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356 records · Page 11

A Simplified Model of VIPER Thermal Management System. Part I: Loop Heat Pipe

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) uses a combination of loop heat pipes (LHPs) and heaters as the primary hardware to modulate the temperature of the electronic boxes and payloads instruments. LHPs have been designed and instrumented to be capable of passive and active shutdown. The goal of the passive shutdown, using a thermal control valve (TCV) to limit the flow of the working fluid, is to preserve thermal energy and avoid unnecessary heat leaks during lunar night. The goal of the active shutdown on the other hand, is to forcefully increase the vehicle internal temperature to bakeout the payload instruments. Several numerical modeling tools are available to analyze LHP performance under the complex set of operational requirements and environments levied on the VIPER Thermal Management System (TMS). Yet, while those numerical modeling tools are capable of detailed performance analysis, they tend to take large computational resources and long computational time. In this paper, a model of a single LHP developed based on control volume approach is presented. By using the control volume approach, the complex geometry of the LHP, and the components attached to it, are reduced to thermal lump capacitances, thus reducing the computation effort. This paper also describes the effort to correlate the proposed LHP model using thermal vacuum (TVAC) test data.

Loop Heat Pipe

A Simplified Model of VIPER Thermal Management System. Part I: Loop Heat Pipe

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) uses a combination of loop heat pipes (LHPs) and heaters as the primary hardware to modulate the temperature of the electronic boxes and payloads instruments. LHPs have been designed and instrumented to be capable of passive and active shutdown. The goal of the passive shutdown, using a thermal control valve (TCV) to limit the flow of the working fluid, is to preserve thermal energy and avoid unnecessary heat leaks during lunar night. The goal of the active shutdown on the other hand, is to forcefully increase the vehicle internal temperature to bakeout the payload instruments. Several numerical modeling tools are available to analyze LHP performance under the complex set of operational requirements and environments levied on the VIPER Thermal Management System (TMS). Yet, while those numerical modeling tools are capable of detailed performance analysis, they tend to take large computational resources and long computational time. In this paper, a model of a single LHP developed based on control volume approach is presented. By using the control volume approach, the complex geometry of the LHP, and the components attached to it, are reduced to thermal lump capacitances, thus reducing the computation effort. This paper also describes the effort to correlate the proposed LHP model using thermal vacuum (TVAC) test data.

Loop Heat Pipe

Simulated Lunar Gravity Testing of VIPER Loop Heat Pipe

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) mission consists of a rover designed to explore the lunar south pole. One of the main challenges faced by the rover during the lunar polar exploration is the adverse thermal environment. Temperatures can fluctuate more than a 100°C between day and night; potentially dropping to −246°C in permanent shadow regions. To maintain the rover components within temperature limits, VIPER’s Thermal Management System (TMS) relies heavily on Loop Heat Pipes (LHPs). To assist the design of the thermal management system, an Engineering Design Unit (EDU) LHP has been tested in several opportunities under thermal vacuum (TVAC) environment. Of particular interest was the LHP performance in lunar gravity. To that end, the EDU LHP was tested at the nominal orientation within the rover assembly, vertical, and inclined such that the gravitational component acting on the LHP evaporator and condenser was 1/6g (lunar gravity is 1/6 of Earth gravity) when compared to the vertical configuration. This paper will examine the LHP conductance as one the key parameters to assess the effect of the gravity on the LHP performance.

Loop Heat Pipe

Overview of the Center for Advanced Space Propulsion

The mission of the Center for Advanced Space Propulsion (CASP), a Center for the Commercial Development of Space (CCDS), is to strengthen U.S. competitiveness in space technology, foster cooperative research with industry and government, assist industry in developing commercial products and services, and perform research in advanced space propulsion. Current areas of focus are (1) advanced chemical propulsion, including high area ratio nozzle performance, variable thrust engine performance, and spray combustion stability; (2) artificial intelligence propulsion applications, including health monitoring of rocket engines, fault pattern detection and diagnosis, and intelligent hypertext applications; (3) microgravity fluid management, including liquid storage and transfer, a subscale orbital fluid transfer experiment, and helical, two-phase flow; (4) electric propulsion, including magnetic annular arc thruster, ion thrustor, and electrostatic plasma accelerator; and (5) laser materials processing.

