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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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NASA NTRS1993

Space Station thermal storage/refrigeration system research and development

Space Station thermal loading conditions represent an order of magnitude increase over current and previous spacecraft such as Skylab, Apollo, Pegasus III, Lunar Rover Vehicle, and Lockheed TRIDENT missiles. Thermal storage units (TSU's) were successfully used on these as well as many applications for ground based solar energy storage applications. It is desirable to store thermal energy during peak loading conditions as an alternative to providing increased radiator surface area which adds to the weight of the system. Basically, TSU's store heat by melting a phase change material (PCM) such as a paraffin. The physical property data for the PCM's used in the design of these TSU's is well defined in the literature. Design techniques are generally well established for the TSU's. However, the Space Station provides a new challenge in the application of these data and techniques because of three factors: the large size of the TSU required, the integration of the TSU for the Space Station thermal management concept with its diverse opportunities for storage application, and the TSU's interface with a two-phase (liquid/vapor) thermal bus/central heat rejection system. The objective in the thermal storage research and development task was to design, fabricate, and test a demonstration unit. One test article was to be a passive thermal storage unit capable of storing frozen food at -20 F for a minimum of 90 days. A second unit was to be capable of storing frozen biological samples at -94 F, again for a minimum of 90 days. The articles developed were compatible with shuttle mission conditions, including safety and handling by astronauts. Further, storage rack concepts were presented so that these units can be integrated into Space Station logistics module storage racks. The extreme sensitivity of spacecraft radiator systems design-to-heat rejection temperature requirements is well known. A large radiator area penalty is incurred if low temperatures are accommodated via a single centralized radiator system. As per the scope of work of this task, the applicability of refrigeration system tailored to meet the specialized requirements of storage of food and biological samples was investigated. The issues addressed were the anticipated power consumption and feasible designs and cycles for meeting specific storage requirements. Further, development issues were assessed related to the operation of vapor compression systems in micro-gravity addressing separation of vapor and liquid phases (via capillary systems).

Dean, W. G.↗
NASA NTRS2014

Calculation of Operations Efficiency Factors for Mars Surface Missions

For planning of Mars surface missions, to be operated on a sol-by-sol basis by a team on Earth (where a "sol" is a Martian day), activities are described in terms of "sol types" that are strung together to build a surface mission scenario. Some sol types require ground decisions based on a previous sol's results to feed into the activity planning ("ground in the loop"), while others do not. Due to the differences in duration between Earth days and Mars sols, for a given Mars local solar time, the corresponding Earth time "walks" relative to the corresponding times on the prior sol/day. In particular, even if a communication window has a fixed Mars local solar time, the Earth time for that window will be approximately 40 minutes later each succeeding day. Further complexity is added for non-Mars synchronous communication relay assets, and when there are multiple control centers in different Earth time zones. The solution is the development of "ops efficiency factors" that reflect the efficiency of a given operations configuration (how many and location of control centers, types of communication windows, synchronous or non-synchronous nature of relay assets, sol types, more-or-less sustainable operations schedule choices) against a theoretical "optimal" operations configuration for the mission being studied. These factors are then incorporated into scenario models in order to determine the surface duration (and therefore minimum spacecraft surface lifetime) required to fulfill scenario objectives. The resulting model is used to perform "what-if" analyses for variations in scenario objectives. The ops efficiency factor is the ratio of the figure of merit for a given operations factor to the figure of merit for the theoretical optimal configuration. The current implementation is a pair of models in Excel. The first represents a ground operations schedule for 500 sols in each operations configuration for the mission being studied (500 sols was chosen as being a long enough time to capture variations in relay asset interactions, Earth/Mars time phasing, and seasonal variations in holidays). This model is used to estimate the ops efficiency factor for each operations configuration. The second model in a separate Excel spreadsheet is a scenario model, which uses the sol types to rack up the total number of "scenario sols" for that scenario (in other words, the ideal number of sols it would take to perform the scenario objectives). Then, the number of sols requiring ground in the loop is calculated based on the soil types contained in the given scenario. Next, the scenario contains a description of what sequence of operations configurations is used, for how many days each, and this is used with the corresponding ops efficiency factors for each configuration to calculate the "ops duration" corresponding to that scenario. Finally, a margin is applied to determine the minimum surface lifetime required for that scenario. Typically, this level of analysis has not been performed until much later in the mission, and has not been able to influence mission design. Further, the notion of moving to sustainable operations during Prime Mission - and the effect that that move would have on surface mission productivity and mission objective choices - has not been encountered until the most recent rover missions (MSL and Mars 2018).

