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All sources NASA NTRS DOE OSTI

NASA NTRS2004

Space Shuttle Upgrades Advanced Hydraulic Power System

Three Auxiliary Power Units (APU) on the Space Shuttle Orbiter each provide 145 hp shaft power to a hydraulic pump which outputs 3000 psi hydraulic fluid to 41 hydraulic actuators. A hydrazine fuel powered APU utilized throughout the Shuttle program has undergone many improvements, but concerns remain with flight safety, operational cost, critical failure modes, and hydrazine related hazards. The advanced hydraulic power system (AHPS), also known as the electric APU, is being evaluated as an upgrade to replace the hydrazine APU. The AHPS replaces the high-speed turbine and hydrazine fuel supply system with a battery power supply and electric motor/pump that converts 300 volt electrical power to 3000 psi hydraulic power. AHPS upgrade benefits include elimination of toxic hydrazine propellant to improve flight safety, reduction in hazardous ground processing operations, and improved reliability. Development of this upgrade provides many interesting challenges and includes development of four hardware elements that comprise the AHPS system: Battery - The battery provides a high voltage supply of power using lithium ion cells. This is a large battery that must provide 28 kilowatt hours of energy over 99 minutes of operation at 300 volts with a peak power of 130 kilowatts for three seconds. High Voltage Power Distribution and Control (PD&C) - The PD&C distributes electric power from the battery to the EHDU. This 300 volt system includes wiring and components necessary to distribute power and provide fault current protection. Electro-Hydraulic Drive Unit (EHDU) - The EHDU converts electric input power to hydraulic output power. The EHDU must provide over 90 kilowatts of stable, output hydraulic power at 3000 psi with high efficiency and rapid response time. Cooling System - The cooling system provides thermal control of the Orbiter hydraulic fluid and EHDU electronic components. Symposium presentation will provide an overview of the AHPS upgrade, descriptions of the four hardware elements, and a summary of development results to date.

Source record↗

NASA NTRS2004

Hydraulic Apparatus for Mechanical Testing of Nuts

The figure depicts an apparatus for mechanical testing of nuts. In the original application for which the apparatus was developed, the nuts are of a frangible type designed for use with pyrotechnic devices in spacecraft applications in which there are requirements for rapid, one-time separations of structures that are bolted together. The apparatus can also be used to test nonfrangible nuts engaged without pyrotechnic devices. This apparatus was developed to replace prior testing systems that were extremely heavy and immobile and characterized by long setup times (of the order of an hour for each nut to be tested). This apparatus is mobile, and the setup for each test can now be completed in about five minutes. The apparatus can load a nut under test with a static axial force of as much as 6.8 x 10(exp 5) lb (3.0 MN) and a static moment of as much as 8.5 x 10(exp 4) lb in. (9.6 x 10(exp 3) N(raised dot)m) for a predetermined amount of time. In the case of a test of a frangible nut, the pyrotechnic devices can be exploded to break the nut while the load is applied, in which case the breakage of the nut relieves the load. The apparatus can be operated remotely for safety during an explosive test. The load-generating portion of the apparatus is driven by low-pressure compressed air; the remainder of the apparatus is driven by 110-Vac electricity. From its source, the compressed air is fed to the apparatus through a regulator and a manually operated valve. The regulated compressed air is fed to a pneumatically driven hydraulic pump, which pressurizes oil in a hydraulic cylinder, thereby causing a load to be applied via a hydraulic nut (not to be confused with the nut under test). During operation, the hydraulic pressure is correlated with the applied axial load, which is verified by use of a load cell. Prior to operation, one end of a test stud (which could be an ordinary threaded rod or bolt) is installed in the hydraulic nut. The other end of the test stud passes through a bearing plate; a load cell is slid onto that end, and then the nut to be tested is threaded onto that end and tightened until the nut and load cell press gently against the bearing plate.

Hinkel, Todd J.↗

NASA NTRS1974

Examples of oil cavitation erosion in positive displacement pumps

The effects of cavitation flow on piston type, positive displacement, hydraulic pumps are discussed. The operating principles of the pump and the components which are most subject to erosion effects are described. The mechanisms of cavitation phenomena are identified from photographic records. Curves are developed to show the solubility of air in water, oil-water emulsion, and industrial hydraulic oil.

Halat, J. A.↗

NASA NTRS1990

STS-31: APU Controller Removal

The launch April 10 of the STS-31 was scrubbed at T-4 minutes due to a faulty valve in auxiliary power unit (APU) number one. The auxiliary power unit is a hydrazine-fueled, turbine-driven power unit that generates mechanical shaft power to drive a hydraulic pump that produces pressure for the orbiter's hydraulic system. This video shows the removal of the STS-31's auxiliary power unit (APU).

