Engineering topics

Pinero, Luis R.

Publications and source records attributed to Pinero, Luis R..

At least 37 records · Page 2

NASA NTRS2006

Status of a Power Processor for the Prometheus-1 Electric Propulsion System

NASA is developing technologies for nuclear electric propulsion for proposed deep space missions in support of the Exploration initiative under Project Prometheus. Electrical power produced by the combination of a fission-based power source and a Brayton power conversion and distribution system is used by a high specific impulse ion propulsion system to propel the spaceship. The ion propulsion system include the thruster, power processor and propellant feed system. A power processor technology development effort was initiated under Project Prometheus to develop high performance and lightweight power-processing technologies suitable for the application. This effort faces multiple challenges including developing radiation hardened power modules and converters with very high power capability and efficiency to minimize the impact on the power conversion and distribution system as well as the heat rejection system. This paper documents the design and test results of the first version of the beam supply, the design of a second version of the beam supply and the design and test results of the ancillary supplies.

Pinero, Luis R.↗

NASA NTRS2005

Development of the NEXT Power Processing Unit

Boeing Electron Dynamic Devices, Inc. (EDD) has designed and fabricated a breadboard version of a 6 kW power processing unit (PPU) for gridded ion thrusters. This breadboard PPU will be integrated with an engineering model 40 cm ion engine designed and tested at NASA Glenn. The results of our tests using resistive loads are reported in this paper. The PPU demonstrated efficiencies to date are higher than 95 percent for the beam supply and higher than 92 percent for the discharge supply at full power. Overall PPU efficiency is greater than 94 percent at full throttle settings.

Phelps, Thomas K.↗

NASA NTRS2005

Power Processing for a Conceptual Project Prometheus Electric Propulsion System

NASA has proposed a bold mission to orbit and explore the moons of Jupiter. This mission, known as the Jupiter Icy Moons Orbiter (JIMO), would significantly increase NASA s capability to explore deep space by making use of high power electric propulsion. One electric propulsion option under study for JIMO is an ion propulsion system. An early version of an ion propulsion system was successfully used on NASA's Deep Space 1 mission. One concept for an ion thruster system capable of meeting the current JIMO mission requirement would have individual thrusters that are 16 to 25 kW each and require voltages as high as 8.0 kV. The purpose of this work is to develop power processing schemes for delivering the high voltage power to the spacecraft ion thrusters based upon a three-phase AC distribution system. In addition, a proposed DC-DC converter topology is presented for an ion thruster ancillary supply based upon a DC distribution system. All specifications discussed in this paper are for design convenience and are speculative in nature.

Scina, Joseph E., Jr.↗

NASA NTRS2005

Multi-Kilowatt Power Module for High-Power Hall Thrusters

Future NASA missions will require high-performance electric propulsion systems. Hall thrusters are being developed at NASA Glenn for high-power, high-specific impulse operation. These thrusters operate at power levels up to 50 kW of power and discharge voltages in excess of 600 V. A parallel effort is being conducted to develop power electronics for these thrusters that push the technology beyond the 5kW state-of-the-art power level. A 10 kW power module was designed to produce an output of 500 V and 20 A from a nominal 100 V input. Resistive load tests revealed efficiencies in excess of 96 percent. Load current share and phase synchronization circuits were designed and tested that will allow connecting multiple modules in parallel to process higher power.

Pinero, Luis R.↗

NASA NTRS2004

Multikilowatt Power Module Designed and Fabricated for High-Power Hall Thrusters

Previous efforts to develop power processing units (PPUs) for Hall thruster systems were targeted for the 1- to 5-kW power range and an output voltage of approximately 300 V. The NASA Glenn Research Center is developing new high-power Hall thrusters with a favorable combination of thrust, specific impulse, and efficiency to enable Earth-orbiting and Mars missions. These thrusters require up to 100 kW of power and a discharge voltage in excess of 800 V.

Pinero, Luis R.↗

NASA NTRS2002

High Performance Power Module for Hall Effect Thrusters

Previous efforts to develop power electronics for Hall thruster systems have targeted the 1 to 5 kW power range and an output voltage of approximately 300 V. New Hall thrusters are being developed for higher power, higher specific impulse, and multi-mode operation. These thrusters require up to 50 kW of power and a discharge voltage in excess of 600 V. Modular power supplies can process more power with higher efficiency at the expense of complexity. A 1 kW discharge power module was designed, built and integrated with a Hall thruster. The breadboard module has a power conversion efficiency in excess of 96 percent and weighs only 0.765 kg. This module will be used to develop a kW, multi-kW, and high voltage power processors.