George W Garrison

The Use of Immersion Rigs for High Temperature Hydrogen Exposure Testing Within the Nuclear Thermal Rocket Element Environmental Simulator (NTREES): NTREES-5 Hydrogen Heat Exchanger (N5HHX-01)

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility at NASA’s Marshall Space Flight Center (MSFC) subjects materials and components typically found on nuclear thermal propulsion (NTP) systems to non-nuclear simulations of prototypic NTP reactor thermohydraulic environments. With 1.2 MW of inductive power available, the currently employed methods to simulate nuclear heating in NTREES consist of 1) inductively heating a test specimen, which typically cannot be performed on ceramic materials, or 2) heating gas that envelops the test specimen. The latter of these has provided a basis for developing so-called “immersion rigs” to be used in NTREES. Furthermore, immersion rigs are especially useful in the case of smaller, technically challenging test specimens. One such device, the “NTREES-5 Hydrogen Heat Exchanger” (N5HHX-01), designed and deployed to test small material coupons to ~0.5 g/s of 2800 K, 500 psi Hydrogen, is discussed herein. To achieve this desired delivery temperature level, the most suitable material for the N5HHX’s construction was pure tungsten, which imposed budgetary and manufacturing challenges. Also discussed in this paper is the design of the N5HHX rig’s sample container, which became the first iteration of improving NTREES small material coupon test operations by permitting rapid changeout of different material samples.

Reactor Testing

Swamp Works Regolith Compaction Technologies

While the level of compaction below the lunar surface increases quickly after only a few cm of depth, in many cases during a construction mission there will be a need to excavate and transport regolith to a new location for cut-and-fill or horizontal construction of structures such as berms. In these cases to achieve high levels of bulk density, compaction must be per-formed. Additionally, in some cases surface technologies such as systems that sinter/melt the surface may desire the maximum possible compaction at the sur-face to improve melting/heating performance and the final material strength properties. Kennedy Space Center’s (KSC) Swamp Works has developed two means of compaction, lunar and mar-tian compaction. Planetary Autonomous Compaction Technology (PACT) which is part of the Multifunction End Effector for Regolith Compaction Acquisition and Transfer (MEERCAT) robotic arm end effector system’s capabilities and the Site Preparation Tooling for Operations on Mobility Platforms (STOMP) vibratory roller compactor. PACT on MEERCAT has been demonstrated to a TRL 5 and STOMP to a TRL 4 in ambient testing. The results of PACT on MEERCAT and STOMP testing will be shared with results for various simulants including BP-1, ICN-LHT-1G (aka CSM-LHT-1G), RDW-LHT-1GH (a simulant developed for the Mason Tipping Point to match characteristics of ICN-LHT-1G), and Exolith LHS-1E. This will also include discussions on methods used to verify relative density before and after compaction and means to verify density effects below depth. To calculate relative density, maximum and minimum densities for simulants were taken from literature and additional lab testing (publication in work).

redwire

Enabling Mission Flexibility to Battery Driven Deep Space Endeavors With Generalized Battery-Health-Monitoring Using Physics-Based and Data-Driven Reduced-Order Models

The needs and requirements for an electrochemical energy storage for deep space exploration is well explored. It is often understood that different mission sites and environmental conditions require different battery chemistries or technologies. Additionally, various engineering solutions are deployed to overcome specific chemical challenges. One often overlooked need is the “health” monitoring of an electrochemical storage system. The term generalized health monitoring, as envisioned in this work, refers to the monitoring of various aspects such as electrode health, electrolyte health, reaction pathway health, cooling system health, sensor health, and BMS health [1]. Generalized health monitoring allows mission leads, engineers, and scientists to incorporate flexibility in mission designs, make on-the-fly mission changes, and extend the duration of science missions. Moreover, it enables automation and data-driven decision-making without compromising safety and performance. Recently, our group developed a hierarchy of thermal reduced-order models (TROM) by combining a physics-based modeling approach and data-driven model reduction techniques applied to flight data [2]. The resulting TROMs were found to be not only accurate but also identifiable from the flight data. Consequently, the coefficient of variance of the model parameters is small over the course of hundreds of flights, allowing for monitoring the parameter evolution trajectories as the battery ages and degrades. These parameters constitute the metrics of the generalized health of a battery. Monitoring their evolution allows such models to be used for anomaly detection and prognostics, improving early detection of abnormal behavior and thus enabling timely maintenance, longer battery life, and enhanced battery safety. For this presentation, the practicality of the thermal model will be validated on a pack of 14cells under various topology configurations such as 1S14P, 2P7S, 7S2P, and 1P14S. It is well known that manufacturing and non-uniform aging lead to variability in the performance of a cell, which is exacerbated by cell balancing during active load. Additionally, in extreme scenarios, the paramount objective is to complete the mission, regardless of the stresses on the battery. Topology-induced balancing issues further stress the battery. The goal of this study is to determine if the noise (identifiability) in the reduced-order thermal model parameters is sensitive to topology, cell spacing, cooling strategy, and manufacturing or age variability. The variability in cells is considered by assuming a multimodal distribution for microscopic parameters of a cell (such as porosity, tortuosity, reaction kinetics, volumetric thermal conductivity, and volumetric heat capacity). The compounded effect of manufacturing variability, topological selection, cooling strategies, and cell balancing ages each cell in a battery differently. The study aims to clarify whether the challenge in extracting maximum information depends on the minimum number of sensors or models used for data extraction.

