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NASA NTRS1996

Parameter Design and Optimal Control of an Open Core Flywheel Energy Storage System

In low earth orbit (LEO) satellite applications spacecraft power is provided by photovoltaic cells and batteries. To overcome battery shortcomings the University of Maryland, working in cooperation with NASA/GSFC and NASA/LeRC, has developed a magnetically suspended flywheel for energy storage applications. The system is referred to as an Open Core Composite Flywheel (OCCF) energy storage system. Successful application of flywheel energy storage requires integration of several technologies, viz. bearings, rotor design, motor/generator, power conditioning, and system control. In this paper we present a parameter design method which has been developed for analyzing the linear SISO model of the magnetic bearing controller for the OCCF. The objective of this continued research is to principally analyze the magnetic bearing system for nonlinear effects in order to increase the region of stability, as determined by high speed and large air gap control. This is achieved by four tasks: (1) physical modeling, design, prototyping, and testing of an improved magnetically suspended flywheel energy storage system, (2) identification of problems that limit performance and their corresponding solutions, (3) development of a design methodology for magnetic bearings, and (4) design of an optimal controller for future high speed applications. Both nonlinear SISO and MIMO models of the magnetic system were built to study limit cycle oscillations and power amplifier saturation phenomenon observed in experiments. The nonlinear models include the inductance of EM coils, the power amplifier saturation, and the physical limitation of the flywheel movement as discussed earlier. The control program EASY5 is used to study the nonlinear SISO and MIMO models. Our results have shown that the characteristics and frequency responses of the magnetic bearing system obtained from modeling are comparable to those obtained experimentally. Although magnetic saturation is shown in the bearings, there are good correlations between the theoretical model and experimental data. Both simulation and experiment confirm large variations of the magnetic bearing characteristics due to air gap growth. Therefore, the gap growth effect should be considered in the magnetic bearing system design. Additionally, the magnetic bearing control system will be compared to other design methods using not only parameter design but H-infinity optimal control and mu synthesis.

Pang, D.↗

NASA NTRS2019

Coilgun Acceleration Model Containing Multiple Interacting Coils

A coilgun operates by pulsing current through an axially-arranged series of independently-controlled coils inductively interacting with a small, electrically-conductive, azimuthally-symmetric projectile to accelerate it to high velocities. The electrical circuits are programmed to pulse current through the coils in such a way so as to impart further electromagnetic acceleration in each stage. A method is developed to calculate the mutual inductance between the coils and between each coil and the projectile. These terms are used to write a system of first-order ordinary differential equations governing the projectile velocity and the current flow in each coil. While the inclusion of the electromagnetic interactions between coils significantly complicates the equation set as more coil sets are included in the problem, casting the problem symbolically in mass matrix form permits solution using standard numerical Runge-Kutta techniques. Comparing a projectile with a single-turn to that comprised of nine-turns, the inductance of the former is much smaller, but this leads to a greater induced projectile current. The lower inductance and greater current appear to offset each other with little difference in the acceleration profile for the two cases. For the limited cases studied, coils with a discharge half-cycle equal to the time for a projectile to transit from one coil to the next yield increased efficiency.

Polzin, Kurt A.↗

NASA NTRS1976

Numerical Studies of Three-dimensional Breakdown in Trailing Vortex Wakes

Finite element, three dimensional relaxation methods are used to calculate the development of vortex wakes behind aircraft for a considerable downstream distance. The inclusion of a self-induction term in the solution, dependent upon local curvature and vortex core radius, permits calculation of finite lifetimes for systems for which infinite life would be predicted two dimensionally. The associated computer program is described together with single-pair, twin-pair, and multiple-pair studies carried out using it. It is found, in single-pair studies, that there is a lower limit to the wavelengths at which the Crow-type of instability can occur. Below this limit, self-induction effects cause the plane of the disturbance waves to rotate counter to the vortex direction. Self induction in two dimensionally generated twin spiral waves causes an increase in axial length which becomes more marked with decreasing initial wavelength. The time taken for vortex convergence toward the center plane is correspondingly increased. The limited parametric twin-pair study performed suggests that time-to-converge increases with increasing flap span. Limited studies of Boeing 747 configurations show correct qualitative response to removal of the outer flap and to gear deployment, as compared with wind tunnel and flight test experience.

