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SION Power and Continental Controls Team in Historic Unmanned Aerial System Flight

Posted on: Friday, 3 March 2006, 12:00 CST

On Feb. 15, 2006, SION Power's lithium sulfur batteries provided the power for an autonomous Unmanned Aerial System (UAS) flight. The electronics and software for the UAS were developed by Continental Controls of Santa Ana, Calif., and installed in a plane designed and built by Dale Tower. This was the first continuous autonomous UAS flight using SION Power lithium sulfur batteries.

The batteries were made by SION using 350 WH/Kg, 2.2 Ah lithium sulfur rechargeable cells. The 12 cell parallel-connected packs were also designed and built by SION Power. These three packs were positioned in the plane to control the center of gravity. Connected in series, the three packs provided the required voltage and power both for the motor and for all other on-board electronics. The entire battery pack weighed less than 600 grams with a total capacity of 190 watt-hours.

SION Power has supplied numerous cells and batteries to UAS manufacturers for bench testing. This was the first long duration, autonomous flight utilizing this new revolutionary and proprietary battery chemistry.

The autonomous guidance, navigation and flight control was enabled by Continental Controls Tiny Guidance Engine (TGE) autopilot. Currently the smallest autopilot on the market, the TGE was supported by a comprehensive Ground Control Station that allows UAS system control, path planning and telemetry recording.

Designed to be ultra-lightweight, the plane had a 110-inch wingspan and a total mass of 635 grams excluding batteries.

The initial goal of the flight was to achieve a 20-hour autonomous flight utilizing a 4 waypoint flight plan. The plane was hand launched and flown for six minutes under manual control. Following take off, all flight controls were transferred to the Tiny Guidance Engine autopilot, designed and manufactured by Continental Controls. The UAS immediately assumed an autonomous flight path uploaded to it from the Ground Control Station. Flight conditions were good with a 15 to 20 knot wind. The UAS flew at 400 feet for more than 60 minutes before a sensor malfunction prematurely terminated the flight.

"It was very exciting to see SION's batteries in action," said Mark Jost, executive vice president, marketing for SION Power. "We are already looking forward to the next flight utilizing our lithium sulfur battery technology in conjunction with Continental Controls excellent flight control technology."

Jim Hynes, Continental Controls Inc. president, stated, "We were exceptionally pleased with the operation of our system during this flight. Our goal is to fly a UAS autonomously using our control electronics and software for 24 hours on a single battery charge."

This was the first of many flights planned by the two companies. New SION Power batteries and control systems by Continental Controls are being readied for the next flight.

SION Power Corp., an innovative battery company headquartered in Tucson, Ariz., is creating a new class of electrochemical energy storage products based on proprietary lithium sulfur (Li-S) rechargeable battery chemistry. SION Power holds 66 patents related to this new battery. The company has 50 employees, including 11 Ph.D.s, and is dedicated to true "Next Generation" technology. For additional information, please contact Mark Jost at 520-799-7643 or via e-mail at mark.jost@sionpower.com.

Continental Controls and Design Inc., a leader in guidance, navigation and control technology located in Huntington Beach, Calif., designs, sells, and supports rapid response innovative solutions for mini and micro UAV applications. CCD's core product is the Tiny Guidance Engine autopilot, which has been integrated into everything from 12-inch MAVs to air-launched guided munitions. For additional information, please contact Matt Ryan at 949-290-8210 or via e-mail at matthew.ryan@continentalctrls.com.

Source: Business Wire

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