Engineering topics

Luis R Pinero

Publications and source records attributed to Luis R Pinero.

3 records

NASA NTRSDate not supplied

The NEXT-C Power Processing Unit: Lessons Learned from the Design, Build, and Test of the NEXT-C PPU for APL's DART Mission

NASA’s Double Asteroid Redirection Test (DART) will be the first-ever planetary defense mission to demonstrate asteroid deflection using kinetic impactor technology. The DART spacecraft will utilize the NASA Evolutionary Xenon Thruster (NEXT), which is a successor to the NSTAR ion propulsion system that successfully propelled NASA’s Deep Space 1 and Dawn spacecraft. In 2015, NASA partnered with Aerojet Rocketdyne and ZIN Technologies on the NEXT-Commercial (NEXT-C) effort to manufacture a Flight-Qualified (TRL 8) power processing unit (PPU). The NEXT-C PPU was based on the heritage gridded ion thruster PPU from NSTAR and NEXT, but with significant improvements in performance and manufacturability. The design goals of the NEXT-C PPU were to achieve the technical performance goals of the PPU in size, mass, and efficiency over a wide range of input voltage and output power. This paper discusses the lessons learned from the design, build, and test of the NEXT-C PPU, and how challenges were overcome to deliver a Flight PPU.

NEXT-C↗

NASA NTRSDate not supplied

Investigation of Rectifier Diode Failures in the NEXT-C Power Processing Unit

NASA's Evolutionary Xenon Thruster-Commercial (NEXT-C) project is tasked with developing flight electric propulsion systems, including both thrusters and power processing units (PPUs). In 2018, the beam supply in a NEXT-C engineering prototype PPU experienced an output rectifier diode failure during development thermal-vacuum testing. A failure investigation led by NASA GRC identified the root cause of the failure as a thermal runaway caused by increased reverse recovery losses in the diodes when the PPU was run at its maximum operating temperature. Significant reverse recovery performance variations were identified in diodes with the same part number but manufactured by different vendors. The failure investigation was able to collect evidence of the increased reverse recovery and replicate the diode failures in a controlled laboratory environment.

George L Thomas↗

NASA NTRSDate not supplied

Sub-kW Class Hall-Effect Thruster Power Processing Unit for Wide Output Range Applications

The National Aeronautics and Space Administration (NASA) Small Spacecraft Electric Propulsion (SSEP) project is maturing high-propellant throughput sub-kilowatt Hall-effect thruster technologies to enable small spacecraft deep space science and exploration missions with high delta-v requirements. In support of this effort, development of a power processing unit (PPU) capable of providing discharge power of up to 1 kW continues to be pursued at the NASA Glenn Research Center (GRC). Previous reported work included a successful integrated test of a scalable, modular breadboard discharge power supply with the NASA-H64M laboratory model Hall-effect thruster and presentation of notional designs for the various auxiliary power supplies needed for thruster operation. Since that time, auxiliary power supply designs have been completed and fabricated, with the cathode heater and keeper power supplies being successfully tested with a hollow cathode assembly (HCA) in the NASA GRC Vacuum Facility 56 (VF-56). The desire for a lower mass, higher efficiency, and more versatile PPU to maximize performance of power and mass-limited small spacecraft has led to the exploration of a discharge power supply based on a series-parallel (LCC) resonant topology. This topology has enabled the discharge power supply to operate over a wider output range at switching frequencies 4-5 times higher than previous design iterations. Simulation models of the topology have been developed and a breadboard of the topology has been fabricated and evaluated on both resistive loads and an integrated Hall thruster test. This paper will present collected performance and integrated test data from both the fabricated auxiliary and resonant discharge power supplies. Advantages of the resonant converter architecture over more traditional pulse-width modulated (PWM) techniques in Hall-effect thruster discharge power supply applications will also be described.

electric propulsion↗