Pinero, Luis R.↗

NASA NTRS2002

NASA's Hall Thruster Program 2002

The NASA Hall thruster program currently supports a number of tasks related to high power thruster development for a number of customers including the Energetics Program (formerly called the Space-based Program), the Space Solar Power Program, and the In-space Propulsion Program. In program year 2002, two tasks were central to the NASA Hall thruster program: 1) the development of a laboratory Hall thruster capable of providing high thrust at high power-, and 2) investigations into operation of Hall thrusters at high specific impulse. In addition to these two primary thruster development activities, there are a number of other on-going activities supported by the NASA Hall thruster program. These additional activities are related to issues such as high-power power processor architecture, thruster lifetime, and spacecraft integration.

Jankovsky, Robert S.↗

NASA NTRS2002

Design of a Modular 5-kW Power Processing Unit for the Next-Generation 40-cm Ion Engine

NASA Glenn Research Center is developing a 5/10-kW ion engine for a broad range of mission applications. Simultaneously, a 5-kW breadboard poster processing unit is being designed and fabricated. The design includes a beam supply consisting of four 1.1 kW power modules connected in parallel, equally sharing the output current. A novel phase-shifted/pulse-width-modulated dual full-bridge topology was chosen for its soft-switching characteristics. The proposed modular approach allows scalability to higher powers as well as the possibility of implementing an N+1 redundant beam supply. Efficiencies in excess of 96% were measured during testing of a breadboard beam power module. A specific mass of 3.0 kg/kW is expected for a flight PRO. This represents a 50% reduction from the state of the art NSTAR power processor.

Pinero, Luis R.↗

NASA NTRS2001

Modular 5-kW Power-Processing Unit Being Developed for the Next-Generation Ion Engine

The NASA Glenn Research Center is developing a 5- to 10-kW ion engine for a broad range of mission applications. Simultaneously, a 5-kW breadboard power-processing unit (PPU) is being designed and fabricated by Boeing Electron Dynamic Devices, Torrance, California, under contract with Glenn. The beam supply, which processes up to 90 percent of the power into this unit, consists of four 1.1-kW power modules connected in parallel, equally sharing the output current. The modular design allows scalability to higher powers as well as the possibility of implementing an N + 1 redundant beam supply. A novel phaseshifted/pulse-width-modulated, dual full-bridge topology was chosen for this module design for its efficient switching characteristics. A breadboard version of the beam power supply module was assembled. Efficiencies ranging between 91.6 and 96.9 percent were measured for an input voltage range of 80 to 160 V, an output voltage range of 800 to 1500 V, and output powers from 0.3 to 1.0 kW. This beam supply could result in a PPU with a total efficiency between 93 and 95 percent at a nominal input voltage of 100 V. This is up to a 4-percent improvement over the state-of-the-art PPU used for the Deep Space 1 mission. A flight-packaged PPU is expected to weigh no more than 15 kg, which represents a 50-percent reduction in specific mass from the Deep Space 1 design. This will make 5-kW ion propulsion very attractive for many planetary missions.

Pinero, Luis R.↗

NASA NTRS2001

Next-Generation Ion Propulsion Being Developed

The NASA Glenn Research Center ion-propulsion program addresses the need for high specific-impulse systems and technology across a broad range of mission applications and power levels. One activity is the development of the next-generation ion-propulsion system as a follow-on to the successful Deep Space 1 system. The system is envisioned to incorporate a lightweight ion engine that can operate over 1 to 10 kW, with a 550-kg propellant throughput capacity. The engine concept under development has a 40-cm beam diameter, twice the effective area of the Deep Space 1 engine. It incorporates mechanical features and operating conditions to maximize the design heritage established by the Deep Space 1 engine, while incorporating new technology where warranted to extend the power and throughput capability. Prototype versions of the engine have been fabricated and are under test at NASA, with an engineering model version in manufacturing. Preliminary performance data for the prototype engine have been documented over 1.1- to 7.3-kW input power. At 7.3 kW, the engine efficiency is 0.68, at 3615-sec specific impulse. Critical component temperatures, including those of the discharge cathode assembly and magnets, have been documented and are within established limits, with significant margins relative to the Deep Space 1 engine. The 1- to 10-kW ion thruster approach described here was found to provide the needed power and performance improvement to enable important NASA missions. The Integrated In-Space Transportation Planning (IISTP) studies compared many potential technologies for various NASA, Government, and commercial missions. These studies indicated that a high-power ion propulsion system is the most important technology for development because of its outstanding performance versus perceived development and recurring costs for interplanetary solar electric propulsion missions. One of the best applications of a highpower electric propulsion system was as an integral part of a solar electric propulsion (SEP) stage to send a payload to outer planet targets. The IISTP studies showed that either trip time or launch vehicle class could be significantly reduced when compared with state-of-the-art systems.

