Since the 1960s, NASA has relied on an old yet dependable technology for powering the International Space Station (ISS), satellites, and other space vehicles: nickel-hydrogen (Ni-H2) batteries (NHBs). These batteries are revered for their durability, long lifespan, and outstanding safety record, even under the most extreme conditions. Let's explore how these batteries function and their potential benefits for modern applications.

Tests conducted on these batteries often involve harsh treatment, such as deliberate perforation using nails or firearms. The results consistently prove the remarkable resilience of NHBs, as there's no explosion, fire, or material ejection—even in cases of hypervelocity impact. The surface temperature remains at a manageable 44 degrees Celsius (112 degrees Fahrenheit) and the pressure and voltage rapidly dissipate, preventing any catastrophic rupture.

Unlike common lithium-ion batteries, NHBs do not develop dendrites, which are tiny metal structures that build upon anodes during charging and can cause short circuits or other failures. This means the batteries can go through approximately 30,000 cycles—or around 30 years of daily use—without compromising their integrity, making them a low-maintenance solution for long-term energy storage.

The battery's chemical makeup is mainly hydrogen and water, meaning they're also environmentally friendly. Additionally, their manufacturing process is straightforward and uses abundant elements, nickel, and hydrogen, thus easing supply chain and cost issues.

Old Tech is New Again

So why is this legacy battery design now relevant again? And why have NHBs and their potential applications been overlooked until now?

Well, despite a 250 percent surge in nickel prices in 2022, the low-maintenance nature and longevity of these batteries potentially save substantial operational costs, particularly for renewable energy storage facilities. Also, when the time comes for disposal, these batteries are almost 100 percent recyclable. But the real reason these legacy batteries have been dormant is cost. Sky high cost! 

But that all might soon change. EnerVenue, a California-based company specializing in energy storage solutions, has embarked on a large grid-scale gigawatt storage facility that will be located in Kentucky and will seek to capitalize on all the potential upsides of using NHBs.

EnerVenue feels that, like the proven technology used by NASA for more than 30 years, their Energy Storage Vessels™ (ESVs) feature an exceptionally long lifespan, eliminating the need for augmentation or oversizing. ESVs can be easily mounted in racks, containers, or stacked in custom warehousing. Their unique chemistry eliminates the need for preventative fire suppression. They can also reliably operate in a wide ambient temperature range without supplementary HVAC. ESVs dramatically reduce operating expenses and feature a much lower cost-per-cycle compared to lithium-ion chemistries.

3/30/30,000: Energy Storage Vessels can cycle up to 3 times per day without rest and boast an expected lifetime of 30 years / 30,000 cycles – enabling unique applications and business models for developers, integrators, and owners. - EnerVenue

The company is addressing the astronomical cost problem primarily by utilizing economies of scale and mass production of their ESVs. These batteries are still pricey, but EnerVenue’s large "gigafactory"—and potential future ones like it—will make them more affordable by eliminating the need for custom designs. By the end of 2023, EnerVenue expects the gigafactory to begin production.

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Irrespective of the specific battery design, converting potential energy into electrical energy necessitates the implementation of a resilient and high-efficiency Battery Management System (BMS). This week's New Tech Tuesday highlights the introduction of BMS solution devices by Vishay / Dale and Nexperia.

The HV Intelligent Battery Shunt HV-IBSS-USB from Vishay / Dale is a reference design made to easily evaluate the low Temperature Coefficient of Resistance (TCR) of shunt WSBE8518. It uses a single USB-C connector to provide power to the circuit and to emulate a serial interface so engineers can conveniently make voltage, current, and temperature readings.

Due to the low TCR of the WSBE8518 (maximum ± 10ppm/K for 100μΩ) alongside the choice of low thermal drift components in the analog frontend, this reference design can achieve an overall TCR of approximately 44ppm/K max. without thermal compensation over the whole temperature range. The device is factory calibrated (values stored in onboard EEprom) to allow for current measurements with 0.2 percent and thermal drift for currents in the range of ±500A.

