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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2007

Critical Issues for Cu(InGa)Se2 Solar Cells on Flexible Polymer Web

Elemental in-line evaporation on glass substrates has been a viable process for the large-area manufacture of CuInSe2-based photovoltaics, with module efficiencies as high as 12.7% [1]. However, lightweight, flexible CuInSe2-based modules are attractive in a number of applications, such as space power sources. In addition, flexible substrates have an inherent advantage in manufacturability in that they can be deposited in a roll-to-roll configuration allowing continuous, high yield, and ultimately lower cost production. As a result, high-temperature polymers have been used as substrates in depositing CuInSe2 films [2]. Recently, efficiency of 14.1% has been reported for a Cu(InGa)Se2-based solar cell on a polyimide substrate [3]. Both metal foil and polymer webs have been used as substrates for Cu(InGa)Se2-based photovoltaics in a roll-to-roll configuration with reasonable success [4,5]. Both of these substrates do not allow, readily, the incorporation of Na into the Cu(InGa)Se2 film which is necessary for high efficiency devices [3]. In addition, polymer substrates, can not be used at temperatures that are optimum for Cu(InGa)Se2 deposition. However, unlike metal foils, they are electrically insulating, simplifying monolithically-integrated module fabrication and are not a source of impurities diffusing into the growing film. The Institute of Energy Conversion (IEC) has modified its in-line evaporation system [6] from deposition onto glass substrates to roll-to-roll deposition onto polyimide (PI) film in order to investigate key issues in the deposition of large-area Cu(InGa)Se2 films on flexible polymer substrates. This transition presented unexpected challenges that had to be resolved. In this paper, two major problems, spitting from the Cu source and the cracking of Mo back contact film, will be discussed and the solution to each will be presented.

Eser, Erten↗

NASA NTRS2016

NH11B-1726: FrankenRaven: A New Platform for Remote Sensing

Small, modular aircraft are an emerging technology with a goal to maximize flexibility and enable multi-mission support. This reports the progress of an unmanned aerial system (UAS) project conducted at the NASA Ames Research Center (ARC) in 2016. This interdisciplinary effort builds upon the success of the 2014 FrankenEye project to apply rapid prototyping techniques to UAS, to develop a variety of platforms to host remote sensing instruments. In 2016, ARC received AeroVironment RQ-11A and RQ-11B Raven UAS from the US Department of the Interior, Office of Aviation Services. These aircraft have electric propulsion, a wingspan of roughly 1.3m, and have demonstrated reliability in challenging environments. The Raven airframe is an ideal foundation to construct more complex aircraft, and student interns using 3D printing were able to graft multiple Raven wings and fuselages into FrankenRaven aircraft. Aeronautical analysis shows that the new configuration has enhanced flight time, payload capacity, and distance compared to the original Raven. The FrankenRaven avionics architecture replaces the mil-spec avionics with COTS technology based upon the 3DR Pixhawk PX4 autopilot with a safety multiplexer for failsafe handoff to 2.4 GHz RC control and 915 MHz telemetry. This project demonstrates how design reuse, rapid prototyping, and modular subcomponents can be leveraged into flexible airborne platforms that can host a variety of remote sensing payloads and even multiple payloads. Modularity advances a new paradigm: mass-customization of aircraft around given payload(s). Multi-fuselage designs are currently under development to host a wide variety of payloads including a zenith-pointing spectrometer, a magnetometer, a multi-spectral camera, and a RGB camera. After airworthiness certification, flight readiness review, and test flights are performed at Crows Landing airfield in central California, field data will be taken at Kilauea volcano in Hawaii and other locations.

remote sensing↗

NASA NTRS1972

Evaluation testing of a closed Brayton-cycle electrical-power-conversion system.

Description of the design and testing of a recuperated, closed Brayton-cycle, electrical power conversion system designated the Brayton Cycle Demonstrator (BCD). The system uses electrical heaters as a heat source, argon as the cycle working fluid, and gas-lubricated foil-type bearings. Objectives of the test program include (1) evaluation of the overall system performance characteristics and influences on spacecraft integration, (2) familiarization of personnel with operational methods, and (3) determination of system flexibility by operating at a number of off-design conditions. Results obtained to date are discussed.

Redding, T. E.↗

NASA NTRS2003

Electronic Power System Application of Diamond-Like Carbon Films

A prototype manufacturing technology for producing high volume efficiency and high energy density diamond-like carbon (DLC) capacitors has been developed. Unique dual ion-beam deposition and web-handling systems have been designed and constructed to deposit high quality DLC films simultaneously on both sides of capacitor grade aluminum foil and aluminum-coated polymer films. An optimized process, using inductively coupled RF ion sources, has been used to synthesize electrically robust DLC films. DLC films are amorphous and highly flexible, making them suitable for the production of wound capacitors. DLC capacitors are reliable and stable over a wide range of AC frequencies from 20 Hz to 1 MHz, and over a temperature range from .500 C to 3000 C. The compact DLC capacitors offer at least a 50% decrease in weight and volume and a greater than 50% increase in temperature handling capability over equal value capacitors built with existing technologies. The DLC capacitors will be suitable for high temperature, high voltage, pulsed power and filter applications.