Patterson, Michael J.↗

NASA NTRS2000

Development Status of a Power Processing Unit for Low Power Ion Thrusters

An advanced breadboard Power Processing Unit (PPU) for a low power ion propulsion system incorporating mass reduction techniques was designed and fabricated. As a result of similar output current requirements, the discharge supply was also used to provide the neutralizer heater and discharge heater functions by using three relays to switch the output connections. This multi-function supply reduces to four the number of power converters needed to produce the required six electrical outputs. Switching frequencies of 20 and 50 kHz were chosen as a compromise between the size of the magnetic components and switching losses. The advanced breadboard PPU is capable of a maximum total output power of 0.47 kW. Its component mass is 0.65 kg and its total mass 1.9 kg. The total efficiency at full power is 0.89.

Pinero, Luis R.↗

NASA NTRS1997

Development of an Ion Thruster and Power Processor for New Millennium's Deep Space 1 Mission

The NASA Solar Electric Propulsion Technology Applications Readiness Program (NSTAR) will provide a single-string primary propulsion system to NASA's New Millennium Deep Space 1 Mission which will perform comet and asteroid flybys in the years 1999 and 2000. The propulsion system includes a 30-cm diameter ion thruster, a xenon feed system, a power processing unit, and a digital control and interface unit. A total of four engineering model ion thrusters, three breadboard power processors, and a controller have been built, integrated, and tested. An extensive set of development tests has been completed along with thruster design verification tests of 2000 h and 1000 h. An 8000 h Life Demonstration Test is ongoing and has successfully demonstrated more than 6000 h of operation. In situ measurements of accelerator grid wear are consistent with grid lifetimes well in excess of the 12,000 h qualification test requirement. Flight hardware is now being assembled in preparation for integration, functional, and acceptance tests.

Sovey, James S.↗

NASA NTRS1997

Space Station Cathode Ignition Test Status at 32,000 Cycles

A plasma contactor system has been baselined for the International Space Station for structural potential control. An ignition procedure was developed for the plasma contactor hollow cathode assembly (HCA). To demonstrate the required 99% HCA ignition reliability over 6,000 cycles, an ignition test was conducted. An accelerated test procedure was employed to rapidly accumulate ignition cycles. The test procedure minimized the differences between accelerated and non-accelerated test results. The development HCA used in this test has achieved 32,000 ignitions to date. The HCA has been qualified for cyclic operation, which could reduce xenon consumption and extend the life of the plasma contactor system.

Zakany, James S.↗

NASA NTRS1997

Development of Power Electronics for a 0.2kW-Class Ion Thruster

Applications that might benefit from low power ion propulsion systems include Earth-orbit magnetospheric mapping satellite constellations, low Earth-orbit satellites, geosynchronous Earth-orbit satellite north-south stationkeeping, and asteroid orbiters. These spacecraft are likely to have masses on the order of 50 to 500 kg with up to 0.5 kW of electrical power available. A power processing unit for a 0.2 kW-class ion thruster is currently under development for these applications. The first step in this effort is the development and testing of a 0.24 kW beam power supply. The design incorporates a 20 kHz full bridge topology with multiple secondaries connected in series to obtain outputs of up to 1200 V(sub DC). A current-mode control pulse width modulation circuit built using discrete components was selected for this application. An input voltage of 28 +/- 4 V(sub DC) was assumed, since the small spacecraft for which this system is targeted are anticipated to have unregulated low voltage busses. Efficiencies in excess of 91 percent were obtained at maximum output power. The total mass of the breadboard was less than 1.0 kg and the component mass was 0.53 kg. It is anticipated that a complete flight power processor could weigh about 2.0 kg.

