Active Battery Management System with Physics Based Life Modeling Topology

EP Systems has been developing Active Balancing Technologies for aerospace application with NASA for more than five years. The focus of these efforts has included cell life algorithms development, airworthy battery management system (BMS) controls, elimination of balancing circuit stabilization capacity, and DC/DC balancing converter design, build, and testing.This effort has built upon collaborations between EP Systems and its university partners and their prior research efforts funded by the NSF.Additionally, the Active Battery Management System (ABMS) also leveraged Battery Control Computer (BCC) technologies developed through the NASA X57 program funding as well as continued EP Systems internal funding. In parallelElectric Power Systems focus is working with airframe partners on the development of hybrid-electric and all-electric air vehicles. This includes the development of large fixed-wing hybrid air vehicles, which would be certified under FAR Part 25 regulations. It also encompasses the developments of small-fixed wing and electric vertical take-off and landing (eVTOL) air vehicles, targeting certification under FAR part 23. This includes the development of a standard product battery module and reconfigurable and scalable system solution called EPiC (Electric Propulsion Ion Core). The proposed technology maturation tasks for this CCRPP program are three-fold: first, perform VV of the BCC software and hardware;second, revise the standard BCC design for appropriate DAL level and lessons learned from Phase IIE; and third, update the Phase IIE balancing circuit design for the EPiC modules. Electric Power Systems is developing technologies to pave the way for electric aircraft propulsion--specifically, FAA certifiable batteries and battery management systems. The technology developed through EP Systems' NASA SBIR program has immediate application towards multiple airborne platforms and aircraft GSE. Certification of the central controller of the Active Battery Management System (ABMS) will immediately enable Part 23 All-Electric and Hybrid Fixed Wing platforms to meet target EIS dates. Additionally, the ability of ABMS to accommodate variability in module capacity has immediate use in GSE applications where second life modules are intended to be used. The shared BMS backbone between the on-board battery and the GSE battery unlocks immediate benefits for all-electric fleet operators. These applications have target entry into service timelines and/or de-risk milestones the next 24 months. Additionally, this technology maturation provides the basis for future larger electric aircraft battery certification--hence, Boeing's co-investment for this CCRPP program. The main technical objectives of the proposed commercialization effort are threefold. First, this program will complete certification of the core central computer developed for the ABMS. Second, the assurance level of the controller developed in the Phase II-E program will be advanced from DAL-C to DAL-A. Third, the program will adapt the ABMS balancer circuits developed to TRL 7 under the Phase II-E program and progress to TRL 8 for pilot demonstration. EP Systems has developed a modular and scalable standard product system for airborne certification and will leverage this development to introduce the SBIR developed technologies. Additionally, integration facilities and methods developed at EP Systems for NASA and other internal and customer funded R&D programs will be leveraged in this commercialization program. These assets include the test systems developed during the Phase IIE program. The ABMS central controller is currently at a SOI 2 state and will proceed through formal V&V in parallel to EP Systems' standard product battery system elements. Deliverables to NASA will include V&V completion report DAL C BMS specification DAL A BMS central controller safety analysis, design, and test reports DAL A BMS specification Active balancer mechanical ICD Active balancer design and test report Active balancer specification
Benefits: Potential NASA applications of the target technology include NASA hybrid demonstrator aircraft programs NASA electric aircraft GSE and charging infrastructure for vehicle testing NASA X57 Maxwell future upgrades Existing Fixed wing applications of the target technology include: Diamond eDA40 Ampaire Eco-Caravan VoltAero Cassio Aura Aero Integral E Potential eVTOL applications (amongst others): Skydrive Supernal Potential GSE applications: Flight schools targeting use of eDA40 and other electric aircraft platforms