Wu, Richard L. C.↗

NASA NTRS2005

Bio-Nanobattery Development and Characterization

A bio-nanobattery is an electrical energy storage device that utilizes organic materials and processes on an atomic, or nanometer-scale. The bio-nanobattery under development at NASA s Langley Research Center provides new capabilities for electrical power generation, storage, and distribution as compared to conventional power storage systems. Most currently available electronic systems and devices rely on a single, centralized power source to supply electrical power to a specified location in the circuit. As electronic devices and associated components continue to shrink in size towards the nanometer-scale, a single centralized power source becomes impractical. Small systems, such as these, will require distributed power elements to reduce Joule heating, to minimize wiring quantities, and to allow autonomous operation of the various functions performed by the circuit. Our research involves the development and characterization of a bio-nanobattery using ferritins reconstituted with both an iron core (Fe-ferritin) and a cobalt core (Co-ferritin). Synthesis and characterization of the Co-ferritin and Fe-ferritin electrodes were performed, including reducing capability and the half-cell electrical potentials. Electrical output of nearly 0.5 V for the battery cell was measured. Ferritin utilizing other metallic cores were also considered to increase the overall electrical output. Two dimensional ferritin arrays were produced on various substrates to demonstrate the feasibility of a thin-film nano-scaled power storage system for distributed power storage applications. The bio-nanobattery will be ideal for nanometerscaled electronic applications, due to the small size, high energy density, and flexible thin-film structure. A five-cell demonstration article was produced for concept verification and bio-nanobattery characterization. Challenges to be addressed include the development of a multi-layered thin-film, increasing the energy density, dry-cell bionanobattery development, and selection of ferritin core materials to allow the broadest range of applications. The potential applications for the distributed power system include autonomously-operating intelligent chips, flexible thin-film electronic circuits, nanoelectromechanical systems (NEMS), ultra-high density data storage devices, nanoelectromagnetics, quantum electronic devices, biochips, nanorobots for medical applications and mechanical nano-fabrication, etc.

King, Glen C.↗

NASA NTRS1992

A combustion driven shock tunnel to complement the free piston shock tunnel T5 at GALCIT

A combustion driven shock tunnel was designed and built at GALCIT to supply the hypersonic facility T5 with 'hot' hydrogen for mixing and combustion experiments. This system was chosen over other options for better flexibility and for safety reasons. The shock tunnel is described and the overall efficiency of the system is discussed. The biggest challenge in the design was to synchronize the combustion driven shock tunnel with T5. To do so, the main diaphragm of the combustion driven shock tunnel is locally melted by an electrical discharge. This local melting is rapidly followed by the complete collapse of the diaphragm in a very repeatable way. A first set of experiments on supersonic hydrogen transverse jets over a flat plate have just been completed with the system and some of the preliminary results are presented.

Belanger, Jacques↗

NASA NTRS2023

Multirotor Test Bed Load and Stress Analysis

The Multirotor Test Bed (MTB) is a new capability for testing a wide array of advanced vertical take-off and landing (VTOL) rotor configurations, with a primary focus on testing in the U.S. Army 7- by 10-Foot Subsonic Wind Tunnel at NASA Ames Research Center. The MTB was designed to allow adjustment of the vertical, lateral, and longitudinal placement of up to six rotors, as well as allow tilt adjustment of each rotor and pitch adjustment of the whole assembly. The six-axis load cells under each rotor give the MTB the capability of measuring the rotor performance in a wide array of configurations. The overall goal of the MTB project is to help gain a better understanding of the performance, control, interactional aerodynamics, and acoustics of multirotor and tilting-rotor systems. The MTB project was initiated to build upon the knowledge and capabilities developed during the multirotor unmanned aerial systems (MUAS) tests in 2015 and 2017. By measuring individual rotor loads and allowing for adjustments to individual rotor position and attitude, the MTB provides a wealth of data on the aeroperformance of arbitrary multirotor configurations. The flexibility in positioning up to six rotors allows the multirotor design space to be parametrically explored and potentially optimized. The MTB is also at a larger scale than the small unmanned aerial systems (UAS) tested before, which allows for testing at rotor tip Reynolds numbers more relevant to full-scale piloted electric vertical take-off and landing (eVTOL) aircraft. This document contains the complete documentation of the design, loads, and stress analysis of the MTB.