Evans, P. F.↗

NASA NTRSDate not supplied

Bioreactor Development for CO2-Based In Situ Resource Utilization Manufacturing

Sustainable long-duration manned missions on both the Moon and Mars will require in situ resource utilization (ISRU). Carbon dioxide (CO2) has great potential as a harvestable resource, making up 95% of the atmosphere on Mars and being produced as respiratory waste in spacecraft and future planetary habitats. Through ISRU, biomanufacturing has the capability to produce a near limitless array of products from local space resources. Here, a CO2-based ISRU recombinant protein producing bioreactor and associated biomanufacturing organisms were designed to produce a highly stable carbonic anhydrase (CA). Candidate organisms were selected by growth characterization on acetate and formic acid, carbon substrates that are synthesized via electrochemical conversion of CO2. To improve growth on the CO2 producing substrate formic acid and for direct integration of ISRU CO2, a synthetic Calvin-Benson-Bassam cycle was designed for use in Escherichia coli. Multiplex genetic modification in E. coli was facilitated by a tailored CRISPR/Cas9 and λ red recombineering two-vector system. For expression of CA, a blue light regulated T7 promoter was employed for dynamic and small molecule free induction. Efficient bioproduction through a fed-batch exponential feeding strategy was determined via mass balance analysis from ISRU substrates to biomass and CA yield. Flux balance analysis was used to model ISRU substrate metabolism and metabolic pathway engineering in candidate organisms under cultivation strategy conditions for both metabolism reconstruction and pathway design optimization. Finally, a small-scale, disposable bag bioreactor for use in the NASA Bioculture System infrastructure was designed to enable CO2-based CA biomanufacturing in reduced-gravity environments.

biomanufacturing↗

NASA NTRSDate not supplied

Bioreactor Development for CO2-Based In Situ Resource Utilization Manufacturing

Sustainable long-duration manned missions on both the Moon and Mars will require in situ resource utilization (ISRU). Carbon dioxide (CO2) has great potential as a harvestable resource, making up 95% of the atmosphere on Mars and being produced as respiratory waste in spacecraft and future planetary habitats. Through ISRU, biomanufacturing has the capability to produce a near limitless array of products from local space resources, which include pharmaceuticals, bioplastics, chemical feedstocks, and industrial enzymes. Here, a CO2-based ISRU recombinant protein bioreactor and associated biomanufacturing organisms were designed to produce a highly stable carbonic anhydrase (CA). Initial work characterized candidate organisms for growth on acetate and formic acid, carbon substrates that can be synthesized via electrochemical conversion of CO2. To improve growth on the CO2 producing substrate formic acid and for direct integration of ISRU CO2, a synthetic Calvin-Benson-Bassam cycle was designed for use in Cyberlindnera jadinii and Escherichia coli. Genetic modifications in E. coli will be facilitated by a tailored CRISPR/Cas9 and λ red recombineering two-vector system. For expression of CA, a blue light regulated T7 promoter was employed for dynamic and small molecule free induction. Efficient bioproduction through a fed-batch exponential feeding strategy was determined via mass balance calculations from ISRU substrates to biomass and CA yield. Flux balance analysis was used to model ISRU substrate metabolism and metabolic pathway engineering in candidate organisms under cultivation strategy conditions for both metabolism reconstruction and pathway design optimization. Finally, a small-scale, disposable bag bioreactor concept for use in the NASA Bioculture System infrastructure was designed to enable CO2-based CA production in reduced-gravity environments.