The TCR is a crucial parameter in current sensing measurements, especially in applications like BMS that involve monitoring and managing current flow in various components, including battery shunts. TCR indicates how a material's electrical resistance changes with changes in temperature. It's expressed as a fractional change in resistance per degree Celsius change in temperature (ΔR/R0 per °C), usually in parts per million per degree Celsius (ppm/°C).

In BMS, TCR plays a significant role for several reasons, including the precise measurement of current flowing into and out of the battery, as well as throughout the battery system. This is essential for monitoring the state of charge (SoC) and state of health (SoH) of the battery. TCR helps compensate for changes in resistance due to temperature variations, allowing for more accurate and consistent current measurements. Additionally, accurate current measurements enable the BMS to detect anomalies and potentially hazardous conditions like overcurrent situations, which can lead to thermal runaway or other safety risks. By compensating for temperature effects, the BMS can respond appropriately to changes in current flow, enhancing the overall safety and efficiency of the battery system.

Nexperia eMode GaN FETs offer a voltage range of 100V to 650V and superior ultra-high frequency switching performance. These general-purpose enhancement mode (eMode) Gallium Nitride Field-Effect Transistors (GaN FETs) deliver fast transition and switching capability with minimal conduction and switching losses.

Enhancement mode FETs are "normally-off," meaning that by default, the transistor is in an "off" state until a specific voltage to its gate terminal is applied, activating the transistor and letting current flow. This type of GaN FET is commonly used in power electronics because it's safer and more predictable—if there's no voltage applied, it stays off, reducing the risk of accidental current flow.

These power FETS are available in a DFN 8mm x 8mm surface mount package. Applications include high power density and high-efficiency power conversion, AC-to-DC and DC-to-DC converters, fast battery charging, and motor drives. For 650V and ≤ 150V industrial and consumer applications, Nexperia e-Mode GaN FETs provide the balance between switching performance and robustness.

Tuesday’s Takeaway

Nickel-hydrogen batteries, despite being old technology, continue to prove their worth, especially in the renewable energy sector. Although their initial cost is high due to the use of expensive metals, advancements in mass production and the potential for cost-saving through their durability and longevity make them an attractive option as energy storage vessels for companies like EnerVenue. As we gear towards more sustainable energy solutions, it's crucial to revisit and optimize tried-and-true technologies like NHBs, which have been quietly powering our space missions for decades.

In the realm of battery management, Vishay / Dale and Nexperia present solutions like the HV Intelligent Battery Shunt, which leverages TCR technology for current sensing measurements to ensure accurate current monitoring while enhancing battery safety and efficiency. Nexperia’s eMode GaN FETs represent a safer and more predictable option in high-power density electronics, designed to remain off until activated, thereby reducing the risk of unintended current flow. These FETs offer efficient power conversion in various applications, showcasing a balance between switching performance and robustness.

Innovation continues to merge lessons from NASA's legacy technology with modern applications, providing solutions that bridge the gap between reliability, sustainability, and efficiency in energy storage and management.

Original Source: Mouser

About the Author

Rudy is a member of the Technical Content Marketing team at Mouser Electronics, bringing 35+ years of expertise in advanced electromechanical systems, robotics, pneumatics, vacuum systems, high voltage, semiconductor manufacturing, military hardware, and project management. As a technology subject matter expert, Rudy supports global marketing efforts through his extensive product knowledge and by creating and editing technical content for Mouser's website. Rudy has authored technical articles appearing in engineering websites and holds a BS in Technical Management and an MBA with a concentration in Project Management. Prior to Mouser, Rudy worked for National Semiconductor and Texas Instruments.

If you are an electronics enthusiast, want to learn the basics of electronics, and improve your basics with some practicals and hands-on projects, then this article is for you. In this article, we are going to look at the top 10 mini-projects that you can build very easily and can help you understand the function and workings of different electronic components.

1. DIY Smart Electronic Candle using LDR

Ordinary candles work fine but they melt away pretty fast making the place nasty, and at times if unattended, it can also lead to fire hazards. This DIY Smart Electronic Candle utilizes an LDR (Light Dependent Resistor) and an LM358 IC to create a flameless candle. When darkness falls, the LDR's resistance increases, triggering the LM358 IC, which, in turn, lights up an LED, mimicking the glow of a real candle. The circuit is calibrated using a potentiometer to adjust sensitivity, ensuring it activates in low-light conditions. Powered by a low-voltage source such as a lithium battery, this project provides a safe and aesthetically pleasing alternative to traditional candles, perfect for decorative or ambient lighting purposes.

