Modular rack battery pack charger for a launch vehicle

A rack system with a controller managing up to five charger modules, each able to charge two batteries. System design, mechanical and electronic development, support to integration and AIT.

Controller front panel: operating touchscreen, emergency stop and forced ventilation
Charger module front panel: for each of the two batteries, charge and discharge status, fault and independent emergency disconnect
Charge curve logged by the operating software: pack voltage against time over a cycle of about ten hours
Assembled charging rack: six stacked modules, each with two independent channels, with battery packs in position and the connecting harness

A charging system for a launch vehicle's on-board battery packs, built as a controller with touchscreen and emergency stop plus independent charger modules: the controller manages up to five, and each module charges two batteries, for a maximum of ten packs followed at once.

The controller front panel carries the bus output, Ethernet, RCBO protection and per-module isolators; the module carries instrumentation, charge and discharge controls and emergency disconnect for each of its two batteries, because on a pack under charge a fault must be isolated individually rather than by stopping the installation.

The operating software logs and plots the charge curve per pack, producing the trace that makes charging a documented operation rather than a wait. IN SY TO held system responsibility.

Role

R1 — System responsible. Scale: cabinet, new build, modular architecture. Customer: the prime contractor of a European launch vehicle.

Work performed

  • System design
  • Rack mechanical and electronic development
  • Support to integration and AIT activities

Sector

Space