Source record↗

DOE OSTI2026

Adaptive Stiffness Power Take-Off System for a Hydraulic Hose-Pump Point Absorber Wave Energy Converter

Two crucial challenges faced in the design of ocean wave energy converters (WECs) are maintaining high capacity factors and remaining robust in everchanging, harsh ocean environments. This study introduces a novel mechanism for achieving reactive WEC control with a soft hydraulic power take-off, thereby addressing both challenges. The device of interest involves a hydraulic pump, constructed from a fluidic flexible matrix composite (F2MC), which is cyclically stretched by driving waves and pressurizes working fluid through a turbine-generator. This class of fiber-reinforced stretch hoses is established for ocean use as robust moorings and shock absorbers. The dynamic properties of the F2MC pump depend on internal pressure, which can be controlled by a continuously variable transmission between the turbine and generator, allowing the system to be adapted for better performance over a wide range of wave conditions. This work presents a dynamic model for operation and adaptive behavior of this power take-off system, experimentally validates components of the model, and performs dynamic simulations of the system that show increases in power production and capacity factor compared to non-adaptive operation for a variety of driving wave conditions. This work develops the basis for future large-scale experimental testing and controller design of this system.

Wave energy conversion, fluidic flexible matrix co↗

NASA NTRS2010

Technical Information/Website Preservation

This document reviews the work of the author in NASA's Motivating Undergraduates in Science and Technology (MUST) internship. The intern worked on the Space Shuttles hydraulic systems (i.e., Auxiliary Power Units (APU's) and Hydraulic Pump Units (HPU's)), and website preservation of the hydraulic technology captured in websites relating to the coming.the Space Shuttle Retirement. Several figures and pictures show an overview of the orbiter's hydraulic systems

PintoRey, Christian R.↗

DOE OSTI2023

An electrified boom actuation system with energy regeneration capability driven by a novel electro-hydraulic unit

This paper presents a novel electrified solution for linear actuation systems, which has undergone a successful in-vehicle demonstration, marking a significant advancement in this field. Aligned with the growing trend towards electrification, this solution holds promise for a wide range of off-road applications. The showcased electrohydraulic actuation architecture enables efficient four-quadrant operation and incorporates energy recovery capabilities. At the core of the system lies a distinctive electro-hydraulic unit, integrating a fixed hydraulic pump and a variable-speed electric motor into a compact and powerful entity. A specialized hydraulic system is designed to efficiently transform electrical energy from the electro-hydraulic unit into boom cylinder actuation. The sizing of the system is determined by the boom operation of a commercial compact loader. The maximum power output of the electro-hydraulic system is approximately 15 kW. The components of the proposed system are integrated into the reference vehicle, and comprehensive performance tests are conducted. The results of the tests performed on the vehicle with the boom lifting and lowering cycle indicate an overall system efficiency of 60%. The electrified solution consumes only about one-third of the energy used by the conventional boom actuation system on the reference machine, while exhibiting energy savings exceeding 75% during specific work phases. The energy savings come mainly from energy regeneration and minimal loss from throttling through the specialized hydraulic circuit design. Finally, the successful demonstration on the reference vehicle underscores the practicality and effectiveness of the proposed electrified solution in current mobile hydraulic applications

42 ENGINEERING↗

DOE OSTI2022

Design and Verification of An Open-Circuit Electro-Hydraulic Actuator System with An Integrated Electro-Hydraulic Unit

This paper proposes an electro-hydraulic actuator (EHA) system, and two novel-designed electro-hydraulic units (EHU) consisting of a fixed-displacement hydraulic pump and a variable-speed electric motor. Both the novel EHU designs integrate an electric machine and a hydraulic machine in a single unit, featuring compactness and power density. However, they differ for salient aspects such as power and electric machine cooling system. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. The efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The measured efficiency of the system can reach 54% with up to 20kN load and 6kW power level.

42 ENGINEERING↗

NASA NTRS1983

Design of hydraulic output Stirling engine

A hydraulic output system for the RE-1000 free piston stirling engine (FPSE) was designed. The hydraulic output system can be readily integrated with the existing hot section of RE-1000 FPSE. The system has two simply supported diaphragms which separate the engine gas from the hydraulic fluid, a dynamic balance mechanism, and a novel, null center band hydraulic pump. The diaphragms are designed to endure more than 10 billion cycles, and to withstand the differential pressure load as high as 14 MPa. The projected thermodynamic performance of the hydraulic output version of RE-1000 FPSE is 1.87 kW at 29/7 percent brake efficiency.