Biomanufacturing, Pathway Engineering, Flux Balanc↗

NASA NTRS2015

Initial Operation of the Nuclear Thermal Rocket Element Environmental Simulator

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility is designed to perform realistic non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and fuel materials. Although the NTREES facility cannot mimic the neutron and gamma environment of an operating NTR, it can simulate the thermal hydraulic environment within an NTR fuel element to provide critical information on material performance and compatibility. The NTREES facility has recently been upgraded such that the power capabilities of the facility have been increased significantly. At its present 1.2 MW power level, more prototypical fuel element temperatures nay now be reached. The new 1.2 MW induction heater consists of three physical units consisting of a transformer, rectifier, and inverter. This multiunit arrangement facilitated increasing the flexibility of the induction heater by more easily allowing variable frequency operation. Frequency ranges between 20 and 60 kHz can accommodated in the new induction heater allowing more representative power distributions to be generated within the test elements. The water cooling system was also upgraded to so as to be capable of removing 100% of the heat generated during testing In this new higher power configuration, NTREES will be capable of testing fuel elements and fuel materials at near-prototypic power densities. As checkout testing progressed and as higher power levels were achieved, several design deficiencies were discovered and fixed. Most of these design deficiencies were related to stray RF energy causing various components to encounter unexpected heating. Copper shielding around these components largely eliminated these problems. Other problems encountered involved unexpected movement in the coil due to electromagnetic forces and electrical arcing between the coil and a dummy test article. The coil movement and arcing which were encountered during the checkout testing effectively destroyed the induction coil in use at the time and resulted in NTREES being out of commission for a couple of months while a new stronger coil was procured. The new coil includes several additional pieces of support structure to prevent coil movement in the future. In addition, new insulating test article support components have been fabricated to prevent unexpected arcing to the test articles. Additional activities are also now underway to address ways in which the radial temperature profiles across test articles may be controlled such that they are more prototypical of what they would encounter in an operating nuclear engine. The causes of the temperature distribution problem are twofold. First, the fuel element test article is isolated in NTREES as opposed to being in the midst of many other mostly identical fuel elements in a nuclear engine. As a result, the fuel element heat flux boundary conditions in NTREES are far from adiabatic as would normally be the case in a reactor. Second, induction heating skews the power distribution such that power is preferentially deposited near the outside of the fuel element. Nuclear heating, conversely, deposits its power much more uniformly throughout the fuel element. Current studies are now looking at various schemes to adjust the amount of thermal radiation emitted from the fuel element surface so as to essentially vary the thermal boundary conditions on the test article. It is hoped that by properly adjusting the thermal boundary conditions on the fuel element test article, it may be possible to substantially correct for the inappropriate radial power distributions resulting from the induction heating so as to yield a more nearly correct temperature distribution throughout the fuel element.

Emrich, William J., Jr.↗

DOE OSTI2025

Operational space for lower hybrid heating scenarios in the full tungsten environment of WEST

In tungsten—W—Environment in Steady-state Tokamak (WEST), the lower hybrid current drive (LHCD) system is key for achieving long pulse operation by providing most of the non-inductive plasma current, as well as a crucial source of electron heating. Therefore, determining the operational space for its application is fundamental. In the present study, the LHCD operational space is deeply analyzed for 0.5 MA pulses. This space is bounded by three limits: (i) the ratio of the LHCD power over density must be above a threshold to compensate tungsten radiation with enough core heating, (ii) the line-averaged density must be high enough to allow good coupling of the hybrid wave with the plasma, and (iii) fast electron ripple losses must be below a limit to avoid reaching a thermal threshold on plasma-facing components. If the tungsten radiation peak or burn-through phase is not safely overcome, a maximum electron temperature of 1.5 keV is obtained, confinement is degraded, and magnetohydrodynamic activity is frequently triggered, potentially causing a disruption. From experimental measurements and interpretative simulations, we highlight the main mechanisms that prevent the plasma from heating up during LHCD power ramp-up. Three parameters play a major role: plasma density, tungsten concentration and LHCD power deposition. A strategy to overcome this limitation is found: a precise density ramp-up performed simultaneously with the increase in LHCD power. Additionally, we show that boronization greatly facilitates the burn-through of tungsten by lowering its content during the heating phase. Finally, taking into account the three constraints given above, the LHCD operational space is determined at power ramp-up and during constant heating phases.

lower hybrid heating and current drive↗

DOE OSTI2026

T&D LIBRA: Simulation Framework for Transmission and Distribution Load and IBR Assessment

