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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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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Closed Brayton Cycle Power Conversion Unit for Fission Surface Power Phase I Final Report

A Closed Brayton cycle power conversion system has been developed to support the NASA fission surface power program. The goal is to provide electricity from a small nuclear reactor heat source for surface power production for lunar and Mars environments. The selected media for a heat source is NaK 78 with water as a cooling source. The closed Brayton cycle power was selected to be 12 kWe output from the generator terminals. A heat source NaK temperature of 850 K plus or minus 25 K was selected. The cold source water was selected at 375 K plus or minus 25 K. A vacuum radiation environment of 200 K is specified for environmental operation. The major components of the system are the power converter, the power controller, and the top level data acquisition and control unit. The power converter with associated sensors resides in the vacuum radiation environment. The power controller and data acquisition system reside in an ambient laboratory environment. Signals and power are supplied across the pressure boundary electrically with hermetic connectors installed on the vacuum vessel. System level analyses were performed on working fluids, cycle design parameters, heater and cooling temperatures, and heat exchanger options that best meet the needs of the power converter specification. The goal is to provide a cost effective system that has high thermal-to-electric efficiency in a compact, lightweight package.

Fuller, Robert L.↗
NASA NTRS2003

Thermal Vacuum Testing of a Novel Loop Heat Pipe Design for the Swift BAT Instrument

An advanced thermal control system for the Burst Alert Telescope on the Swift satellite has been designed and an engineering test unit (ETU) has been built and tested in a thermal vacuum chamber. The ETU assembly consists of a propylene loop heat pipe, two constant conductance heat pipes, a variable conductance heat pipe (VCHP), which is used for rough temperature control of the system, and a radiator. The entire assembly was tested in a thermal vacuum chamber at NASA/GSFC in early 2002. Tests were performed with thermal mass to represent the instrument and with electrical resistance heaters providing the heat to be transferred. Start-up and heat transfer of over 300 W was demonstrated with both steady and variable condenser sink temperatures. Radiator sink temperatures ranged from a high of approximately 273 K, to a low of approximately 83 K, and the system was held at a constant operating temperature of 278 K throughout most of the testing. A novel LHP temperature control methodology using both temperature-controlled electrical resistance heaters and a small VCHP was demonstrated. This paper describes the system and the tests performed and includes a discussion of the test results.

Ottenstein, Laura↗
NASA NTRS1993

Temperature dependence of protein solubility-determination, application to crystallization, and growth kinetics studies

A scintillation method was developed for determinations of the temperature dependence of the solubility, and of nucleation induction times of proteins, in 50-100 mu(l) volumes of solution. Solubility data for lysozyme and horse serum albumin were obtained for various combinations of pH and precipitant concentrations. These data and the nucleation induction information were used for dynamic crystallization control, that is, for the controlled separation of nucleation and growth stages. Individual lysozyme and horse serum albumin crystals were grown in 15-20 mu(l) solution volumes contained in x-ray capillaries. The morphology and kinetics of the growth and dissolution of lysozyme in aqueous solutions with 2.5 percent NaCl and at pH = 4.5 was studied in situ with a depth resolution of 300 A (4 unit cells) by high resolution optical microscopy and digital image processing. The bulk super- or under saturation, sigma, of the solution inside a closed growth cell was controlled by temperature. The growth habit was bound by (110) and (101) faces that grew through layer spreading, although with different growth rate dependencies on supersaturation/temperature. At sigma less than 10 (obtained at higher temperatures) growth was purely kinetic ally controlled, with impurity effects (macrostep formation and kinetic hindrance) becoming significant for sigma less than 2. At sigma greater than 10 (lower temperatures), anisotropies in the interfacial kinetics were more pronounced, with interfacial kinetics and bulk transport becoming equally important to the growth morphology. Growth rates were growth history dependent. The formation of striations (layers of irregularly incorporated solution) was unambiguously correlated with growth temperature variations. Etching exposed dislocations and various high-index faces whose growth morphologies were studied during return to the steady state growth form. Growth steps were observed to originate from two-dimensional nuclei or from outcrops of growth striations, and from dislocations that preferentially formed in growth sector boundaries.