Multirotor Test Bed↗

NASA NTRS2011

Joint Radioisotope Electric Propulsion Studies - Neptune System Explorer

The Neptune System Explorer (NSE) mission concept study assessed opportunities to conduct Cassini-like science at Neptune with a radioisotope electric propulsion (REP) based spacecraft. REP is based on powering an electric propulsion (EP) engine with a radioisotope power source (RPS). The NSE study was commissioned under the Joint Radioisotope Electric Propulsion Studies (JREPS) project, which sought to determine the technical feasibility of flagship class REP applications. Within JREPS, special emphasis was given toward identifying tall technology tent poles, as well as recommending any new RPS technology developments that would be required for complicated REP missions. Based on the goals of JREPS, multiple RPS (e.g. thermoelectric and Stirling based RPS) and EP (e.g. Hall and ion engines) technology combinations were traded during the NSE study to determine the most favorable REP design architecture. Among the findings from the study was the need for >400We RPS systems, which was driven by EP operating powers and the requirement for a long-lived mission in the deep solar system. Additionally multiple development and implementation risks were identified for the NSE concept, as well as REP missions in general. Among the strengths of the NSE mission would be the benefits associated with RPS and EP use, such as long-term power (approx. 2-3kW) at Neptune and flexible trajectory options for achieving orbit or tours of the Neptune system. Although there are still multiple issues to mitigate, the NSE concept demonstrated distinct advantages associated with using REP for deep space flagship-class missions.

radioisotope power source (RPS)↗

NASA NTRS2010

Two-Speed Gearbox Dynamic Simulation Predictions and Test Validation

Dynamic simulations and experimental validation tests were performed on a two-stage, two-speed gearbox as part of the drive system research activities of the NASA Fundamental Aeronautics Subsonics Rotary Wing Project. The gearbox was driven by two electromagnetic motors and had two electromagnetic, multi-disk clutches to control output speed. A dynamic model of the system was created which included a direct current electric motor with proportional-integral-derivative (PID) speed control, a two-speed gearbox with dual electromagnetically actuated clutches, and an eddy current dynamometer. A six degree-of-freedom model of the gearbox accounted for the system torsional dynamics and included gear, clutch, shaft, and load inertias as well as shaft flexibilities and a dry clutch stick-slip friction model. Experimental validation tests were performed on the gearbox in the NASA Glenn gear noise test facility. Gearbox output speed and torque as well as drive motor speed and current were compared to those from the analytical predictions. The experiments correlate very well with the predictions, thus validating the dynamic simulation methodologies.

Lewicki, David G.↗

NASA NTRS1973

Results of solar electric thrust vector control system design, development and tests

Efforts to develop and test a thrust vector control system TVCS for a solar-energy-powered ion engine array are described. The results of solar electric propulsion system technology (SEPST) III real-time tests of present versions of TVCS hardware in combination with computer-simulated attitude dynamics of a solar electric multi-mission spacecraft (SEMMS) Phase A-type spacecraft configuration are summarized. Work on an improved solar electric TVCS, based on the use of a state estimator, is described. SEPST III tests of TVCS hardware have generally proved successful and dynamic response of the system is close to predictions. It appears that, if TVCS electronic hardware can be effectively replaced by control computer software, a significant advantage in control capability and flexibility can be gained in future developmental testing, with practical implications for flight systems as well. Finally, it is concluded from computer simulations that TVCS stabilization using rate estimation promises a substantial performance improvement over the present design.

Fleischer, G. E.↗

NASA NTRS1989

Space Station Freedom power management and distribution design status

The design status of the power management and distribution electric power system for the Space Station Freedom is presented. The current design is a star architecture, which has been found to be the best approach for meeting the requirement to deliver 120 V dc to the user interface. The architecture minimizes mass and power losses while improving element-to-element isolation and system flexibility. The design is partitioned into three elements: energy collection, storage and conversion, system protection and distribution, and management and control.

Javidi, S.↗

NASA NTRSDate not supplied

Hybrid Modeling for Complex Systems Health Management

The research work presents application of hybrid physics-informed machine learning to a representative electric powertrain for unmanned aerial vehicles. The model is composed of physics-derived and empirical equations, integrated with connected networks that are strategically placed within the model to substitute equations that are subject to large uncertainty. Polynomial fit driven by heuristics or empirical observations can be substituted by more flexible networks that can minimize the error between model predictions and observations without being restricted to a predefined functional form. This modeling strategy allows training of networks deep inside the model and unknown parameters in a single learning stage. The powertrain model consists of Li-ion batteries, electronic speed controller with pulse-width modulation, and brush-less DC motor with connected propeller. Results obtained from combination of laboratory and simulation tests are discussed in this work.