Toscano, W. M.↗

DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗

NASA NTRS2012

A Hydraulic Motor-Alternator System for Ocean-Submersible Vehicles

An ocean-submersible vehicle has been developed at JPL that moves back and forth between sea level and a depth of a few hundred meters. A liquid volumetric change at a pressure of 70 bars is created by means of thermal phase change. During vehicle ascent, the phase-change material (PCM) is melted by the circulation of warm water and thus pressure is increased. During vehicle descent, the PCM is cooled resulting in reduced pressure. This pressure change is used to generate electric power by means of a hydraulic pump that drives a permanent magnet (PM) alternator. The output energy of the alternator is stored in a rechargeable battery that powers an on-board computer, instrumentation and other peripherals.The focus of this paper is the performance evaluation of a specific hydraulic motor-alternator system. Experimental and theoretical efficiency data of the hydraulic motor and the alternator are presented. The results are used to evaluate the optimization of the hydraulic motor-alternator system. The integrated submersible vehicle was successfully operated in the Pacific Ocean near Hawaii. A brief overview of the actual test results is presented.

alternator↗

DOE OSTI2020

Development of the Underwater Disc Saw Used to Segment the Internals of Taiwan Research Reactor - 20038

Taiwan Research Reactor will be dismantled in the period of 2022 to 2027 according to the approved dismantling plan. Based on the sampling and analyzing results, some internals of Taiwan Research Reactor must be segmented under the water because of their higher radiation, and the calandria is one of them. To dismantle this calandria, Institute of Nuclear Energy Research develops an underwater disc saw that is driven by a hydraulic pump and will be used to segment the shell of the calandria. In this article, Taiwan Research Reactor and the structure of the calandria are briefly depicted, and the segmentation processes of this calandria and the design of this disc saw are also included. Besides, the trial of cutting the shell of the simplified full size calandria mockup is briefly demonstrated in this article. Further tests will be performed in the near future to figure out which parts or functions of this disc saw need to be modified to get better cutting performance. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Maritime Fuel Cell Generator Project: 2018 – 2023

This report summarizes activity in the Maritime Fuel Cell (MarFC) Generator Project from 2018 – 2023. FY 2018 saw the implementation of upgrades and repairs, making the unit more reliable and operator friendly. In FY2019 the team engaged the Scripps Institution of Oceanography (SIO) to use the MarFC to provide zero-emission shore power to the research vessel R/V Robert Gordon Sproul while in port at the Nimitz Marine Facility in San Diego, CA. In FY2020, the MarFC unit was shipped to San Diego, CA. A fueling contract with IGX was established to support MarFC operations at SIO, with renewable hydrogen provided by the California State University Los Angeles (CSULA) hydrogen station. The project team (Sandia, Cummins/Hydrogenics) provided training to SIO staff on the technical details of the MarFC, the safe use of hydrogen in general and the MarFC in particular. The first fueling of the unit at the SIO pier was successfully completed by IGX. The first powering of a vessel with fuel-cell shore power was conducted with the R/V Robert Gordon Sproul. While the mechanical systems (lights, AC, ventilation, hydraulics, pumps and cranes) were powered without incident, problems arose when powering the computer systems. Inspections carried out in FY2021 revealed the MarFC needed routine maintenance. Maintenance was performed and the unit was upgraded. The MarFC was turned on after the year pause, and initial test data on power levels and stability were collected. FY2022 was a year spent repairing, upgrading and testing the MarFC unit. Spikes in power and voltage were observed above 60 kW that could potentially extend below 60 kW with time. Such spikes could cause problems with the Sproul electrical systems. These age-related problems, the extended time for the Sproul spent in dry dock for scheduled upgrades, and the associated need to reschedule the vessel’s high-priority science missions made it no longer possible to deploy the unit at SIO. After due consideration, the decision was made by DOE, MARAD and the project team to cease the deployment, remove the MarFC from SIO, and not pursue further deployment activities. On December 2, 2022, the MarFC unit was removed from the Scripps Nimitz Marine Facility and shipped to Fridley, Michigan. The Cummins/Hydrogenics plan for the unit is to assess the condition of the MarFC subcomponents, and then use it as a training/learning system for technical employees new to hydrogen fuel-cell technology. After summarizing project activity from 2018 – 2023, this report provides a review of lessons learned. This report provides next steps in contemplating a follow-on project that would further advance the use of fuel-cell-based shore power in a marine setting. A comparison is made of the project results to the original objectives. This report ends with an accounting of presentations stemming from the project, and a list of references.