Rosenberger, Franz↗
NASA NTRS1996

Development of the Plant Growth Facility for Use in the Shuttle Middeck and Test Units for Ground-Based Experiments

The plant growth facility (PGF), currently under development as a Space Shuttle middeck facility for the support of research on higher plants in microgravity, is presented. The PGF provides controlled fluorescent lighting and the active control of temperature, relative humidity and CO2 concentration. These parameters are designed to be centrally controlled by a dedicated microprocessor. The status of the experiment can be displayed for onboard analysis, and will be automatically archived for post-flight analysis. The facility is designed to operate for 15 days and will provide air filtration to remove ethylene and trace organics with replaceable potassium permanganate filters. Similar ground units will be available for pre-flight experimentation.

Chapman, David K.↗
DOE OSTI2025

Unveiling the nature of Ga-based chalcogenides for electrical switching selectors

Three-dimensional phase-change memory with stackable crossbar architecture is a promising technology to meet the urgent demands for high-density storage and rapid information processing in the era of explosive data growth. The performance depends strongly on the properties of ovonic threshold switching (OTS) selectors, which control the on/off states of memory units. Amorphous GaS serves as an outstanding OTS material, distinguished by its sizable mobility gap and high crystallization temperature, while the underlying mechanism continues to be inadequately comprehended. Here, in this work, we systematically studied the structural and electronic properties of amorphous Ga-X (X = S/Se/Te) using first-principles calculations. The results show that Ga atoms adopt tetrahedral motifs, while S/Se/Te atoms predominantly exhibit the structure of a distorted triangular pyramid. This structural arrangement is ascribed to the substantial dative bonds formed by the lone-pair electrons of the anions and the vacant sp3 orbitals around Ga atoms. Large mobility gaps (e.g., GaS: 2.43 eV, GaSe: 1.76 eV, GaTe: 1.26 eV) and distinct mid-gap states (e.g., ∼0.66 eV above valence band tail) ensure that these three chalcogenide glasses can be switched on under an external electric field while effectively suppressing leakage current without a bias, and the defect electronic states originate from short, robust Ga-Ga bonds due to the formation of distorted chain-like local structures. Our research elucidates the mechanisms of amorphous Ga-X as OTS materials, enriching the spectrum of electrical switching selectors by incorporating III-VI chalcogenides. This inclusion offers novel opportunities for the refinement and optimization of high-density integrated memory systems.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Convective flow effects on protein crystal growth

The experimental setup for the in-situ high resolution optical monitoring of protein crystal growth/dissolution morphologies was substantially improved. By augmenting the observation system with a temperature-controlled enclosure, laser illumination for the interferometric microscope, and software for pixel by pixel light intensity recording, a height resolution of about two unit cells for lysozyme can now be obtained. The repartitioning of Na(+) and Cl(-) ions between lysozyme solutions and crystals was studied. Quite unexpectedly, it was found that the longer crystals were in contact with their solution, the lower was their ion content. The development of a model for diffusive-convective transport and resulting distribution of the growth rate on facets was completed. Results obtained for a realistic growth cell geometry show interesting differences between 'growth runs' at 1g and 0g. The kinematic viscosity of lysozyme solutions of various supersaturations and salt concentrations was monitored over time. In contrast to the preliminary finding of other authors, no changes in viscosity were found over four days. The experimental setup for light scattering investigations of aggregation and nucleation in protein solutions was completed, and a computer program for the evaluation of multi-angle light scattering data was acquired.

Rosenberger, Franz↗
NASA NTRS2002

Integrated Stirling Convertor and Hall Thruster Test Conducted

An important aspect of implementing Stirling Radioisotope Generators on future NASA missions is the integration of the generator and controller with potential spacecraft loads. Some recent studies have indicated that the combination of Stirling Radioisotope Generators and electric propulsion devices offer significant trip time and payload fraction benefits for deep space missions. A test was devised to begin to understand the interactions between Stirling generators and electric thrusters. An electrically heated RG- 350 (350-W output) Stirling convertor, designed and built by Stirling Technology Company of Kennewick, Washington, under a NASA Small Business Innovation Research agreement, was coupled to a 300-W SPT-50 Hall-effect thruster built for NASA by the Moscow Aviation Institute (RIAME). The RG-350 and the SPT-50 shown, were installed in adjacent vacuum chamber ports at NASA Glenn Research Center's Electric Propulsion Laboratory, Vacuum Facility 8. The Stirling electrical controller interfaced directly with the Hall thruster power-processing unit, both of which were located outside of the vacuum chamber. The power-processing unit accepted the 48 Vdc output from the Stirling controller and distributed the power to all the loads of the SPT-50, including the magnets, keeper, heater, and discharge. On February 28, 2001, the Glenn test team successfully operated the Hall-effect thruster with the Stirling convertor. This is the world's first known test of a dynamic power source with electric propulsion. The RG-350 successfully managed the transition from the purely resistive load bank within the Stirling controller to the highly capacitive power-processing unit load. At the time of the demonstration, the Stirling convertor was operating at a hot temperature of 530 C and a cold temperature of -6 C. The linear alternator was producing approximately 250 W at 109 Vac, while the power-processing unit was drawing 175 W at 48 Vdc. The majority of power was delivered to the Hall thruster discharge circuit operating at 115 Vdc and 0.9 A. Testing planned for late 2001 will examine the possibility of directly driving the Hall thruster discharge circuit using rectified and filtered output from the Stirling alternator.