Automation

Designing a Propylene-Glycol Coolant Servicer System for Gateway’s Internal Active Thermal Control System

A human spacecraft ATCS—especially one using single-phase coolant loops exposed to cabin atmospheric conditions—requires periodic degassing and refilling to support long-duration missions of 15 to 30 years. During initial fill operations, system maintenance, gas permeation, and quick-disconnect mating or de-mating, small amounts of gas can gradually enter the coolant system over time. This can lead to degraded heat transfer performance, pump cavitation, and potentially pump vapor lock if a significant gas volume accumulates over time. Additionally, system leaks and routine fluid sampling can gradually reduce accumulator volumes to unacceptable levels, requiring periodic refills. In more severe cases, catastrophic changes in fluid composition may necessitate emergency draining, refilling, and degassing to ensure continued system functionality. These risks were identified and mitigated on the ISS ITCS through the development of a dual-membrane degasser ORU and a Fluid Servicer System ORU for coolant refilling. These systems were developed for the fully water-based ISS ITCS Coolant[1]. The Gateway space station, the first permanent human habitat in lunar orbit, uses a propylene-glycol/water coolant mixture, which has significantly different fluid properties compared to pure water. Because microgravity degassing technologies are sensitive to fluid surface tension and viscosity, existing ISS hardware is not suitable for servicing a propylene-glycol-based TCS. Unlike the ISS, the Gateway will operate in a higher-radiation environment and must meet stricter mass constraints due to its location outside of low earth orbit. This Government Furnished Equipment (GFE) flight hardware project aims to develop a lightweight, radiation-resistant Coolant Servicer System (CSS) capable of degassing and refilling Gateway’s propylene-glycol water-based IATCS.

Propylene Glycol Water

Heat Capacity and Thermal Relaxation of Bulk Helium Very Near the Lambda Point

In October 1992 a low temperature experiment was flown on the Space Shuttle in low Earth orbit. The objective of the mission was to measure the heat capacity and thermal conductivity of helium very close to the lambda point with the smearing effect of gravity removed. We report preliminary results from the experiment, and compare them with related measurements performed on the ground. The sample was s sphere of helium 3.5 cm in diameter contained within a copper calorimeter of vey high thermal conductivity. The calorimeter was attached to a pair of high resolution paramagnetic salt thermometers with noise levels in the 10 -10 K range and suspended from a high stability thermal isolation system. During the mission we found that the resolution of the thermometers was degraded somewhat due to the impact of charged particles. This effect limited the useful resolution of the measurements to about two nanokelvins from the lambda point. The results reported here are limited to about ten nanokelvins from the transition.

John A Lipa

Designing a Propylene-Glycol Coolant Servicer System for Gateway’s Internal Active Thermal Control System

A human spacecraft ATCS—especially one using single-phase coolant loops exposed to cabin atmospheric conditions—requires periodic degassing and refilling to support long-duration missions of 15 to 30 years. During initial fill operations, system maintenance, gas permeation, and quick-disconnect mating or de-mating, small amounts of gas can gradually enter the coolant system over time. This can lead to degraded heat transfer performance, pump cavitation, and potentially pump vapor lock if a significant gas volume accumulates over time. Additionally, system leaks and routine fluid sampling can gradually reduce accumulator volumes to unacceptable levels, requiring periodic refills. In more severe cases, catastrophic changes in fluid composition may necessitate emergency draining, refilling, and degassing to ensure continued system functionality. These risks were identified and mitigated on the ISS ITCS through the development of a dual-membrane degasser ORU and a Fluid Servicer System ORU for coolant refilling. These systems were developed for the fully water-based ISS ITCS Coolant[1]. The Gateway space station, the first permanent human habitat in lunar orbit, uses a propylene-glycol/water coolant mixture, which has significantly different fluid properties compared to pure water. Because microgravity degassing technologies are sensitive to fluid surface tension and viscosity, existing ISS hardware is not suitable for servicing a propylene-glycol-based TCS. Unlike the ISS, the Gateway will operate in a higher-radiation environment and must meet stricter mass constraints due to its location outside of low earth orbit. This Government Furnished Equipment (GFE) flight hardware project aims to develop a lightweight, radiation-resistant Coolant Servicer System (CSS) capable of degassing and refilling Gateway’s propylene-glycol water-based IATCS.