This paper introduces T&D LIBRA, a HELICS-based dynamic co-simulation framework designed for transmission and distribution (T&D) load and inverter-based resource assessment. This framework is designed to model interactions between single-phase induction motors (i.e., Motor-D), distributed energy resources (DERs) and the transmission network, emphasizing system stability during fault conditions. The primary objective of this research is to study the fault-induced delayed voltage recovery (FIDVR) behavior of the T&D networks using the co-simulation framework and to compare the results with conventional PSS/E only simulations. Simulations are validated using T&D co-simulations with a single distribution node and the IEEE 123-bus distribution test case. The co-simulation results demonstrate the value of using T&D co-simulations to capture motor stalling, DER tripping and other sources of voltage diversity on distribution networks.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1993

Performance of ceramic superconductors in magnetic bearings

Magnetic bearings are large-scale applications of magnet technology, quite similar in certain ways to synchronous machinery. They require substantial flux density over relatively large volumes of space. Large flux density is required to have satisfactory force density. Satisfactory dynamic response requires that magnetic circuit permeances not be too large, implying large air gaps. Superconductors, which offer large magnetomotive forces and high flux density in low permeance circuits, appear to be desirable in these situations. Flux densities substantially in excess of those possible with iron can be produced, and no ferromagnetic material is required. Thus the inductance of active coils can be made low, indicating good dynamic response of the bearing system. The principal difficulty in using superconductors is, of course, the deep cryogenic temperatures at which they must operate. Because of the difficulties in working with liquid helium, the possibility of superconductors which can be operated in liquid nitrogen is thought to extend the number and range of applications of superconductivity. Critical temperatures of about 98 degrees Kelvin were demonstrated in a class of materials which are, in fact, ceramics. Quite a bit of public attention was attracted to these new materials. There is a difficulty with the ceramic superconducting materials which were developed to date. Current densities sufficient for use in large-scale applications have not been demonstrated. In order to be useful, superconductors must be capable of carrying substantial currents in the presence of large magnetic fields. The possible use of ceramic superconductors in magnetic bearings is investigated and discussed and requirements that must be achieved by superconductors operating at liquid nitrogen temperatures to make their use comparable with niobium-titanium superconductors operating at liquid helium temperatures are identified.

Kirtley, James L., Jr.↗

NASA NTRS2003

New Technique of High-Performance Torque Control Developed for Induction Machines

Two forms of high-performance torque control for motor drives have been described in the literature: field orientation control and direct torque control. Field orientation control has been the method of choice for previous NASA electromechanical actuator research efforts with induction motors. Direct torque control has the potential to offer some advantages over field orientation, including ease of implementation and faster response. However, the most common form of direct torque control is not suitable for the highspeed, low-stator-flux linkage induction machines designed for electromechanical actuators with the presently available sample rates of digital control systems (higher sample rates are required). In addition, this form of direct torque control is not suitable for the addition of a high-frequency carrier signal necessary for the "self-sensing" (sensorless) position estimation technique. This technique enables low- and zero-speed position sensorless operation of the machine. Sensorless operation is desirable to reduce the number of necessary feedback signals and transducers, thus improving the reliability and reducing the mass and volume of the system. This research was directed at developing an alternative form of direct torque control known as a "deadbeat," or inverse model, solution. This form uses pulse-width modulation of the voltage applied to the machine, thus reducing the necessary sample and switching frequency for the high-speed NASA motor. In addition, the structure of the deadbeat form allows the addition of the high-frequency carrier signal so that low- and zero-speed sensorless operation is possible. The new deadbeat solution is based on using the stator and rotor flux as state variables. This choice of state variables leads to a simple graphical representation of the solution as the intersection of a constant torque line with a constant stator flux circle. Previous solutions have been expressed only in complex mathematical terms without a method to clearly visualize the solution. The graphical technique allows a more insightful understanding of the operation of the machine under various conditions.