Mason, Lee S.↗
NASA NTRS2013

Thermal Infrared Sensor (TIRS) Instrument Thermal Subsystem Design and Lessons Learned

The Thermal Infrared Sensor (TIRS) is one of two instruments on the Landsat Data Continuity Mission (LDCM), which is scheduled to launch in February of 2013. The TIRS instrument was officially added to the mission later in the flow, which led to a highly aggressive schedule that became one of the main drivers during instrument development. The thermal subsystem design of the TIRS Sensor Unit is comprised of five thermal zones which range in temperature from less than 43 Kelvin to 330 Kelvin. Most zones are proportional heater controlled, and all are within a volume of 35 cu.ft. A two-stage cryocooler is used to cool the "cold stage" including three QWIP detectors to less than 43 Kelvin, and cool the "warm stage" to 105 Kelvin. The excess power dissipation from the cryocooler is rejected via ammonia transport heat pipes to a dedicated Cryocooler Radiator with embedded ammonia heat pipes. The cryogenic subsystem includes a series of shells used to radiatively and conductively isolate the cold stage from the warmer surroundings. The Optical System (telescope) is passively cooled to 180-190 Kelvin using a "thermal link" (comprised of a Flexible Conductive Thermal Strap and an APG Bar) which couples the telescope stage to a dedicated radiator with embedded ethane heat pipes. The Scene Select Mechanism, which is responsible for moving the Scene Select Mirror to three distinct positions (including Nadir, Space, and On-board Black Body Calibrator pointing), runs nominally at 278 Kelvin and is thermally isolated from the cryogenic thermal zones. The On-board Black Body Calibrator requires a dedicated radiator which allows for a temperature range of 260-330 Kelvin at the Source. The detectors are powered by the FPE Box, which is mounted to the nadir external surface of the composite honeycomb structure. There are two additional electronics boxes which are wet-mounted directly to the spacecraft shear panel, the Main Electronics Box and Cryocooler Electronics Box; thermal control of these boxes is the responsibility of Orbital Sciences Corporation, the spacecraft developer. The TIRS thermal subsystem design was successfully verified during months of testing campaign, from component & subsystem level to two instrument-level thermal vacuum tests. The Instrument, despite an aggressive schedule, was delivered to the spacecraft vendor in February of 2012 and is currently undergoing the final stages of spacecraft environmental testing in preparation for launch.

Otero, Veronica↗
DOE OSTI2023

Demonstrate FARM supervisory capabilities for a thermal energy storage problem for the DETAIL facility: IES Simulation Ecosystem Control System Development

The goal of the power dispatch problem for an Integrated Energy System (IES) is to adjust the power output and the heat flow of each component to maximize the profitability of the whole unit. Facilities that can integrate real-time digital signals, mock nuclear power, thermal energy storage and industrial heat use via high-temperature electrolysis were constructed at INL to support the research activities. The Dynamic Energy Technology and Integration Laboratory (DETAIL) houses the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET) and the Thermal Energy Distribution System (TEDS). In this report, the hierarchical control system architecture proposed in June 2023 milestone for the flexible operation of DETAIL facility is finalized and demonstrated. A brief description of the components and the corresponding Dymola models from the HYRBID repository is first provided. Then, the current control strategy is presented. In particular, the approach for generating the set-point trajectories to be fed to the PI controllers is analyzed, and its limits were identified. To preserve safe operation over both long-time and real-time horizons, the integration of a Supervisory Control layer embedding a modified version of FARM (Feasible Actuator Range Modifier) module is proposed. FARM is a component of the RAVEN-based FORCE framework designed to support HERON module at optimizing the operation of IES units. The proposed control system for DETAIL foresees FARM to be applied twice, i.e., the original version (“FARM-Validator”) aiding the solution of the power dispatch problem, and a modified version (“FARM-Supervisory”) coordinating the PID controllers. Despite the kernel of the two modules is the same, their tasks are quite different. The former intervenes at the beginning of each hour to prevent constraint violations over long time periods, the latter addresses real-time control tasks and monitors the response of constrained variables at a much finer time resolution. A tentative procedure for training the embedded Digital Twins with the experimental data is also proposed. Finally, the capabilities of the designed architecture and the impact of the added Supervisory Control layer are demonstrated by simulating a representative power dispatch scenario.

