{"id":51499,"date":"2018-06-25T15:02:41","date_gmt":"2018-06-25T15:02:41","guid":{"rendered":"https:\/\/one.sightlinemg.com\/defensenews\/uncategorized\/2018\/06\/25\/new-batteries-from-dod-agency-boosts-performance-safety-for-military-weapons-systems\/"},"modified":"2026-08-07T23:43:48","modified_gmt":"2026-08-07T23:43:48","slug":"new-batteries-from-dod-agency-boosts-performance-safety-for-military-weapons-systems","status":"publish","type":"post","link":"https:\/\/one.sightlinemg.com\/defensenews\/commentary\/2018\/06\/25\/new-batteries-from-dod-agency-boosts-performance-safety-for-military-weapons-systems\/","title":{"rendered":"New batteries from DoD agency boosts performance, safety for \r\nmilitary weapons systems"},"content":{"rendered":"\n

Some key military weapons systems are being updated with new power sources as a result of Defense Logistics Agency partnerships with Army industrial sites and battery manufacturers.<\/p>\n\n\n\n

Engineers from DLA\u2019s Battery Network research and development program are working on the development of a new lithium ion-based power system for the TOW 2 anti-tank missile system and new lead-acid batteries used on armored vehicles such as the Bradley Fighting Vehicle.<\/p>\n\n\n\n

Lead-acid batteries currently used in the 4HN and 2HN configurations were common in the 1950s and 1960s to keep cars running, said Matt Hutchens, an industrial engineer who leads the BATTNET program.<\/p>\n\n\n\n

Download the \u201dMilitary Logistics\u201d e-book for free.<\/a><\/b>
<\/p>\n\n\n\n

They require users to deal with the messy and potentially dangerous task of opening the cells and refilling them with acid.<\/p>\n\n\n\n

Today they have been replaced with safer, more powerful alternatives.<\/p>\n\n\n\n

\u201cIndustry got away from what\u2019s called a liquid electrolyte and moved to a gel or glasslike material that\u2019s solid. It actually lengthens the life of the battery and takes away the hazardous issues of dealing with acid. They also charge quicker, hold the charge longer and have fewer issues in terms of disposal,\u201d he said.<\/p>\n\n\n\n

In 2017, the U.S. Army Tank Automotive Research, Development and Engineering Center reached out to DLA inquiring if it was possible for the 4HN and 2HN batteries to be replaced with ones made with new absorbent glass material.<\/p>\n\n\n\n

\u201cPart of the problem was we couldn\u2019t find any of the big producers of lead-acid batteries that wanted to fool with these military-unique batteries that DLA buys only 1,000-2,000 of a year,\u201d he said.<\/p>\n\n\n\n

The interest from the Army spurred DLA to search for such a manufacturer. Hutchens found a company that produces green lead-acid batteries and owns some of the original patents for a glasslike material that has become an industry standard. Earlier this year, DLA awarded the company a contract to engineer, design and assemble new 4HN and 2HN lead-acid batteries that DLA can procure.<\/p>\n\n\n\n

The project will be executed in two-phases, beginning with the production of 10 handmade prototypes that will be tested by TARDEC. Once the design and prototypes are approved, the contractor will provide 10 batteries built on its production line for TARDEC qualification.<\/p>\n\n\n\n

The BATTNET program is also behind major improvements in the battery used to power the TOW 2 anti-tank missile system. The current battery is comprised of a nickel cadmium assembly with a detached charging system that was designed in the 1970s and failed to meet war fighters\u2019 performance goals.<\/p>\n\n\n\n

\u201cThe customer wasn\u2019t happy with the number of missile firings they were getting. Ideally, they wanted to get over 90 missile firings, either live or simulated, in one charge. They weren\u2019t getting anywhere near that, and it takes time to recharge the batteries,\u201d Hutchens said.<\/p>\n\n\n\n

DLA partnered with U.S. Army Aviation and Missile Command and a design team starting in October 2016. After more than a year of tests and design improvements, a new lithium-ion based power system is expected to be in production this year.<\/p>\n\n\n\n

The new system has several benefits, including a reduction in weight by about 120 pounds and potential procurement savings of $8 million a year.<\/p>\n\n\n\n

\u201cOne of the things we were able to do was consolidate all the electronics that you need for charging management into the existing battery format. So the old charger went away, the power conditioner went away and the battery for the night vision sight went away,\u201d he added.<\/p>\n\n\n\n

The customer wanted to maintain the battery box\u2019s size so it could slide into the current guidance system. The customer also recognized during the project\u2019s initial stages that the box was large enough to hold two BB-2590 lithium-ion batteries. Two BB-2590s could meet all the power requirements of the missile guidance system and the night vision sight.<\/p>\n\n\n\n

\u201cThe BB-2590 is a standard-issue battery that\u2019s already qualified and used in a lot of different systems run by the Army and Marine Corps. It\u2019s one of our major logistics items, and DLA has multiple qualified suppliers,\u201d Hutchens said. \u201cThe new design can also use two BA-5590 non-rechargeable batteries if necessary.\u201d<\/p>\n\n\n\n

DLA\u2019s BATTNET program was created in 2010 to address sustainment problems, improve manufacturing capabilities and bring new manufacturing technologies to DLA\u2019s supply chain. By investing time and funds in the research and development of batteries, it helps the agency provide better products to customers and it benefits the military services, which usually put their money toward new equipment rather than solving sustainment problems.<\/p>\n\n\n\n

\u201cDLA R&D doesn\u2019t design a new weapon system or its components,\u201d Hutchens said. \u201cWe\u2019re just looking at existing components and saying: \u2018What kind of problems are we seeing? And are there some things we could work with the services to solve?\u2019 That frees up their money for more critical needs.\u201d<\/p>\n\n\n\n

Beth Reece is with the U.S. Defense Logistics Agency.<\/i><\/p>\n","protected":false},"excerpt":{"rendered":"

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