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NASA NTRS2010

Test Results from a High Power Linear Alternator Test Rig

Stirling cycle power conversion is an enabling technology that provides high thermodynamic efficiency but also presents unique challenges with regard to electrical power generation, management, and distribution. The High Power Linear Alternator Test Rig (HPLATR) located at the NASA Glenn Research Center (GRC) in Cleveland, OH is a demonstration test bed that simulates electrical power generation from a Stirling engine driven alternator. It implements the high power electronics necessary to provide a well regulated DC user load bus. These power electronics use a novel design solution that includes active rectification and power factor control, active ripple suppression, along with a unique building block approach that permits the use of high voltage or high current alternator designs. This presentation describes the HPLATR, the test program, and the operational results.

Birchenough, Arthur G.↗

NASA NTRS2010

Test Results From a High Power Linear Alternator Test Rig

Stirling cycle power conversion is an enabling technology that provides high thermodynamic efficiency but also presents unique challenges with regard to electrical power generation, management, and distribution. The High Power Linear Alternator Test Rig (HPLATR) located at the NASA Glenn Research Center (GRC) in Cleveland, Ohio is a demonstration test bed that simulates electrical power generation from a Stirling engine driven alternator. It implements the high power electronics necessary to provide a well regulated DC user load bus. These power electronics use a novel design solution that includes active rectification and power factor control, active ripple suppression, along with a unique building block approach that permits the use of high voltage or high current alternator designs. This report describes the HPLATR, the test program, and the operational results.

Birchenough, Arthur G.↗

NASA NTRS2019

Requirements Development and Management on the Psyche Project

In January 2017, Psyche was one of two mission concepts selected by NASA for flight as part of the 14th Discovery mission competition. The project has been staffing up and maturing the spacecraft, instrument and mission system baseline designs on the path towards a 2022 launch. During much of 2018, the Project has been executing the lifecycle stage called Phase B, “Preliminary Design and Technology Completion,” one key element of which is the development and management of requirements at various levels. In the case of the Psyche project, this process has been particularly unique for several reasons. The project utilizes a Solar Electric Propulsion (SEP) Chassis from Space Systems Loral (SSL), a high volume manufacturer of commercial geostationary (GEO) telecom spacecraft based on the 1300 satellite bus. While SSL has an extensive, well-vetted set of requirements based on their very successful Earth-orbiting product line, translating that heritage to a deep space science mission required special care. In addition to the differences associated with the deep space environment and longer communication times, new interfaces had to be incorporated. While a substantial portion of the Flight System consists of the SEP Chassis, there were several new interfaces within various subsystems between SSL components and those provided by JPL and other contractors. Managing these interfaces through requirements at a relatively higher level than normally seen on internal or external builds proved challenging. Finally, the Psyche spacecraft plans to host the flight terminal of the Deep Space Optical Communications (DSOC) technology demonstration, which is itself a separate project with its own requirements that must be flowed down and managed. This paper will present an overview of the requirement development and management process for the Psyche project. It will discuss in detail the various challenges summarized above, the methods and decisions chosen to address them, and evaluate their overall effectiveness at this stage in the project.

Elkins-Tanton, Linda T.↗

NASA NTRS1990

The COLD-SAT experiment for cryogenic fluid management technology

The COLD-SAT spacecraft design experiments are described. COLD-SAT will be placed into an initial 1300 km circular orbit by an Atlas commercial launch vehicle. Electric power, experiment control and data management, attitude control, and propulsive accelarations for the experiments will be provided by the three-axis-controlled spacecraft bus. To provide data on the effects that low gravity levels might have on the heat and mass transfer processes involved, low levels of accelaration will be created. The COLD-SAT experiment will be configured into a module. The spacecraft experiment module will include three liquid hydrogen tanks; fluid transfer, pressurization and venting equipment; and instrumentation. Since the largest tank has helium-purged MLI to prevent ingress and freezing of air on the launchpad, it will contain all the liquid hydrogen at the point of launching. The hydrogen tanking system used for the Centaur upper stage of the Atlas will load and top off this tank. Atlas, with its liquid hydrogen upper stage, large payload fairing, and large launch margin, simplifies COLD-SAT design and integration.