Pinero, Luis R.↗

NASA NTRS1997

Power Electronics for a Miniaturized Arcjet

A 0.3 kW Power Processing Unit (PPU) was designed, tested on resistive loads, and then integrated with a miniaturized arcjet. The main goal of the design was to minimize size and mass while maintaining reasonable efficiency. In order to obtain the desired reductions in mass, simple topologies and control methods were considered. The PPU design incorporates a 50 kHz, current-mode-control, pulse-width-modulated (PWM), push-pull topology. An input voltage of 28 +/- 4V was chosen for compatibility with typical unregulated low voltage busses anticipated for smallsats. An efficiency of 0.90 under nominal operating conditions was obtained. The component mass of the PPU was 0.475 kg and could be improved by optimization of the output filter design. The estimated mass for a flight PPU based on this design is less than a kilogram.

Pinero, Luis R.↗

NASA NTRS1996

NSTAR Ion Thruster and Breadboard Power Processor Functional Integration Test Results

A 2.3 kW Breadboard Power Processing Unit (BBPPU) was developed as part of the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) Program. The NSTAR program will deliver an electric propulsion system based on a 30 cm xenon ion thruster to the New Millennium (NM) program for use as the primary propulsion system for the initial NM flight. The final development test for the BBPPU, the Functional Integration Test, was carried out to demonstrate all aspects of BBPPU operation with an Engineering Model Thruster. Test objectives included: (1) demonstration and validation of automated thruster start procedures, (2) demonstration of stable closed loop control of the thruster beam current, (3) successful response and recovery to thruster faults, and (4) successful safing of the system during simulated spacecraft faults. These objectives were met over the specified 80-120 VDC input voltage range and 0.5-2.3 output power capability of the BBPPU. Two minor anomalies were noted in discharge and neutralizer keeper current. These anomalies did not affect the stability of the system and were successfully corrected.

Hamley, John A.↗

NASA NTRS1995

Development Status of the NSTAR Ion Propulsion System Power Processor

A 0.5-2.3 kW xenon ion propulsion system is presently being developed under the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) program. This propulsion system includes a 30 cm diameter xenon ion thruster, a Digital Control Interface Unit, a xenon feed system, and a power processing unit (PPU). The PPU consists of the power supply assemblies which operate the thruster neutralizer, main discharge chamber, and ion optics. Also included are recycle logic and a digital microcontroller. The neutralizer and discharge power supplies employ a dual use configuration which combines the functions of two power supplies into one, significantly simplifying the PPU. Further simplification was realized by implementing a single thruster control loop which regulates the beam current via the discharge current. Continuous throttling is possible over a 0.5-2.3 kW output power range. All three power supplies have been fabricated and tested with resistive loads, and have been combined into a single breadboard unit with the recycle logic and microcontroller. All line and load regulation test results show the power supplies to be within the NSTAR flight PPU specified power output of 1.98 kW. The overall efficiency of the PPU, calculated as the combined efficiencies of the power supplies and controller, at 2.3 kW delivered to resistive loads was 0.90. The component was 6.16 kg. Integration testing of the neutralizer and discharge power supplies with a functional model thruster revealed no issues with discharge ignition or steady state operation.

Hamley, John A.↗

NASA NTRS1995

Integration issues of a plasma contactor Power Electronics Unit

A hollow cathode-based plasma contactor is baselined on International Space Station Alpha (ISSA) for spacecraft charge control. The plasma contactor system consists of a hollow cathode assembly (HCA), a power electronics unit (PEU), and an expellant management unit (EMU). The plasma contactor has recently been required to operate in a cyclic mode to conserve xenon expellant and extend system life. Originally, a DC cathode heater converter was baselined for a continuous operation mode because only a few ignitions of the hollow cathode were expected. However, for cyclic operation, a DC heater supply can potentially result in hollow cathode heater component failure due to the DC electrostatic field. This can prevent the heater from attaining the proper cathode tip temperature for reliable ignition of the hollow cathode. To mitigate this problem, an AC cathode heater supply was therefore designed, fabricated, and installed into a modified PEU. The PEU was tested using resistive loads and then integrated with an engineering model hollow cathode to demonstrate stable steady-state operation. Integration issues such as the effect of line and load impedance on the output of the AC cathode heater supply and the characterization of the temperature profile of the heater under AC excitation were investigated.

Pinero, Luis R.↗