25 ENERGY STORAGE↗
DOE OSTI2023

Deployment of Dynamic Neural Network Optimization to Minimize Heat Rate During Ramping for Coal Power Plants (Final Technical Report)

Much success was achieved throughout the course of this project. A successful implementation of Dynamic Neural Network Optimization (D-NNO) was coupled with Adaptive Predictive Controls (APC) and a novel hardware installation comprised of an advanced sensor network (ASN) measuring mass-weighted averages of flue gas constituents above the horizontal superheater of a coal-fired utility boiler. From 2019 through 2023 (including an extension due to COVID delays), the team was able to prototype, evaluate, deploy, iterate, and ultimately finalize an advanced closed-loop control D-NNO system which demonstrated the ability to: •improve unit efficiency ~2.0% relative to unoptimized operation (represented as total fuel fired per MWh generated) •improve unit NOx emission rates 10%+ beyond static optimization baselines •improve unit temperature stability as much as 58% and on average 12% •improve operating load stability as much as 35% The culmination of this project has generated an advanced methodology of deploying specially designed recurrent neural networks (long short-term memory, gated recurrent unit, encoder-decoder networks, transformers, etc.), customized trajectory planning and closed-loop optimization modules capable of adapting to live electric grid responses and demands, self-tuning and adaptive expert controls constantly adjusting prediction parameters to real-time unit behavior, and a hardware/software package able to reliably calculate net unit heat rate (NUHR) in real-time using flue gas constituents, machine learning, and known combustion relationships. Through this real-time NUHR value, immediate feedback on system adjustments relative to operating efficiency was available, allowing for rapid improvements to system performance. In addition to development and deployment of the advanced D-NNO system, the approach methodology has been readily commercialized through the project platform Griffin Open Systems, LLC, the D-NNO software platform host. Similar methodologies to those developed by this project have already been deployed at 5 other units across the United States, with another 6 implementations scheduled, and more expected. Over the course of the project, multiple academic papers were submitted and accepted for publication within esteemed academic journals, and PhD students were trained and graduated, as well as undergraduate students becoming involved and participating to project objectives.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1987

Impact of thermal energy storage properties on solar dynamic space power conversion system mass

A 16 parameter solar concentrator/heat receiver mass model is used in conjunction with Stirling and Brayton Power Conversion System (PCS) performance and mass computer codes to determine the effect of thermal energy storage (TES) material property changes on overall PCS mass as a function of steady state electrical power output. Included in the PCS mass model are component masses as a function of thermal power for: concentrator, heat receiver, heat exchangers (source unless integral with heat receiver, heat sink, regenerator), heat engine units with optional parallel redundancy, power conditioning and control (PC and C), PC and C radiator, main radiator, and structure. Critical TES properties are: melting temperature, heat of fusion, density of the liquid phase, and the ratio of solid-to-liquid density. Preliminary results indicate that even though overalll system efficiency increases with TES melting temperature up to 1400 K for concentrator surface accuracies of 1 mrad or better, reductions in the overall system mass beyond that achievable with lithium fluoride (LiF) can be accomplished only if the heat of fusion is at least 800 kJ/kg and the liquid density is comparable to that of LiF (1880 kg/cu m.

Juhasz, Albert J.↗
NASA NTRS1987

Impact of thermal energy storage properties on solar dynamic space power conversion system mass

A 16 parameter solar concentrator/heat receiver mass model is used in conjunction with Stirling and Brayton Power Conversion System (PCS) performance and mass computer codes to determine the effect of thermal energy storage (TES) material property changes on overall PCS mass as a function of steady state electrical power output. Included in the PCS mass model are component masses as a function of thermal power for: concentrator, heat receiver, heat exchangers (source unless integral with heat receiver, heat sink, regenerator), heat engine units with optional parallel redundancy, power conditioning and control (PC and C), PC and C radiator, main radiator, and structure. Critical TES properties are: melting temperature, heat of fusion, density of the liquid phase, and the ratio of solid-to-liquid density. Preliminary results indicate that even though overall system efficiency increases with TES melting temperature up to 1400 K for concentrator surface accuracies of 1 mrad or better, reductions in the overall system mass beyond that achievable with lithium fluoride (LiF) can be accomplished only if the heat of fusion is at least 800 kJ/kg and the liquid density is comparable to that of LiF (1800 kg/cu m).