Schuster, J. R.↗

NASA NTRS1976

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 9: Closed-cycle MHD

A closed-cycle MHD system for an electric power plant was studied. It consists of 3 interlocking loops, an external heating loop, a closed-cycle cesium seeded argon nonequilibrium ionization MHD loop, and a steam bottomer. A MHD duct maximum temperature of 2366 K (3800 F), a pressure of 0.939 MPa (9.27 atm) and a Mach number of 0.9 are found to give a topping cycle efficiency of 59.3%; however when combined with an integrated gasifier and optimistic steam bottomer the coal to bus bar efficiency drops to 45.5%. A 1978 K (3100 F) cycle has an efficiency of 55.1% and a power plant efficiency of 42.2%. The high cost of the external heating loop components results in a cost of electricity of 21.41 mills/MJ (77.07 mills/kWh) for the high temperature system and 19.0 mills/MJ (68.5 mills/kWh) for the lower temperature system. It is, therefore, thought that this cycle may be more applicable to internally heated systems such as some futuristic high temperature gas cooled reactor.

Tsu, T. C.↗

NASA NTRS2016

Challenges with Electrical, Electronics, and Electromechanical Parts for James Webb Space Telescope

James Webb Space Telescope (JWST) is the space-based observatory that will extend the knowledge gained by the Hubble Space Telescope (HST). Hubble focuses on optical and ultraviolet wavelengths while JWST focuses on the infrared portion of the electromagnetic spectrum, to see the earliest stars and galaxies that formed in the Universe and to look deep into nearby dust clouds to study the formation of stars and planets. JWST, which commenced creation in 1996, is scheduled to launch in 2018. It includes a suite of four instruments, the spacecraft bus, optical telescope element, Integrated Science Instrument Module (ISIM, the platform to hold the instruments), and a sunshield. The mass of JWST is approximately 6200 kg, including observatory, on-orbit consumables and launch vehicle adaptor. Many challenges were overcome while providing the electrical and electronic components for the Goddard Space Flight Center hardware builds. Other difficulties encountered included developing components to work at cryogenic temperatures, failures of electronic components during development and flight builds, Integration and Test electronic parts problems, and managing technical issues with international partners. This paper will present the context of JWST from a EEE (electrical, electronic, and electromechanical) perspective with examples of challenges and lessons learned throughout the design, development, and fabrication of JWST in cooperation with our associated partners including the Canadian Space Agency (CSA), the European Space Agency (ESA), Lockheed Martin and their respective associated partners. Technical challenges and lessons learned will be discussed.

EEE Parts↗

NASA NTRS1982

Systems evaluation of thermal bus concepts

Thermal bus concepts, to provide a centralized thermal utility for large, multihundred kilowatt space platforms, were studied and the results are summarized. Concepts were generated, defined, and screened for inclusion in system level thermal bus trades. Parametric trade studies were conducted in order to define the operational envelope, performance, and physical characteristics of each. Two concepts were selected as offering the most promise for thermal bus development. All of four concepts involved two phase flow in order to meet the required isothermal nature of the thermal bus. Two of the concepts employ a mechanical means to circulate the working fluid, a liquid pump in one case and a vapor compressor in another. Another concept utilizes direct osmosis as the driving force of the thermal bus. The fourth concept was a high capacity monogroove heat pipe. After preliminary sizing and screening, three of these concepts were selected to carry into the trade studies. The monogroove heat pipe concept was deemed unsuitable for further consideration because of its heat transport limitations. One additional concept utilizing capillary forces to drive the working fluid was added. Parametric system level trade studies were performed. Sizing and weight calculations were performed for thermal bus sizes ranging from 5 to 350 kW and operating temperatures in the range of 4 to 120 C. System level considerations such as heat rejection and electrical power penalties and interface temperature losses were included in the weight calculations.

Stalmach, D. D.↗

NASA NTRS2000

High Voltage Design Concepts for Launch Vehicles and Orbital Spacecraft Applications

With the advent of design concepts such as, electromechanical actuation and "more electric" initiatives, has come the need for electrical power buses and electronic equipment to operate at higher than normal dc voltages to meet power requirements while keeping current levels to manageable levels. This new bus voltage has been typically 270 Volts dc nominal for launch vehicles, and 120 Volt dc for the International Space Station. This paper will discuss the new design applications for high voltage dc power in existing and future launch vehicles and spacecraft and the potential problems associated therewith. These new applications must be operational from lift-off, ascent, on orbit and descent in all of the pressure and temperature conditions for each, i.e. through the "Paschen region" twice. This paper will also attempt to stimulate an interest in the academic and professional communities to support and conduct research needed for design data applicable to high voltage dc usage.