Link: DIY Smart Electronic Candle using LDR

2. Fridge Door Alarm Circuit using 555 and LDR

This fridge Door Alarm Circuit is a good solution that will inform the user about the door in prolonged open. This circuit triggers the alarm if the door of the Fridge is left open for a long time. 

As soon as we open the Door of the refrigerator, LDR senses it and starts the countdown using the 555 Timer, and after a preset time, the buzzers start beeping as an alarm signal.

Link: Fridge Door Alarm Circuit using 555 and LDR

3. 555 Timer Based Electronic Code Lock Circuit

The 555 Timer Electronic Code Lock Circuit is a digital security system that requires pressing specific four buttons simultaneously to unlock. Utilizing a 555 IC in monostable mode, it operates without a microcontroller. When the correct combination is entered, an LED stays on for around 5 seconds, indicating access. With 8 buttons, the lock offers 40,000 unique combinations, enhancing security. The system's simplicity lies in its straightforward design and lack of complex electronics, making it an efficient and accessible solution for digital code-based locks.

Link: 555 Timer Based Electronic Code Lock Circuit

4. Clap Switch

The Clap Switch project is an ingenious electronic circuit that turns on a light or device in response to a clap sound. Utilizing an electric condenser microphone as a sound sensor, the circuit translates the sound energy into electrical signals. When a clap or similar sound is detected, the microphone triggers a transistor, activating a 555 timer IC. The IC, in turn, illuminates an LED for a specific duration before automatically switching it off.

Link: Clap Switch

5. Fire Alarm using Thermistor

The Fire Alarm using Thermistor project presents a simple yet effective fire detection system. It utilizes a Thermistor, NPN transistor, and a 555 Timer IC to sense temperature changes indicative of a fire. When the Thermistor detects a rise in temperature, its resistance decreases, triggering the transistor to turn off. This action activates the 555 Timer IC, which generates an oscillating signal to drive a buzzer. The circuit's sensitivity is adjustable using a variable resistor. 

Link: Fire Alarm using Thermistor

6. Simple Battery Level Indicator using Op-amp

The "Simple Battery Level Indicator using Op-amp" project is a straightforward and effective solution for monitoring 12V batteries. Leveraging the LM324 Quad Op-amp IC, it employs a reference voltage system with Zener diodes and resistors to establish specific voltage thresholds. When compared to the battery voltage, LEDs light up to indicate the charge level, eliminating the need for complex calculations. Its simplicity and cost-efficiency make it suitable for diverse applications, such as portable electronics and automotive systems.

Link: Simple Battery Level Indicator using Op-amp

7. Solar Powered Cell Phone Charger Circuit:

The "Solar Powered Cell Phone Charger Circuit" project offers a practical solution for charging mobile phones using solar energy. It utilizes three 5.5V 245mA Monocrystalline solar panels connected in parallel to provide a stable 5.5V and 735mA output. A 5V Boost Converter ensures constant voltage, and a switch controls the charging process. The circuit's efficiency was confirmed using the "Ampere" app, demonstrating its effectiveness in charging a mobile phone even under varying solar radiation.

Link:  Solar Powered Cell Phone Charger Circuit

8. DIY Musical Doorbell Circuit using UM66T

The "DIY Musical Doorbell Circuit using UM66T" project empowers enthusiasts to create a musical doorbell with minimal components, including UM66T-19L Melody Generator IC, transistors, resistors, and a speaker. This accessible tutorial guides users through assembling the circuit, utilizing a time delay feature to control the musical tone duration upon button press. The UM66T IC, operating between 1.5V to 4.5V, generates specific tunes when triggered. Transistors amplify the IC's output before reaching the 8-ohm speaker, ensuring audibility.