Juhasz, Albert J.↗
NASA NTRS1999

The Effects of Gravity on ZBLAN Glass

Heavy metal fluoride glass fibers show promise in applications such as surgical lasers, spectroscopy and imaging fiber bundles. ZBLAN, which is within this class has been studied for a number of years. ZBLAN's theoretical attenuation coefficient is approximately 0.002 dB/km which is much better than that of fused silica at 0.2 dB/km. However, due to impurities and crystallites the attenuation coefficients achieved to date are considerably larger than those of fused silica. Impurities can be controlled with better processing techniques. Crystallization has been found to be a function of gravity. It is found that heating to the crystallization temperature in unit gravity results in crystallization while heating in reduced gravity does not. The exact mechanism for this phenomenon is not known but is speculated to be related to stress.

Tucker, Dennis S.↗
NASA NTRS2006

Universal Controller for Spacecraft Mechanisms

An electronic control unit has been fabricated and tested that can be replicated as a universal interface between the electronic infrastructure of a spacecraft and a brushless-motor (or other electromechanical actuator) driven mechanism that performs a specific mechanical function within the overall spacecraft system. The unit includes interfaces to a variety of spacecraft sensors, power outputs, and has selectable actuator control parameters making the assembly a mechanism controller. Several control topologies are selectable and reconfigurable at any time. This allows the same actuator to perform different functions during the mission life of the spacecraft. The unit includes complementary metal oxide/semiconductor electronic components on a circuit board of a type called rigid flex (signifying flexible printed wiring along with a rigid substrate). The rigid flex board is folded to make the unit fit into a housing on the back of a motor. The assembly has redundant critical interfaces, allowing the controller to perform time-critical operations when no human interface with the hardware is possible. The controller is designed to function over a wide temperature range without the need for thermal control, including withstanding significant thermal cycling, making it usable in nearly all environments that spacecraft or landers will endure. A prototype has withstood 1,500 thermal cycles between 120 and +85 C without significant deterioration of its packaging or electronic function. Because there is no need for thermal control and the unit is addressed through a serial bus interface, the cabling and other system hardware are substantially reduced in quantity and complexity, with corresponding reductions in overall spacecraft mass and cost.

Levanas, Greg↗
NASA NTRS2022

Improved representation of agricultural land use and crop management for large-scale hydrological impact simulation in Africa using SWAT+

To date, most regional and global hydrological models either ignore the representation of cropland or consider crop cultivation in a simplistic way or in abstract terms without any management practices. Yet, the water balance of cultivated areas is strongly influenced by applied management practices (e.g. planting, irrigation, fertilization, and harvesting). The SWAT+ (Soil and Water Assessment Tool) model represents agricultural land by default in a generic way, where the start of the cropping season is driven by accumulated heat units. However, this approach does not work for tropical and subtropical regions such as sub-Saharan Africa, where crop growth dynamics are mainly controlled by rainfall rather than temperature. In this study, we present an approach on how to incorporate crop phenology using decision tables and global datasets of rainfed and irrigated croplands with the associated cropping calendar and fertilizer applications in a regional SWAT+ model for northeastern Africa. We evaluate the influence of the crop phenology representation on simulations of leaf area index (LAI) and evapotranspiration (ET) using LAI remote sensing data from Copernicus Global Land Service (CGLS) and WaPOR (Water Productivity through Open access of Remotely sensed derived data) ET data, respectively. Results show that a representation of crop phenology using global datasets leads to improved temporal patterns of LAI and ET simulations, especially for regions with a single cropping cycle. However, for regions with multiple cropping seasons, global phenology datasets need to be complemented with local data or remote sensing data to capture additional cropping seasons. In addition, the improvement of the cropping season also helps to improve soil erosion estimates, as the timing of crop cover controls erosion rates in the model. With more realistic growing seasons, soil erosion is largely reduced for most agricultural hydrologic response units (HRUs), which can be considered as a move towards substantial improvements over previous estimates. We conclude that regional and global hydrological models can benefit from improved representations of crop phenology and the associated management practices. Future work regarding the incorporation of multiple cropping seasons in global phenology data is needed to better represent cropping cycles in areas where they occur using regional to global hydrological models.