Propylene Glycol Water

The Chemical Composition of the Cores of the Terrestrial Planets and the Moon

Using models of the quasi-chemical theory of solutions, the activity coefficients of silicon are calculated in the melts Fe-Si, Ni-Si, and Fe-Ni-Si. The calculated free energies of solution of liquid nickel and silicon in liquid iron in the interval 0 to 1400 kbar and 1500 to 4000 K, shows that Fe-Ni-Si alloy is stable under the conditions of the outer core of the Earth and the cores of the terrestrial planets. The oxidation-reduction conditions are studied, and the fugacity of oxygen in the mantles of the planets and at the core-mantle boundary are calculated. The mechanism of reduction of silicon is analyzed over a broad interval of P and T. The interaction between the matter of the core and mantle is studied, resulting in the extraction of silicon from the mantle and its solution in the material of the core. It is concluded that silicon can enter into the composition of the outer core of the Earth and Venus, but probably does not enter into the composition of the cores of Mercury, Mars, and the Moon, if in fact the latter possesses one.

O L Kuskov

Swamp Works Regolith Compaction Technologies

While the level of compaction below the lunar surface increases quickly after only a few cm of depth, in many cases during a construction mission there will be a need to excavate and transport regolith to a new location for cut-and-fill or horizontal construction of structures such as berms. In these cases to achieve high levels of bulk density, compaction must be per-formed. Additionally, in some cases surface technolo-gies such as systems that sinter/melt the surface may desire the maximum possible compaction at the sur-face to improve melting/heating performance and the final material strength properties. Kennedy Space Center’s (KSC) Swamp Works has developed two means of compaction, lunar and mar-tian compaction. Planetary Autonomous Compaction Technology (PACT) which is part of the Multifunction End Effector for Regolith Compaction Acquisition and Transfer (MEERCAT [1]) robotic arm end effector system’s capabilities and the Site Preparation Tooling for Operations on Mobility Platforms (STOMP [2]) vibratory roller compactor. PACT on MEERCAT has been demonstrated to a TRL 5 and STOMP to a TRL 4 in ambient testing. The results of PACT on MEERCAT and STOMP testing will be shared with results for various simulants including BP-1, ICN-LHT-1G (aka CSM-LHT-1G), RDW-LHT-1GH (a simulant developed for the Mason Tipping Point to match characteristics of ICN-LHT-1G), and Exolith LHS-1E. This will also include discus-sions on methods used to verify relative density before and after compaction and means to verify density effects below depth. To calculate relative density, maximum and minimum densities for simulants were taken from literature [3] [4] [5] and additional lab test-ing (publication in work).

vibration

Practical Battery Thermal Modeling Techniques

Lithium-ion batteries are thermo-electrochemical devices, whereby nearly every facet of their functionality and performance are thermally driven. As a result, it is important to have thermal modeling techniques that effectively capture the intricacies of both the electrochemical nature of the battery and also the complex thermal network that typically results from the design of the battery thermal management system. Here we present a thermal modeling workflow and a set of general assumptions for how to construct a thermal model of a Li-ion battery pack. We use a 14-cell bank of 18650-format Li-ion cells, loosely based on a proposed alternative battery design for Orion, as the example. Although the workflow is performed with Thermal Desktop and related utilities, the focus of this presentation is less about software specific techniques, but rather is focused on the assumptions and conditions that should be used in a model (regardless of the tool used to build the model). Example cases and results will be presented for charge, discharge, and thermal runaway.