Link: DIY Musical Doorbell Circuit using UM66T

9. DIY Foam Cutter Using the IRF540N MOSFET

The "DIY Foam Cutter Using the IRF540N MOSFET" project introduces a portable hot wire foam cutting tool designed for crafters and hobbyists working with Styrofoam and polystyrene. Utilizing Nichrome wire and an IRF540N MOSFET, this DIY tool offers precise control over heat, enabling intricate designs and models. The circuit features a 2S 3A Battery Protection BMS for efficient power management and longer battery life. A 3D-printed case houses the components, ensuring portability and durability. With adjustable heat settings through a 100KΩ potentiometer, users can tailor the tool to their specific needs.

Link: DIY Foam Cutter Using the IRF540N MOSFET

10. Simple Wireless Power Transmission Circuit to Glow an LED

The "Simple Wireless Power Transmission Circuit to Glow an LED" project illustrates wireless electricity transfer principles using a transmitter and receiver setup. Utilizing coils and a transistor, the transmitter generates a high-frequency electromagnetic field. The receiver captures this field's energy and illuminates an LED without physical connections. While limited in power, the project showcases fundamental wireless energy transfer concepts.

Link: Simple Wireless Power Transmission Circuit to Glow an LED

Lithium battery systems are increasingly moving to higher capacity and increased voltage levels as the trend toward electrifying mobility, tools, and industrial equipment continues. Though excellent for enhanced mobility and productivity, these higher battery cell counts and voltage levels mean that battery management system (BMS) technology needs to advance to accommodate this trend. Given the complexity, increased cost, and safety requirements of the latest electrified devices and equipment, BMS must also have greater capability and features for enhanced communication functions, fuel gauging, cell balancing, timing, and accommodating various lithium battery chemistries.

Primer On Lithium Battery Technology

Lithium batteries are energy storage devices stored within chemicals that are trapped in battery cells with a positive electrode (cathode) and a negative electrode (anode). Lithium-ion batteries are based on materials with layered crystalline structures where the lithium ions can migrate between layers, known as intercalation compounds. The discharge cycle of a lithium-ion battery sees the lithium ions migrate from the anode to the cathode, which induces electrons to move in an opposing direction from the cathode to the anode. This allows for energy transfer for the battery's terminals and the electrical load. The voltage level and current output at the lithium battery terminals depend on the number of lithium ions that are migrating. When voltage levels begin to sag, the current is reduced, as the number of lithium ions available to migrate decreases.

The charge cycle of a lithium battery works in the opposite way, where inducing a voltage at the terminals of the lithium battery causes the lithium ions to reverse their migration across the electrolyte and re-embed within the negative electrode. Modern lithium batteries can be made of a variety of different intercalation compounds for the cathode, the most common being lithium-ion (li-ion), lithium-ion polymer (LiPo), and lithium iron phosphate (LiFePO4). The negative electrode of lithium batteries is often graphite. However, ongoing experimentation and efforts exist to develop higher performing batteries using various anode, cathode, and electrolyte materials and technologies.

Given the highly reactive nature of lithium batteries, it is necessary to monitor the batteries' temperature, current, and voltage characteristics during charging and discharging. Without proper battery monitoring and control, a lithium battery cell, even if it is made of "safer" or more stable lithium compounds, may reach a state of thermal runaway. This runaway could cause damage to the cell electrodes or housing, possibly leading to an uncontrolled chemical reaction where the battery cells could catch fire or even explode.

Many lithium battery systems are composed of several lithium battery cells in series to reach higher voltage levels and in parallel to achieve higher current output levels. Given the tolerances in fabrication, inconsistent aging of lithium batteries, and many other factors, the discrepancies between the battery voltage and current characteristics can result in several possible performance degradations or battery damaging conditions. For instance, if a battery cell is in series or parallel to other lithium battery cells and isn’t performing to specification, that cell may act as a load. This results in the degraded battery drawing current, while the voltage of the other cells may be reduced below a safe threshold.

These discrepancies are why cell balancing technology is critical in lithium batteries with more than one cell. Systems that incorporate battery monitoring, control, and cell balancing are commonly known as battery management systems (BMS). As lithium battery technology has advanced and become more widely used, BMS technology has also advanced to ensure greater safety, performance, and longevity for lithium battery systems (Figure 1).