Hall, David K.↗

NASA NTRS2003

A Power Conversion Concept for the Jupiter Icy Moons Orbiter

The Jupiter Icy Moons Orbiter (JIMO) mission is currently under study by the Office of Space Science under the Project Prometheus Program. JIMO is examining the use of Nuclear Electric Propulsion (NEP) to carry scientific payloads to three Jovian moons. A potential power system concept includes dual 100 kWe Brayton converters, a deployable pumped loop heat rejection subsystem, and a 400 Vac Power Management and Distribution (PMAD) bus. Many trades were performed in aniving at this candidate power system concept. System-level studies examined design and off-design operating modes, determined startup requirements, evaluated subsystem redundancy options, and quantified the mass and radiator area of reactor power systems from 20 to 200 kWe. In the Brayton converter subsystem, studies were performed to investigate converter packaging options, and assess the induced torque effects on spacecraft dynamics due to rotating machinery. In the heat rejection subsystem, design trades were conducted on heat transport approaches, material and fluid options, and deployed radiator geometries. In the PMAD subsystem, the overall electrical architecture was defined and trade studies examined distribution approaches, voltage levels, and cabling options.

Mason, Lee S.↗

NASA NTRS1996

Design of a power management and distribution system for a thermionic-diode powered spacecraft

The Electrical Systems Development Branch of the Power Technology Division at the NASA Lewis Research Center in Cleveland, Ohio is designing a Power Management and Distribution (PMAD) System for the Air Force's Integrated Solar Upper Stage (ISUS) Engine Ground Test Demonstration (EGD). The ISUS program uses solar-thermal propulsion to perform orbit transfers from Low Earth Orbit (LEO) to Geosynchronous Orbit (GEO) and from LEO to Molnya. The ISUS uses the same energy conversion receiver to perform the LEO to High Earth Orbit (HEO) transfer and to generate on-orbit electric power for the payloads. On-orbit power generation is accomplished via two solar concentrators heating a dual-cavity graphite-core which has Thermionic Diodes (TMD's) encircling each cavity. The graphite core and concentrators together are called the Receiver and Concentrator (RAC). The TDM-emitters reach peak temperatures of approximately 2200K, and the TID-collectors are run at approximately 1000K. Because of the high Specific Impulse (I(sup sp)) of solar thermal propulsion relative to chemical propulsion, and because a common bus is used for communications, GN&C, power, etc., a substantial increase in payload weight is possible. This potentially allows for a stepdown in the required launch vehicle size or class for similar payload weight using conventional chemical propulsion and a separate spacecraft bus. The ISUS power system is to provide 1000W(sub e) at 28+/-6V(sub dc) to the payload/spacecraft from a maximum TID generation capability of 1070W(sub e) at 2200K. Producing power with this quality, protecting the spacecraft from electrical faults and accommodating operational constraints of the TID's are the responsibilities of the PMAD system. The design strategy and system options examined along with the proposed designs for the Flight and EGD configurations are discussed herein.

Kimnach, Greg L.↗

NASA NTRS1982

Development of management technology for large power systems

Autonomous power management has been proposed as a method to perform optimization of power subsystem performance in connection with the management of multikilowatt space platforms. A concept for a 250-kW utility-type power subsystem was developed. A Cassegrain concentrator solar array primary source is conditioned by a solar array switching unit which supplies seventeen 220 +20 Vdc power channels. A power management subsystem provides the monitoring and control of the overall electrical power subsystem. The discussed system concept for autonomous management of high power space platforms utilizes on-board microprocessors in a decentralized data management architecture. A data bus protocol and a data bus contention resolution scheme were selected in conjunction with the dencentralized management architecture.

Decker, D. K.↗

NASA NTRS2010

International Space Station Common Cabin Air Assembly Water Separator On-Orbit Operation, Failure, and Redesign

