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A -- LITHIUM-BASED, POLYMER ELECTROLYTE REGENERATIVE BATTERY SYSTEM FOR THE BANTAM REUSABLE LAUNCH VEHICLE (RLV) SOL RFP3-129006 DUE 010700 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#RFP3-1290 06. E-MAIL: Gary A. Golinski, Gary.A.Golinski@grc.nasa.gov. This is a modification to the synopsis entitled Lithium-Based, Polymer Electrolyte Regenerative Battery System the Bantam Reusable Launch Vehicle (RLV)for SOLICITATION NO. RFP3-129006 which was posted on 12/6/99. You are notified that the following changes are made: The Statement of Work entitled, "Bantam Statement of Work (9/9/99)" is hereby replaced by the following Statement of Work entitled, "Lithium Based Battery Statement of Work (11/19/99)". LITHIUM-BASED BATTERY STATEMENT OF WORK (11/19/99) Background The purpose of this procurement 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 a small reusable launch vehicle (RLV). This vehicle is intended to demonstrate mission-enabling technologies for RLVs by carrying out multiple low-cost, rapid turnaround orbital missions. An all-electric on-board system providing energy for all requirements, including electromechanical flight control actuators is envisioned. Technology efforts under this procurement 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 system that will contribute significantly toward the achievement of the RLV cost and performance goals. These goals include: cost per launch of $1million; 200 pound (91 kg) payload; 24 launches per year per vehicle; and vehicle life of 100 flights. Objective An important objective of this program is to confirm that the lithium-based, polymer electrolyte battery possesses weight, volume, durability and performance characteristics that will contribute significantly to vehicle goals. Equally important is to verify that the battery can be designed as part of an integrated system that will provide significant reductions in cost for hardware, operations and maintenance. A Demonstration Unit is required that will 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; and (3) a "universal" interface for the battery set that provides simple connection either to the ground-based control and protection system, or to a simulated flight vehicle main bus and data acquisition/health monitoring system. A final objective is to demonstrate, by battery flight qualification tests, that the battery structural design 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. Design and evaluation of Demonstration Unit battery. 5. Design and preliminary evaluation of electronic charge/discharge control and cell protection system. 6. Design and integration of battery system electrical interface. 7. Performance evaluation of the Demonstration Unit. 8. Design and qualification of flight battery. 9. 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 review by RLV Project personnel at the NASA Marshall Space Flight Center. Contractor shall acquire the most recent information that will ultimately influence the 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 project goal of multiple low-cost, rapid turnaround orbital missions 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 cost for the flight batteries, the ground service equipment, and for maintenance and operations. Task 3. Demonstration Unit Definition 3.1 Consistent with the data acquired in Task 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. The definition shall include an appropriate mission power profile, typifying Demonstration Unit requirements in the context of the RLV requirements. Task 4. Battery Design and Evaluation 4.1 Based on the definitions of 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. 4.2 Battery design shall conform not only to the capacity and performance requirements of 3.1 and the performance capability of the chosen cell technology measured in 4.1,, but also the requirements imposed by 2.1, the overall system concept. Other design considerations shall include temperature 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 and connector(s) that provides connection to an electrical interface for mating 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 6). 4.3 Based on the battery design of 4.2, 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. 4.4 Battery structural and interface components shall be fabricated, and battery assembly shall be completed by incorporating cells based on the design validated in 4.3. 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. 4.5 Upon successful testing of the prototype battery, fabrication and characterization shall proceed for the remaining Demonstration Unit batteries. Task 5. Battery Control Unit Design and Preliminary Evaluation 5.1 Based upon the integrated battery/control system concept of 2.1, the Demonstration Unit requirements of 3.1 and the RLV project 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. The system 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. Task 6. Electrical Interface Design and Integration 6.1 In parallel with the design of the Demonstration Unit battery and control systems, the battery electrical interface shall be designed. The design shall permit easy connection of each battery to either the control system for charging and testing of the battery system, or to a simulated flight vehicle main bus and data acquisition/health monitoring system. 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. This Task is therefore primarily an integration effort, to coordinate the flow of information between the design groups. Task 7. Demonstration Unit Evaluation 7.1 Upon fabrication and check-out of the battery set, the system interface and the electronic charge/discharge control and cell protection system, 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 and data acquisition system 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 be carried out under the thermal conditions defined for the various mission segments Task 8. Design and Qualification of Flight Battery 8.1 To the extent necessary, the prototype battery design of 4.2 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. Task 9. Reporting 9.1 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. 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 or components (e.g.,TRL 5). Cell production facilities shall be in place and capable of producing cell components and complete cells of sufficient size and quantity to support this project and any subsequent follow-on. Stringent quality control practices and standards shall be adhered to. In the Proposal and the Schedule, Offerer shall specify review procedures for system definitions, system and component designs and test plans. These reviews may 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 tasks. In the Proposal, Offerer shall suggest test items and quantities to be delivered to NASA GRC for concurrent evaluation. Based on technical progress, project schedule and funding limitations, NASA may determine in the following instances that successful completion of the contract effort cannot reasonably be expected under the existing constraints, and that the contract effort shall be terminated: 1. Failure to reach single-cell performance goals. a) Generic goals: Specific energy > 125 wh/kg; energy density > 250 wh/l. b) Mission-specific goals: To be defined in Task 3.1 and evaluated in Task 4.1. 2. Failure to reach battery-level performance goals. a) Generic goals: Specific energy > 100 wh/kg; energy density >200 wh/l. b) Mission-specific goals: To be defined in Task3.1 and evaluated in Task 4.3. 3. Failure to develop either an electronic charge/discharge control and cell protection system or a battery electrical interface, together providing the intended simplicity of operation and minimal operations and maintenance requirements. Evaluated in Task 6.1. 4. Occurrence of unexpected cost centers that exceed available funds. COMMENTS ON THE STATEMENT OF WORK ARE WELCOMED. The due date for receipt of comments is not extended. Offerors are responsible for monitoring this site for the release of the solicitation and any amendments. Potential offerors are responsible for downloading their own copy of the solicitation and amendments (if any). [INSERT ANY APPLICABLE NOTES] Posted 12/06/99 (D-SN405992). (0340)

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