Trends in New Lithium Battery Systems

For many power garden tools, construction tools, mobility, and industrial equipment, gasoline and corded electric systems have dominated the markets for over a century. However, the developments in lithium battery technology have led to the transcendence of electric battery-powered tools for everything from mobility to equipment to everyday necessities. Examples include battery electric string trimmers, blowers, chainsaws, SDS drills, scooters, e-bikes, motorcycles/mopeds, concrete saws, and portable welders. These battery electric systems are commonly made with 20V, 40V, 60V, and 80V, with higher voltage levels likely becoming popular.

The success of battery-operated tools and mobility systems naturally results in even higher performance, which necessitates increasing the voltage levels, capacity, and current capability of the lithium battery systems powering these devices. Due to lithium technology's cell voltage level limits, increasing the number of cells in series is the only way to reach higher voltage levels. Drawing too much current from or dumping too much current into a lithium cell can result in cell damage and catastrophic failure. Increasing the current output/input capability will increase the number of lithium cells in parallel. Therefore, enhancing the overall capacity of a lithium battery system may require even greater numbers of parallel series of cells or much higher capacity lithium battery cells.

Intelligent BMS Step Up to Meet the Challenge of Modern Lithium Battery Systems

Given that lithium battery systems are being developed to push the performance of battery electric systems for various applications—from electric vehicles (EVs) and electric backup generators to autonomous mobile robots—BMS technologies must also advance to accommodate these new higher voltage levels, capacity, and current input/output battery systems.

Qorvo's intelligent BMS (PAC22140/PAC25140), with an integrated microcontroller unit (MCU) and cell balancing technology (Figure 2), is a natural evolution of simple BMS that merely monitored the battery and shut off charging when either temperature or voltage levels reached unacceptable thresholds. These new BMS chips can monitor 10-series (10S) to 20S li-Ion, Li-Polymer, and LiFePO4 battery packs, including the most common lithium battery technologies. Qorvo’s new BMS include a FLASH-programmable MCU (Arm® Cortex®-M0) with power management, current/voltage/temperature sense, drive circuits for charge/discharge FETs, and protection fuses. Moreover, these intelligent BMS also include built-in UART/SPI, I2C/SMBus, and even CAN communication on some units.

Since it is essential to evaluate new BMS chips and familiarize oneself with their programming and control aspects, Qorvo provides an evaluation kit (PAC22140EVK1 and PAC225140EVK1) for these chips.

These evaluation kits are complete hardware solutions for evaluating the new intelligent BMS devices and also enable solution development with access to all of the device's signals and all the necessary circuitry to energize the MCU and internal peripherals (Figure 3).

Conclusion

The growth in popularity and utility of lithium battery electric systems has pushed the boundaries on voltage, capacity, and current capability. With greater series cell counts and higher user performance expectations, these new battery electric systems must be appropriately managed and cell-balanced with the latest intelligent BMS technology. Qorvo's new intelligent BMS technologies aid in developing new BMS solutions that augment present lithium battery technology with more efficient cell balancing, monitoring, and protection features.

Original Source: Mouser

About the Author

Principal of Information Exchange Services: Jean-Jacques DeLisle Jean-Jacques (JJ) DeLisle attended the Rochester Institute of Technology, where he graduated with a BS and MS degree in Electrical Engineering. While studying, JJ pursued RF/microwave research, wrote for the university magazine, and was a member of the first improvisational comedy troupe @ RIT. Before completing his degree, JJ contracted as an IC layout and automated test design engineer for Synaptics Inc. After 6 years of original research—developing and characterizing intra-coaxial antennas and wireless sensor technology—JJ left RIT with several submitted technical papers and a US patent.

Further pursuing his career, JJ moved with his wife, Aalyia, to New York City. Here, he took on work as the Technical Engineering Editor for Microwaves & RF magazine. At the magazine, JJ learned how to merge his skills and passion for RF engineering and technical writing.

In the next phase of JJ’s career, he moved on to start his company, RFEMX, seeing a significant need in the industry for technically competent writers and objective industry experts. Progressing with that aim, JJ expanded his companies scope and vision and started Information Exchange Services (IXS).