Layback, Sharon L.↗
DOE OSTI2021

Standards development for modules in high temperature micro-environments

Photovoltaic (PV) module qualification standards, IEC 61215 and IEC 61730, were designed to apply to “general open-air climates” and IEC 61730 specifically indicated applicability of ambient air temperature of 40°C. Additionally, these standards provided allowances for so-called “open rack mounted PV modules” without a clear definition of “open-rack.” These implied restrictions and allowances meant that hotter climates or thermally restrictive installation methods may not be covered by these often customer-mandated certification standards. This is particularly salient for the significant growth regions of the Middle East and India that would be expected to operate at significantly higher temperatures. The applicability of these documents raised issues over the definition of “open rack” and the fact that the geographic location is just as important as the mounting configuration in assessing the impact of the micro-environment of a PV module. This work summarizes the scientific background for IEC Technical Specification 63126:2020 ED1, titled “Guidelines for qualifying PV modules components and materials for operation at high temperatures.” This standard was recently published by the IEC and is the first step in a systematic effort to rework these standards to address the question of temperature more directly. Instead of specifying a mounting condition, we specify different suites of tests suitable for a system (PV module, mounting style, and location) defined by the 98th percentile cell temperature. With a defined temperature regime to work from, this allowed us to use existing literature research combined with additional modeling work to determine, which tests would need to be modified. This resulted in suggested changes to material thermal indices, thermal cycling temperatures, hot spot testing, ultraviolet testing, and bypass diode testing among other tests and characteristics described in this study.

14 SOLAR ENERGY↗
DOE OSTI2022

Life after 30 years - a PV system in Colorado

The PV system consisted of 155 monocrystalline Si Arco M53 panels, installed in 1987. 80 were installed on a fixed tilt rack, and 75 on 5 separate dual-axis passive trackers. The system was decommissioned in 2017 due a campus re-design and building expansion at the Platte River Power Authority (PPRA) site. Prior to decommissioning a site visit established the following failure type observations: EVA browning (100%), cracked cells (60%), and cracked wires or grommets (9%, or more if replacements were made selectively on cracked parts). EVA browning is typical in modules of this vintage, whereas the occurrence of so many cracked cells is surprising and is likely weather-related. The fairly frequent occurrence of cracked wires and grommets serves as a reminder that accelerated testing of these components is important for goals of low-cost 50-year energy generation. In smaller numbers, thermal effects (7%), bent frames (1%), and cell corrosion (<1%) were observed. A sample of 20 modules was selected and brought to NREL for in-depth characterization. Because baseline measurements were not available using the nameplate rating, which can be inaccurate, revealed a mean module sample degradation of 0.7 %/year. Sporadic production data during the 30 years determined a system degradation rate closer to 1.2 %/year. Subsequently, four of these modules were re-mounted outdoors at NREL and are now approaching a total lifetime of 34 years.

durability↗
DOE OSTI2025

Comparing Outdoor to Indoor Performance for Bifacial Modules Affected by Polarization-Type Potential-Induced Degradation