lithium-ion battery

Airports as Energy Nodes Activity Summary

Advanced aircraft concepts that use non-traditional aviation energy storage methods such as batteries or cryogenic hydrogen are in development and expected to enter regular service at airports worldwide within the next decade. The energy needs for these aircraft may quickly overwhelm the existing energy infrastructure at airports, particularly at smaller and more remote facilities. Without energy upgrades, these airports will not be able to host these advanced vehicles, but without the advanced vehicle traffic, these airports will not have the rationale or funding to build up their energy infrastructure. The Airports as Energy Nodes (ÆNodes) activity, a collaboration between the National Aeronautics and Space Administration (NASA) and the National Renewable Energy Laboratory (NREL), was executed to understand and model the energy needs that advanced aircraft concepts may levy on these smaller airports, determine cost-effective approaches to enhance the airport energy infrastructure, and demonstrate the enhanced resilience of these energy infrastructure upgrades to the airport and surrounding community via “digital twin” simulation at relevant energy and dynamic time scales. The ÆNodes team also investigated future reference aircraft designs and materials to enable cryogenic hydrogen storage for aircraft. The ÆNodes team conducted analysis at two U.S. airport partner sites — Winchester Regional Airport in Winchester, Virginia, and Tweed/New Haven Airport in New Haven, Connecticut. The goal of this partnership was to develop data and reference infrastructure designs that could accommodate advanced aircraft in the future at these airports while also enhancing the resiliency of the energy supply to the surrounding airport community, which could be used to capture funding to enable the infrastructure upgrades. Over the course of the study, a method was developed to estimate air traffic requiring advanced energy services over the course of a year using a mix of historical data and companion studies on advanced aircraft transportation networks. The study has concluded at NASA but continues at NREL, who will develop a final report discussing the energy infrastructure upgrades and digital twin results. Preliminary results indicate that unrestricted adoption of advanced battery-electric aircraft may double traffic at these airports and increase peak daily power usage by an order of magnitude, while increase electricity energy needs by a factor of two to four. The infrastructure upgrades necessary to accommodate these increased energy needs could be used to provide enhanced energy services to the airport community to offset the cost and increase the utility of the upgrades, which will be described in the NREL final report.

Airports

Chapter 3: Thermal Exchanges and Temperature Stress

Thermal comfort during space flight is discussed. Heat production of man during space flight and wear loss as a mean of dissipating heat are described. Water cooled garments are also considered, along with tolerance for extreme heat and body heat storage. Models of human temperature regulation are presented in the form of documented FORTRAN programs.

Paul Webb

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) thermal management system (TMS) relies on four loop heat pipes (LHPs) to transport electronic waste heat to the vehicle cooling radiative surface and avoid overheating. The TMS has also ten constant conductance heat pipes (CCHPs) dedicated to balance the thermal load within the internal environment where the avionics boxes are mounted, also called warm electronic box (WEB), and to transport the heat from two of the science payload instruments. The TMS also uses two thermal straps to thermally link the batteries to the WEB. These thermal components, in addition to heaters, thermostat, multi-layer insulation (MLIs), and isolators forms the core of the VIPER TMS. The complex heat transport balance managed by the TMS is challenging to characterize and model. The more fidelity and granularity of a model, the more costly the computational resources needed and the longer the simulation and modeling time. When the priority is to provide quick but reliable assessments of the thermal performance or real time thermal feedback for training of console operators, simplified modeling tools are needed. To satisfy that need, this paper describes the effort to develop and correlate a model of VIPER TMS based on control volume approach. The correlation effort in particular focuses on hibernation, cold thermal balance, and hot thermal balance data from the integrated vehicle thermal vacuum (TVAC) test. Thus, the correlated model captures the heat leaks during hibernations and the performance at two extremes, bounding, operating scenarios.

Loop Heat Pipe

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) thermal management system (TMS) relies on four loop heat pipes (LHPs) to transport electronic waste heat to the vehicle cooling radiative surface and avoid overheating. The TMS has also ten constant conductance heat pipes (CCHPs) dedicated to balance the thermal load within the internal environment where the avionics boxes are mounted, also called warm electronic box (WEB), and to transport the heat from two of the science payload instruments. The TMS also uses two thermal straps to thermally link the batteries to the WEB. These thermal components, in addition to heaters, thermostat, multi-layer insulation (MLIs), and isolators forms the core of the VIPER TMS. The complex heat transport balance managed by the TMS is challenging to characterize and model. The more fidelity and granularity of a model, the more costly the computational resources needed and the longer the simulation and modeling time. When the priority is to provide quick but reliable assessments of the thermal performance or real time thermal feedback for training of console operators, simplified modeling tools are needed. To satisfy that need, this paper describes the effort to develop and correlate a model of VIPER TMS based on control volume approach. The correlation effort in particular focuses on hibernation, cold thermal balance, and hot thermal balance data from the integrated vehicle thermal vacuum (TVAC) test. Thus, the correlated model captures the heat leaks during hibernations and the performance at two extremes, bounding, operating scenarios.

Thermal Modeling