crop phenology↗
NASA NTRS2015

Design and Demonstration of the Mars Organic Molecule Analyzer (MOMA) on the ExoMars 2018 Rover

The Mars Organic Molecule Analyzer (MOMA) investigation is a key astrobiology experiment scheduled to launch on the joint ESA-Roscosmos ExoMars 2018 rover mission. MOMA will examine the chemical composition of geological samples acquired from depths of up to two meters below the martian surface, where fragile organic molecules may be protected from destructive cosmic radiation and/or oxidative chemical reactions. The heart of the MOMA mass spectrometer subsystem (i.e., MOMA-MS) is a miniaturized linear ion trap (LIT) that supports two distinct modes of operation to detect: i) volatile and semi-volatile, low-to-moderate mass organics (less than or equal to 500 Da) via pyrolysis coupled with gas chromatography mass spectrometry (pyr/GCMS); and, ii) more refractory, moderate-to-high mass compounds (up to 1000 Da) via laser desorption (LDMS) at ambient Mars pressures. Additionally, the LIT mass analyzer enables selective ion trapping via multi-frequency waveform ion excitation (e.g., stored waveform inverse Fourier transform, or SWIFT), and structural characterization of complex molecules using tandem mass spectrometry (MSIMS). A high-fidelity Engineering Test Unit (ETU) of MOMAMS, including the LIT subassembly, dual-gun electron ionization source, micropirani pressure gauge, solenoid-driven aperture valve, redundant detection chains, and control electronics, has been built and tested at NASA GSFC under relevant operational conditions (pressure, temperature, etc.). Spaceflight qualifications of individual hardware components and integrated subassemblies have been validated through vibration, shock, thermal, lifetime, and performance evaluations. The ETU serves as a pathfinder for the flight model buildup, integration and test, as the ETU meets the form, fit and function of the flight unit that will be delivered to MPS in late 2015. To date, the ETU of MOMA-MS has been shown to meet or exceed all functional requirements, including mass range, resolution, accuracy, instrumental drift, and Iimit-of-detection specifications, thereby enabling the primary science objectives of the MOMA investigation and ExoMars 2018 mission.

Mars Organic Molecule Analyzer↗
NASA NTRSDate not supplied

Control System Development for A Zero Boil-Off Hydrogen Storage Demonstration With Two-Stage Active Cooling

A NASA team is designing and building a test article to demonstrate the long duration storage of liquid hydrogen via active cooling (cryocoolers) while implementing a two-stage cooling approach. This activity is one of a large portfolio of NASA’s Space Technology Mission Directorate funded activities which focuses on the technology maturation needed for long duration storage of cryogenic liquid in-space. The current state-of-the-art for liquid hydrogen storage on-orbit is on the order of hours while NASA’s planned missions require storage for months, or even years. To enable such a long duration, Zero Boil-Off conditions must be achieved which requires passive technologies to minimize environmental heat loads, but also active cooling to intercept and reject the remaining heat to deep space. The implementation of active cooling results in a significant amount of dry mass added to the vehicle. Utilizing a Two-Stage Cooling approach, analysis and testing to date indicates the Zero Boil-Off of liquid hydrogen can be achieved with less mass and electrical power relative to a single-stage cooling approach where only one cryocooler is used. This activity will demonstrate the fully integrated suite of technologies needed to enable the Two-Stage Cooling approach which includes Multi-Layer Insulation blankets, Low Conductivity Structures, a Tube-On-Tank Heat Exchanger, Tube-On-Shield Heat Exchanger and a Two-Stage Cryogenerator (both 90 Kelvin and 20 Kelvin) with each stage having an independently controlled circulation loop. The bulk of the heat load is intercepted by the 90 Kelvin loop via a thin foil heat exchanger internal to the insulation blankets (also known as a Broad Area Cooling Shield), with the remainder removed at cryofluid temperature (20 Kelvin) by tubes directly welded to the outer tank surface. In this paper, we examine the challenges of controlling the system, and describe the development of control algorithms and software for future testing with liquid hydrogen. The interactions between the cryofans which control circulation loop mass flow rates, electrical heaters which vary the cryocooler lift to simulate the operation of variable-lift flight units, tank heaters which can vary the overall heat load, and the effects of changes in circulation loop pressure as temperatures change, can be complex and must be well understood to maintain steady-state propellant conditions and achieve Zero Boil-Off. Parallel PID loops and watchdog programs implemented on the user interface system will help bring the systems to steady state operation and keep them at selected operating points within acceptable error, while avoiding runaway feedback loops.

cryogenics↗