Bifacial photovoltaic (PV) modules have the advantage of using light reflected off of the ground to contribute to power production. Predicting the energy gain is challenging and requires complex models to do so accurately. Often, module degradation over time is neglected in models for the sake of simplicity or is underestimated. Comparing outdoor and indoor current–voltage (I–V) performance for bifacial modules is more challenging than for monofacial modules, as there are additional variables to consider such as rear albedo non-uniformity, cell mismatch, and their effects on temperature. This challenge is compounded when heterogeneous degradation modes occur, such as polarization-type potential-induced degradation (PID-p). To examine the effects of PID-p on I–V predictions using an empirical data-driven approach, 16 bifacial PERC modules are installed outdoors on racks with different albedo conditions. A subset is exposed to high-voltage biases of −1500 V or +1500 V. Outdoor data are traced at irradiance ranges of 150–250 W/m 2 , 500–600 W/m 2 , and 900–1000 W/m 2 . These curves are corrected using control module temperature, wire resistivity, and module resistance measured indoors. We examine several methods to transform indoor I–V curves to accurately, and more simply than existing methods, approximate outdoor performance for bifacial modules without and with varying levels of PID-p degradation. This way, bifacial performance modeling can be more accessible and informed by fielded, degraded modules. Distributions of percent errors between indoor and outdoor performance parameters and Mean Absolute Percent Errors (MAPEs) are used to assess method quality. Results including low-irradiance data (150–250 W/m 2 ) are discussed but are filtered for quantifying method quality as these data introduce substantial errors. The method with the most optimal tradeoff between low MAPE and analysis simplicity involves measuring the front side of a module indoors at an irradiance equal to plane-of-array irradiance plus the product of module bifaciality and albedo irradiance. This method gives MAPE values of 1–6.5% for non-degraded and 1.6–5.9% for PID-p degraded module performance.

14 SOLAR ENERGY↗
NASA NTRS2004

Stirling Engine Controller

Stirling technology is being developed to replace RTG s (Radioisotope Thermoelectric Generators), more specifically a stirling convertor, which is a stirling engine coupled to a linear alternator. Over the past three decades, the stirling engine has been designed to perform different functions. Stirling convertors have been designed to decrease fuel consumption in automobiles. They have also been designed for terrestrial and space applications. Currently NASA Glenn is using the convertor for space based applications. A stiring converter is a better means of power for deep space mission and "dusty" mission, like the Mars Rovers, than solar panels because it is not affected by dust. Spirit and Opportunity, two Mars rovers currently navigating the planet, are losing their ability to generate electricity because dust is collecting on their solar panels. Opportunity is losing more energy because its robotic arm has a heater with a switch that can not be turned off. The heater is not needed at night, but yet still runs. This generates a greater loss of electricity and in turn diminishes the performance of the rover. The stirling cycle has the potential to provide very efficient conversion of heat energy to electric a1 energy, more so than RTG's. The stirling engine converts the thermal energy produced by the decaying radioisotope to mechanical energy; the linear alternator converts this into electricity. convertor. Since the early 1990's tests have been performed to maximize the efficiency of the stirling converter. Many months, even years, are dedicated to preparing and performing tests. Currently, two stirling convertors #'s 13 and 14, which were developed by Stirling Technology Company, are on an extended operation test. As of June 7th, the two convertors reached 7,500 hours each of operation. Before the convertors could run unattended, many safety precautions had to be examined. So, special instrumentation and circuits were developed to detect off nominal conditions and also safely shutdown the engines. The test will last for a period of 8000 to 9000 hours. Other types of tests that have been performed are: performance mapping, controller development, launch environment, and vibration emissions testing. Currently, the thermo-mechanical system branch is housing a RG-350, a stirling convertor. The convertor was used in previous tests such as a Hall Thruster test, world s first integrated test of a dynamic power system with electric propulsion. Another test performed was to conclude if free piston stirling convertors can be synchronized for vibration balancing, with no thermodynamic or electrical connections and not cause both to shutdown if one failed. The ability to reduce vibration by synchronizing convertor operation but still be able to operate when one partner fails is pertinent in space and terrestrial applications. The convertor is now being brought back into operation and a controller is in the process of being developed. This convertor will be used as a testbed for new controllers. I worked with Mary Ellen Roth on the electric engineering aspects of the RG-350. My main goal was to enhance the data collection process. I worked on different aspects of the RG-350, with a main focus on the engine controller. I drew a schematic of the wire connections in the engine controller, using PCB Express, so that a plan could be devised to connect the power meter properly between the output of the engine and the engine controller. I measured the power using two different instruments: Valhalla Scientific power meter and Ohio Semitronics power measurement device. The convertor is connected to an Agilent 34970A Data Acquisition/Switch Unit, which allows the user to measure, record, and monitor voltage, current, frequency, and temperature. I assisted in preparing the Data Acquisition for general operation. I also helped test a panel of transducers, which will be placed in the rack that powers and monitors the convertor.

Blaze, Gina M.↗