The ability to control the temperature and humidity of an environment or habitat is critical for human survival. These factors are important to maintaining human health and comfort, as well as maintaining mechanical and electrical equipment in good working order to support the human and to accomplish mission objectives. The temperature and humidity of the International Space Station (ISS) United States On-orbit Segment (USOS) cabin air is controlled by the Common Cabin Air Assembly (CCAA). The CCAA consists of a fan, a condensing heat exchanger (CHX), an air/water separator, temperature and liquid sensors, and electrical controlling hardware and software. The Water Separator (WS) pulls in air and water from the CHX, and centrifugally separates the mixture, sending the water to the condensate bus and the air back into the CHX outlet airstream. Two distinct early failures of the CCAA Water Separator in the Quest Airlock forced operational changes and brought about the re-design of the Water Separator to improve the useful life via modification kits. The on-orbit operational environment of the Airlock presented challenges that were not foreseen with the original design of the Water Separator. Operational changes were instituted to prolong the life of the third installed WS, while waiting for newly designed Water Separators to be delivered on-orbit. The modification kit design involved several different components of the Water Separator, including the innovative use of a fabrication technique to build the impellers used in Water Separators out of titanium instead of aluminum. The technique allowed for the cost effective production of the low quantity build. This paper will describe the failures of the Water Separators in the Quest Airlock, the operational constraints that were implemented to prolong the life of the installed Water Separators throughout the USOS, and the innovative re-design of the CCAA Water Separator.

Balistreri, Steven F., Jr.↗

NASA NTRSDate not supplied

Cryogenically-Operable Electronics for Surviving the Lunar Night

Current solar-powered robotic lunar landers and rovers have not demonstrated survivability of the extreme cold temperatures seen during the 354-hour lunar night. To address this capability gap, we have been investigating the feasibility of a passive hibernation approach to enable low-cost solar- and battery-powered missions to operate over multiple lunar cycles. This strategy relies on isolating the batteries from the main bus during the lunar night and allowing cells to freeze as temperatures descend as low as 50K. The entire power architecture remains in a hibernation state with no electrical activity until lunar dawn. When the sun returns over the horizon, the now-illuminated solar arrays begin generating power. In order to manage the array power, architecture consisting of cryogenically-operable COTS electronics must be utilized. This architecture will distribute and control power to subsystems - importantly controlling heaters to bring the frozen lithium-ion battery cells to normal operating conditions. This alternative approach to lunar operations will enable low-cost commercial lunar landers and payloads to passively survive the night and continue to operate over multiple lunar cycles without a significant impact to cost or payload mass. Research last year focused on creating a power supply that was capable of operation at cryogenic temperatures. At the end of FY23, our team successfully designed and manufactured a Sequential Switching Shunt Regulator (S3R) that is operational in a cryogenic vacuum chamber. It is capable of full operation down to the coldest lunar night temperatures (~50K). Our presentation will provide an overview of the Lunar Hibernation strategy but will focus mainly on the technical details of this cryogenically-operable shunt regulator and test results.

Cryogenic↗

NASA NTRS1992

Spacelab, Spacehab, and Space Station Freedom payload interface projects

Contributions were made to several projects. Howard Nguyen was assisted in developing the Space Station RPS (Rack Power Supply). The RPS is a computer controlled power supply that helps test equipment used for experiments before the equipment is installed on Space Station Freedom. Ron Bennett of General Electric Government Services was assisted in the design and analysis of the Standard Interface Rack Controller hardware and software. An analysis was made of the GPIB (General Purpose Interface Bus), looking for any potential problems while transmitting data across the bus, such as the interaction of the bus controller with a data talker and its listeners. An analysis was made of GPIB bus communications in general, including any negative impact the bus may have on transmitting data back to Earth. A study was made of transmitting digital data back to Earth over a video channel. A report was written about the study and a revised version of the report will be submitted for publication. Work was started on the design of a PC/AT compatible circuit board that will combine digital data with a video signal. Another PC/AT compatible circuit board is being designed to recover the digital data from the video signal. A proposal was submitted to support the continued development of the interface boards after the author returns to Memphis State University in the fall. A study was also made of storing circuit board design software and data on the hard disk server of a LAN (Local Area Network) that connects several IBM style PCs. A report was written that makes several recommendations. A preliminary design review was started of the AIVS (Automatic Interface Verification System). The summer was over before any significant contribution could be made to this project.

