Development of a multiplexed bypass control system for aerospace batteries

A breadboard bypass control system was developed to control a battery comprised of 26 JPL-developed negative limited Ni-Cd cells. The system was designed to automatically remove cells from the circuit when their voltages exceeded a fixed limit on charge and fell below a fixed limit on discharge. Major components of the system consisted of a cell voltage monitor, a multiplexing circuit, and individual electromechanical relays for each cell. The system was found to function well in controlling the battery during a simulated 10-month MM-71 mission and a 2-month simulated low earth orbit cycling mission. A flight version of the bypass system was estimated to have a total parts count of 150 and total weight of 1.63 kg. When fully developed, the system shows promise for improving life and reliability of spacecraft batteries.