PINNS↗

NASA NTRS2009

A Distributed Prognostic Health Management Architecture

This paper introduces a generic distributed prognostic health management (PHM) architecture with specific application to the electrical power systems domain. Current state-of-the-art PHM systems are mostly centralized in nature, where all the processing is reliant on a single processor. This can lead to loss of functionality in case of a crash of the central processor or monitor. Furthermore, with increases in the volume of sensor data as well as the complexity of algorithms, traditional centralized systems become unsuitable for successful deployment, and efficient distributed architectures are required. A distributed architecture though, is not effective unless there is an algorithmic framework to take advantage of its unique abilities. The health management paradigm envisaged here incorporates a heterogeneous set of system components monitored by a varied suite of sensors and a particle filtering (PF) framework that has the power and the flexibility to adapt to the different diagnostic and prognostic needs. Both the diagnostic and prognostic tasks are formulated as a particle filtering problem in order to explicitly represent and manage uncertainties; however, typically the complexity of the prognostic routine is higher than the computational power of one computational element ( CE). Individual CEs run diagnostic routines until the system variable being monitored crosses beyond a nominal threshold, upon which it coordinates with other networked CEs to run the prognostic routine in a distributed fashion. Implementation results from a network of distributed embedded devices monitoring a prototypical aircraft electrical power system are presented, where the CEs are Sun Microsystems Small Programmable Object Technology (SPOT) devices.

Bhaskar, Saha↗

NASA NTRS1988

The GSFC Flight Support System for on-orbit satellite servicing

To plan and execute a successful on-orbit satellite servicing mission, space support hardware, a serviceable spacecraft design, and flexible ground operations are required. This paper addresses space support hardware and in particular the Goddard Space Flight Center (GSFC) Satellite Servicing Project's (SSP) Flight Support System (FSS). The FSS is designed to be compatible with the Space Transportation System Orbiter and to support on-orbit servicing of Multimission Modular Spacecraft. It provides mechanical, electrical, and thermal support to the spacecraft during the servicing mission. Standardization of spacecraft design, components, and interfaces is required to make a satellite serviceable. Spacecraft ground operation capabilities must accommodate servicing mission requirements. Space support tools and equipment, such as the Power Ratchet Tool, assists the astronaut during time critical EVA operations to more efficiently perform the servicing mission.

Griffin, Thomas J.↗

NASA NTRS2018

Status Report on Aeroelasticity in the Vehicle Development for X-57 Maxwell

Risk reduction is the objective of the X-57 Maxwell aeroelasticity team. The X-57, NASA’s experimental electric propulsion aircraft, has a long thin wing with primary propulsion systems located at the wing tips and high lift motors distributed along the span. Many of the classical aeroelastic concerns associated with such a configuration were addressed through early design decisions. The as-designed intermediate flight vehicle configurations show flutter mechanisms associated with flexible models of control surface systems –the stabilator, flaps and ailerons. Improvements to the analytical models, based on ground test data and project decisions about flight operations, show improved prospects of the vehicle being aeroelastically stable throughout the flight envelope. On-going ground testing and further analyses will lend credibility to the flutter predictions and vehicle safety.

Heeg, Jennifer↗

NASA NTRS2026

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗

NASA NTRSDate not supplied

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Peter Moschetti↗

NASA NTRS1988

Successful expert systems for space shuttle payload integration

Expert systems are successfully applied to solve recurring NASA Space Shuttle orbiter payload integration problems. Recurrence of these problems is the result of each Space Shuttle mission being unique. The NASA Space Shuttle orbiter was designed to be extremely flexible in its ability to handle many types and combinations of satellites and experiments. This flexibility results in different and unique engineering resource requirements for each of the payload satellites and experiments. The first successful expert system to be applied to these problems was the Orbiter Payload Bay Cabling Expert System (EXCABL), developed at Rockwell International Space Transportation Systems Division. The operational version of EXCABL was delivered in 1986 and successfully solved the payload electrical support services cabling layout problem. As a result of this success, a second expert system, Expert Drawing Matching System (EXMATCH), was developed to generate a list of the reusable installation drawings available for each EXCABL solution. EXMATCH went operational in 1987. As a result of these initial successes, the need for a third expert system was defined and is awaiting development. This new Expert System, called Technical Order Listing Expert System (EXTOL), will generate a list of all the applicable reusable installation drawings available to support the total payload bay mission provisioning and installation effort. This paper describes these expert systems, the individual problems that they were designed to solve, their individual solutions, and the degree of success achieved. These expert systems' instantiate the applicability of this technology to the solution of real-world Space Shuttle payload integration problems.

Morris, Keith↗