08 HYDROGEN↗

NASA NTRS1974

Design of H2-O2 space shuttle APU. Volume 1: APU design

The H2-O2 space shuttle auxiliary power unit (APU) program is a NASA-Lewis effort aimed at hardware demonstration of the technology required for potential use on the space shuttle. It has been shown that a hydrogen-oxygen power unit (APU) system is an attractive alternate to the space shuttle baseline hydrazine APU system for minimum weight. It has the capability for meeting many of the heat sink requirements for the space shuttle vehicle, thereby reducing the amount of expendable evaporants required for cooling in the baseline APU. Volume 1 of this report covers preliminary design and analysis of the current reference system and detail design of the test version of this reference system. Combustor test results are also included. Volume 2 contains the results of the analysis of an initial version of the reference system and the computer printouts of system performance. The APU consists of subsystems for propellant feed and conditioning, turbopower, and control. Propellant feed and conditioning contains all heat exchangers, valves, and the combustor. The turbopower subsystem contains a two-stage partial-admission pressure-modulated, 400-hp, 63,000-rpm turbine, a 0-to 4-g lubrication system, and a gearbox with output pads for two hydraulic pumps and an alternator (alternator not included on test unit). The electronic control functions include regulation of speed and system temperatures; and start-and-stop sequences, overspeed (rpm) and temperature limits, failsafe provisions, and automatic shutdown provisions.

Harris, E.↗

NASA NTRS1975

H2O2 space shuttle APU

A cryogenic H2-O2 auxiliary power unit (APU) was developed and successfully demonstrated. It has potential application as a minimum weight alternate to the space shuttle baseline APU because of its (1) low specific propellant consumption and (2) heat sink capabilities that reduce the amount of expendable evaporants. A reference system was designed with the necessary heat exchangers, combustor, turbine-gearbox, valves, and electronic controls to provide 400 shp to two aircraft hydraulic pumps. Development testing was carried out first on the combustor and control valves. This was followed by development of the control subsystem including the controller, the hydrogen and oxygen control valves, the combustor, and a turbine simulator. The complete APU system was hot tested for 10 hr with ambient and cryogenic propellants. Demonstrated at 95 percent of design power was 2.25 lb/hp-hr. At 10 percent design power, specific propellant consumption was 4 lb/hp-hr with space simulated exhaust and 5.2 lb/hp-hr with ambient exhaust. A 10 percent specific propellant consumption improvement is possible with some seal modifications. It was demonstrated that APU power levels could be changed by several hundred horsepower in less than 100 msec without exceeding allowable turbine inlet temperatures or turbine speed.

Source record↗

NASA NTRS1976

Flight simulation testing equipment for composite material systems

A test program is discussed which aims at establishing the time-temperature-stress characteristics of several classes of high-temperature composite materials in order to determine their suitability for applications in supersonic cruise aircraft. Five advanced composite materials (a boron epoxy, a boron polyimide, a graphite epoxy, a graphite polyimide, and diffusion-bonded boron aluminum) are being evaluated using a flight-test simulator capable of long-term automatic testing based on random loading and realistic flight temperature profiles. The design, construction, and checkout of this simulator are described along with the digital load programmer, load magnitude controllers, the hydraulic pumping system, the heating and cooling systems, the control console, and the data recording system. Typical results for short-term tests performed at constant temperatures and accelerated load rates are presented in terms of a random-load spectrum and a wearout model.

Haskins, J. F.↗

NASA NTRS1982

The OSS-1/STS-3 mission

Integration, test, flight operations, program and science management, and experiment results from the OSS-1/STS-3 flight are reviewed. The experimental pallet, manufactured by ESA members, carried instrumentation for astronomy, space plasma studies, physics, planetology, solar physics, and life sciences. The ability of the equipment to operate in a worst-case Orbiter thermal environment was tested, as was the plasma environment around the Orbiter. The solar UV spectral irradiance monitor microprocessor was found to reset concurrently with start-up of the Shuttle hydraulic pumps. Degradations were also observed in one of the three solar flare X ray polarimeter modules, the thermal cannister experiment microprocessor, and the scientific data recorder no. 2. The Orbiter was determined to perform well during firing of an electron beam. A contamination monitor recorded matter accretion to be dependent on the solar orientation of the Orbiter. Finally, the distribution of the responsibilities and tasks for mission management are reviewed.

Kissin, K.↗

NASA NTRS1983

Hydrazine gas generator performance on Space Shuttle

The design, functions, performance, and applications of the hydrazine gas generators (GG) on the STS are detailed. The GGs provide gas horse power for the APUs that drive the hydraulic pumps on the SRBs, which have two cross-linked systems. The Orbiter has three-cross-linked APU systems, used for gimballing the main engine and booster nozzles, actuating the main engine fuel valves and the ET umbilical disconnect, actuation of the control surfaces, and powering the landing gear, brakes, and nose wheel steering. The major design components of the Orbiter GGs are an injector, a catalyst bed, a decomposition chamber, an exhaust nozzle, and an interface structure, with the main structural material being Hasteloy B. Hydrazine injected and dispersed into the catalyst bed decomposes into gas and exits for expansion in an APU turbine. Twenty-six GGs have flown on missions STS-1 through STS-6 with over three tons of hydrazine having been expended over 44 hr of operations, as no refurbishment to that point was necessary.

Patterson, I. J.↗