Smith, Dean Lance↗

NASA NTRS2014

Mars Sample Return and Flight Test of a Small Bimodal Nuclear Rocket and ISRU Plant

A combined Nuclear Thermal Rocket (NTR) flight test and Mars Sample Return mission (MSR) is explored as a means of "jump-starting" NTR development. Development of a small-scale engine with relevant fuel and performance could more affordably and quickly "pathfind" the way to larger scale engines. A flight test with subsequent inflight postirradiation evaluation may also be more affordable and expedient compared to ground testing and associated facilities and approvals. Mission trades and a reference scenario based upon a single expendable launch vehicle (ELV) are discussed. A novel "single stack" spacecraft/lander/ascent vehicle concept is described configured around a "top-mounted" downward firing NTR, reusable common tank, and "bottom-mount" bus, payload and landing gear. Requirements for a hypothetical NTR engine are described that would be capable of direct thermal propulsion with either hydrogen or methane propellant, and modest electrical power generation during cruise and Mars surface insitu resource utilization (ISRU) propellant production.

George, Jeffrey A.↗

NASA NTRS2020

Hybrid Electric MC-12 Ground Testing Plan Chapter

In the commercial aviation world, hybrid/electric propulsion is a promising technology for fuel, emissions, and noise reduction in support of the challenging goals established by 2050 EU Flightpath/SRIA, NASA ARMD Strategic Implementation Plan, and the US Air Force ATTAM programs. Ongoing results indicate operational benefits are possible in those three technical areas. Considering military applications, hybrid/electric propulsion may yield further significant improvements by enabling new, unorthodox mission capabilities. Potential benefits are expected in the areas of vehicle signature reduction (lower noise, lower exhaust signature), usage in enhanced flight environments, minimized human-in-the-loop workload by offering a platform compatible with future goals of autonomous operations facilitation, maintenance cost reductions, and performance burst/dash energy. Additional synergies are likely when used in conjunction with energy weapons. Some potential areas of mutual interest could include, dusty operations capability, remote supply capability, extended surveillance, dispatch able power, fuel-flexible vehicles, and autonomous rescue equipment. Many of the key technologies that have been demonstrated in ground operation must now be qualified for altitude conditions. We expect to have many flight qualified powertrain systems over the next decade for military planners to choose from for new future battlefield capability. This requires new flight-weight and flight-efficient powertrain components, fault tolerant power management, and electromagnetic interference mitigation technologies. Moreover, initial studies indicate some combination of ambient and cryogenic thermal management and relatively high bus voltages when compared to state of practice will be required to achieve a net system benefit. Developing all these powertrain technologies within a realistic aircraft architectural geometry and under realistic operational conditions requires a unique electric aircraft test bed. The MC-12 surveillance aircraft is an ideal military aircraft for demonstrating some of the benefits of incorporating hybrid electric propulsion. This report details an approach for full-scale ground-based altitude testing the hybrid electric MC-12 powertrain through a full flight profile.

military electric aircraft propulsion↗

NASA NTRS1980

High voltage systems (tube-type microwave)/low voltage system (solid-state microwave) power distribution

SPS satellite power distribution systems are described. The reference Satellite Power System (SPS) concept utilizes high-voltage klystrons to convert the onboard satellite power from dc to RF for transmission to the ground receiving station. The solar array generates this required high voltage and the power is delivered to the klystrons through a power distribution subsystem. An array switching of solar cell submodules is used to maintain bus voltage regulation. Individual klystron dc voltage conversion is performed by centralized converters. The on-board data processing system performs the necessary switching of submodules to maintain voltage regulation. Electrical power output from the solar panels is fed via switch gears into feeder buses and then into main distribution buses to the antenna. Power also is distributed to batteries so that critical functions can be provided through solar eclipses.

Nussberger, A. A.↗

NASA NTRS2013

Electric Machine with Boosted Inductance to Stabilize Current Control

High-powered motors typically have very low resistance and inductance (R and L) in their windings. This makes the pulse-width modulated (PWM) control of the current very difficult, especially when the bus voltage (V) is high. These R and L values are dictated by the motor size, torque (Kt), and back-emf (Kb) constants. These constants are in turn set by the voltage and the actuation torque-speed requirements. This problem is often addressed by placing inductive chokes within the controller. This approach is undesirable in that space is taken and heat is added to the controller. By keeping the same motor frame, reducing the wire size, and placing a correspondingly larger number of turns in each slot, the resistance, inductance, torque constant, and back-emf constant are all increased. The increased inductance aids the current control but ruins the Kt and Kb selections. If, however, a fraction of the turns is moved from their "correct slot" to an "incorrect slot," the increased R and L values are retained, but the Kt and Kb values are restored to the desired values. This approach assumes that increased resistance is acceptable to a degree. In effect, the heat allocated to the added inductance has been moved from the controller to the motor body, which in some cases is preferred.

Abel, Steve↗