Kenny, Barbara H.↗

NASA NTRS2010

Advanced Flip Chips in Extreme Temperature Environments

The use of underfill materials is necessary with flip-chip interconnect technology to redistribute stresses due to mismatching coefficients of thermal expansion (CTEs) between dissimilar materials in the overall assembly. Underfills are formulated using organic polymers and possibly inorganic filler materials. There are a few ways to apply the underfills with flip-chip technology. Traditional capillary-flow underfill materials now possess high flow speed and reduced time to cure, but they still require additional processing steps beyond the typical surface-mount technology (SMT) assembly process. Studies were conducted using underfills in a temperature range of -190 to 85 C, which resulted in an increase of reliability by one to two orders of magnitude. Thermal shock of the flip-chip test articles was designed to induce failures at the interconnect sites (-40 to 100 C). The study on the reliability of flip chips using underfills in the extreme temperature region is of significant value for space applications. This technology is considered as an enabling technology for future space missions. Flip-chip interconnect technology is an advanced electrical interconnection approach where the silicon die or chip is electrically connected, face down, to the substrate by reflowing solder bumps on area-array metallized terminals on the die to matching footprints of solder-wettable pads on the chosen substrate. This advanced flip-chip interconnect technology will significantly improve the performance of high-speed systems, productivity enhancement over manual wire bonding, self-alignment during die joining, low lead inductances, and reduced need for attachment of precious metals. The use of commercially developed no-flow fluxing underfills provides a means of reducing the processing steps employed in the traditional capillary flow methods to enhance SMT compatibility. Reliability of flip chips may be significantly increased by matching/tailoring the CTEs of the substrate material and the silicon die or chip, and also the underfill materials. Advanced packaging interconnects technology such as flip-chip interconnect test boards have been subjected to various extreme temperature ranges that cover military specifications and extreme Mars and asteroid environments. The eventual goal of each process step and the entire process is to produce components with 100 percent interconnect and satisfy the reliability requirements. Underfill materials, in general, may possibly meet demanding end use requirements such as low warpage, low stress, fine pitch, high reliability, and high adhesion.

Ramesham, Rajeshuni↗

NASA NTRS2003

Investigation of Combined Motor/Magnetic Bearings for Flywheel Energy Storage Systems

Dr. Hofmann's work in the summer of 2003 consisted of two separate projects. In the first part of the summer, Dr. Hofmann prepared and collected information regarding rotor losses in synchronous machines; in particular, machines with low rotor losses operating in vacuum and supported by magnetic bearings, such as the motor/generator for flywheel energy storage systems. This work culminated in a presentation at NASA Glenn Research Center on this topic. In the second part, Dr. Hofmann investigated an approach to flywheel energy storage where the phases of the flywheel motor/generator are connected in parallel with the phases of an induction machine driving a mechanical actuator. With this approach, additional power electronics for driving the flywheel unit are not required. Simulations of the connection of a flywheel energy storage system to a model of an electromechanical actuator testbed at NASA Glenn were performed that validated the proposed approach. A proof-of-concept experiment using the D1 flywheel unit at NASA Glenn and a Sundstrand induction machine connected to a dynamometer was successfully conducted.

Hofmann, Heath↗

NASA NTRS2010

Testing of Liquid Metal Components for Nuclear Surface Power Systems

The capability to perform testing at both the module/component level and in near prototypic reactor configurations using a non-nuclear test methodology allowed for evaluation of two components critical to the development of a potential nuclear fission power system for the lunar surface. A pair of 1 kW Stirling power convertors, similar to the type that would be used in a reactor system to convert heat to electricity, were integrated into a reactor simulator system to determine their performance using pumped NaK as the hot side working fluid. The performance in the pumped-NaK system met or exceed the baseline performance measurements where the converters were electrically heated. At the maximum hot-side temperature of 550 C the maximum output power was 2375 watts. A specially-designed test apparatus was fabricated and used to quantify the performance of an annular linear induction pump that is similar to the type that could be used to circulate liquid metal through the core of a space reactor system. The errors on the measurements were generally much smaller than the magnitude of the measurements, permitting accurate performance evaluation over a wide range of operating conditions. The pump produced flow rates spanning roughly 0.16 to 5.7 l/s (2.5 to 90 GPM), and delta p levels from less than 1 kPa to 90 kPa (greater than 0.145 psi to roughly 13 psi). At the nominal FSP system operating temperature of 525 C the maximum efficiency was just over 4%.

