus shall be equipped to plug directly into the Demonstration Unit electrical interface. Task 9. Electrical Interface Design and Integration 9.1 In parallel with the design of the Demonstration Unit battery and control systems, and the simulated flight vehicle main bus, the battery electrical interface shall be designed. The design shall permit easy connection of each battery (or, group of batteries), through the interface, to either the control system for charging and testing of the batteries, or to a simulated flight vehicle main bus, including the battery set data acquisition/health monitoring system and discharge controller, if required. It shall be of prime concern to integrate the efforts of the battery system, control system and simulated flight vehicle system designers to assure compatible and proper connections. Task 10. Reporting 10.1 Technical, financial and schedule reporting shall be in accordance with the Reports of Work Provision of the Contract. As part of the Project Final Report, an Executive Summary containing major results and conclusions shall be presented. Optional Task O-1. Prototype Battery Fabrication and Evaluation O-1.1 Battery structural and interface components shall be fabricated, and battery assembly shall be completed by incorporating cells based on the design validated in 6.1. Testing of this prototype battery shall be relevant to the mission requirements of the Demonstration Unit, and shall evaluate the electrical and thermal characteristics of the battery. Optional Task O-2. Demonstration Unit Battery Set Fabrication and Characterization O-2.1 Upon successful testing of the prototype battery, fabrication and characterization shall proceed for the remaining Demonstration Unit batteries. Optional Task O-3. Demonstration Unit Evaluation O-3.1 Upon fabrication and check-out of the battery set, the system interface, the electronic charge/discharge control and cell protection system and the simulated flight vehicle main bus, the complete Demonstration Unit shall be evaluated. Proper electrical continuity from the battery, through the interface, to the control system or to the simulated main bus shall be verified. Battery discharge for simulated flight operation shall be according to the power profile of 3.1. It shall confirm proper data acquisition, and validate the chosen mode, if any, of battery control during discharge. Simulation of ground operations shall confirm the ability of the controller to properly charge the batteries and equilibrate the individual cells, and to carry out standard cycling for testing purposes. Evaluations shall include thermal conditions defined for the various mission segments. Optional Task O-4. Flight Battery Design and Qualification O-4.1 To the extent necessary, the prototype battery design of 5.1, evaluated in O-1.1, shall be modified to reflect those RLV requirements of 1.1 that are relevant to flight qualification. This redesigned battery shall be fabricated and tested to verify its ability to withstand the critical environmental exposures of launch and flight. Testing shall include functional performance, tolerance to the shock, acceleration and vibrational launch stresses over a multi-mission lifetime, and operation in the flight thermal and vacuum environment. ***************************************************** SUPPORTING INFORMATION AND PROPOSAL INSTRUCTIONS The battery technology being proposed shall be sufficiently advanced that no significant effort will be required to develop cell chemistry, increase cell or battery size or upgrade production capabilities. Automated, continuous cell production facilities shall be operational and capable of producing cell components, cells and batteries of sufficient size and quantity to support estimated Project requirements. Minimum acceptable cell size shall be twenty (20) ampere-hours. Because the number and the rating of batteries required for the Demonstration Unit will not be defined until completion of Task 3 of the Contract effort, assume initially, for sizing and costing estimates in the Proposal, that the battery system for the Demonstration Unit consists of two parallel strings, each of two series-connected batteries. Each of the four batteries shall be assumed rated at twelve (12) volts, twenty (20) ampere-hours. In the Proposal and the Schedule, Offerer shall suggest procedures for the review of system definitions, system and component designs and test plans. These reviews shall take place via written communication, teleconference or formal meetings, as appropriate in each case. After each review, NASA GRC concurrence shall be obtained before proceeding with the respective and subsequent tasks. In the Proposal, Offerer shall suggest test items and quantities to be delivered to NASA GRC for concurrent evaluation. ***************************************************** The government will choose the proposal which it deems to be the Best Value. The best value characteristics are as follows: 1. Adequacy of proposed level of cost sharing relative to the proposed Contract effort and cost to the government. 2. Evidence of maturity of battery technology and production capability: Current cell size of at least twenty (20) ampere hours; cell-level energy density >250 watt hours/liter; cell-level specific energy >125 watt hours/kilogram; automated, continuous production capability adequate for estimated Project requirements. 3. Evidence of relevant electric/electronic control system development experience, and an understanding of the proposed battery technology's vulnerabilities and requirements for control and protection. 4. Quality of discussion of the proposed approach to developing and meeting the Demonstration Unit performance requirements, and how this approach will contribute to RLV cost-reduction goals. 5. Quality of proposed Project Plan regarding schedule, deliverables and review/approval scenario. The Government does not intend to acquire a commercial item using FAR Part 12. See Note 26. The SIC Code and Size Standard are 3691 and 500 employees, respectively. The DPAS Rating for this procurement is DO-C9. The provisions and clauses in the RFO are those in effect through FAC 97-14. It is estimated that the Government's share of the costs of the Basic effort will have a value equivalent to three engineering man-years. It is estimated that the Government's share of the costs of the Optional effort will have a value equivalent to five engineering man-years. All qualified responsible sources may submit an offer which shall be considered by the agency. An ombudsman has been appointed -- See Internet Note "B". Prospective offerors shall submit four copies of a Technical and Cost Proposal to Gary Golinski at Mail Stop 500-306 before close of business March 24, 2000. The cost proposal should be at a minimum separated into Basic and Option portions and should be in sufficient detail for the government to perform a Price Analysis. It is the offeror's responsibility to monitor the Internet site for the release of amendments (if any). Potential offerors will be responsible for downloading their own copy of the amendments (if any). Any referenced notes can be viewed at the following URL: http://genesis.gsfc.nasa.gov/nasanote.html Posted 02/04/00 (D-SN422180). (0035)

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