Polzin, K. A.↗

NASA NTRS2003

Tetracycline-inducible system for regulation of skeletal muscle-specific gene expression in transgenic mice

Tightly regulated control of over-expression is often necessary to study one aspect or time point of gene function and, in transgenesis, may help to avoid lethal effects and complications caused by ubiquitous over-expression. We have utilized the benefits of an optimized tet-on system and a modified muscle creatine kinase (MCK) promoter to generate a skeletal muscle-specific, doxycycline (Dox) controlled over-expression system in transgenic mice. A DNA construct was generated in which the codon optimized reverse tetracycline transactivator (rtTA) was placed under control of a skeletal muscle-specific version of the mouse MCK promoter. Transgenic mice containing this construct expressed rtTA almost exclusively in skeletal muscles. These mice were crossed to a second transgenic line containing a bi-directional promoter centered on a tet responder element driving both a luciferase reporter gene and a tagged gene of interest; in this case the calpain inhibitor calpastatin. Compound hemizygous mice showed high level, Dox dependent muscle-specific luciferase activity often exceeding 10,000-fold over non-muscle tissues of the same mouse. Western and immunocytochemical analysis demonstrated similar Dox dependent muscle-specific induction of the tagged calpastatin protein. These findings demonstrate the effectiveness and flexibility of the tet-on system to provide a tightly regulated over-expression system in adult skeletal muscle. The MCKrtTA transgenic lines can be combined with other transgenic responder lines for skeletal muscle-specific over-expression of any target gene of interest.

NASA Discipline Musculoskeletal↗

NASA NTRS1972

Fabrication and test of a space power boiler feed electromagnetic pump. 3: Endurance and final performance tests

A three-phase helical induction electromagnetic pump designed for the boiler feed pump of a potassium Rankine cycle space power system was developed and built. It was mounted in a liquid metal test loop and successfully tested over a range of potassium temperatures from 900 to 1400 F, flow rates from 0.75 to 4.85 lb/sec, developed pressures up to 340 psi, net positive suction head from 1 to 22 psi, and NaK coolant temperatures from 800 to 950 F. Maximum efficiency at design point conditions of 3.25 lb/sec flow rate, 240 psi developed head, 1000 F potassium inlet temperature, and 800 F NaK coolant inlet temperature was 16.3 percent. After the performance tests the pump was operated without any difficulty at design point for 10,000 hours, and then a limited number of repeat performance tests were made. There was no appreciable change in pump performance after 10,000 hours of operation. A supplementary series of tests using the quasi-square wave power output of a dc to three-phase ac inverter showed that the pump would operate without difficulty at a frequency as low as 25 Hz, with little loss in efficiency.

Powell, A. H.↗

NASA NTRS1978

System design of the annular suspension and pointing system /ASPS/

This paper presents the control system design for the Annular Suspension and Pointing System. Actuator sizing and configuration of the system are explained, and the control laws developed for linearizing and compensating the magnetic bearings, roll induction motor and gimbal torquers are given. Decoupling, feedforward and error compensation for the vernier and gimbal controllers is developed. The algorithm for computing the strapdown attitude reference is derived, and the allowable sampling rates, time delays and quantization of control signals are specified.

Cunningham, D. C.↗

NASA NTRS1984

Solar powered actuator with continuously variable auxiliary power control

A solar powered system is disclosed in which a load such as a compressor is driven by a main induction motor powered by a solar array. An auxiliary motor shares the load with the solar powered motor in proportion to the amount of sunlight available, is provided with a power factor controller for controlling voltage applied to the auxiliary motor in accordance with the loading on that motor. In one embodiment, when sufficient power is available from the solar cell, the auxiliary motor is driven as a generator by excess power from the main motor so as to return electrical energy to the power company utility lines.

Nola, F. J.↗

NASA NTRS2010

The Mothball, Sustainment, and Proposed Reactivation of the Hypersonic Tunnel Facility (HTF) at NASA Glenn Research Center Plum Brook Station

The Hypersonic Tunnel Facility (HTF) located at the NASA Glenn Research Center s Plum Brook Station in Sandusky, Ohio, is the nation s only large-scale, non-vitiated, hypersonic propulsion test facility. The HTF, with its 4-story graphite induction heater, is capable of duplicating Mach 5, 6, and 7 flight conditions. This unique propulsion system test facility has experienced several standby and reactivation cycles. The intent of the paper is to overview the HTF capabilities to the propulsion community, present the current status of HTF, and share the lessons learned from putting a large-scale facility into mothball status for a later restart

Thomas, Scott R.↗