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This report describes the Phase 1 process and analysis used to select a refrigerant and thermodynamic cycle as the basis of a vapor compression heat pump requiring a high temperature lift, then to perform a preliminary design to implement the selected concept, including major component selection. Use of a vapor compression heat pump versus other types was based on prior work performed for the Electric Power Research Institute. A high lift heat pump is needed to enable a thermal control system to remove heat down to 275 K from a habitable volume when the external thermal environment is severe. For example, a long-term lunar base habitat will reject heat from a space radiator to a 325 K environment. The first step in the selection process was to perform an optimization trade study, quantifying the effect of radiator operating temperature and heat pump efficiency on total system mass; then, select the radiator operating temperature corresponding to the lowest system mass. Total system mass included radiators, all heat pump components, and the power supply system. The study showed that lunar night operation, with no temperature lift, dictated the radiator size. To operate otherwise would require a high mass penalty to store power. With the defined radiation surface, and heat pump performances assumed to be from 40 percent to 60 percent of the Carnot ideal, the optimum heat rejection temperature ranged from 387 K to 377 K, as a function of heat pump performance. Refrigerant and thermodynamic cycles were then selected to best meet the previously determined design conditions. The system was then adapted as a ground-based prototype lifting temperature to 360 K (versus 385 K for flight unit) and using readily available commercial-grade components. Over 40 refrigerants, separated into wet and dry compression behavioral types, were considered in the selection process. Refrigerants were initially screened for acceptable critical temperature. The acceptable refrigerants were analyzed in ideal single and two-stage thermodynamic cycles. Top candidates were analyzed assuming realistic component limits and system pressure drops, and were evaluated for other considerations such as safety, environmental impact, and commercial availability. A maximum coefficient of performance (COP) of 56 percent of the Carnot ideal was achievable for a three-stage CFC-11 cycle operating under the flight conditions above. The program was completed by defining a control scheme and by researching and selecting the major components, compressor and heat exchangers, that could be used to implement the thermodynamic cycle selected. Special attention was paid to using similar technologies for the SIRF and flight heat pumps resulting in the commercially available equivalent of the flight unit. A package concept was generated for the components selected and mass and volume estimated.
Based on the geometry of Mars Environment Survey (MESUR) Pathfinder aeroshell and an estimated Mars entry trajectory, two-dimensional axisymmetric time dependent calculations have been obtained using GIANTS (Gauss-Siedel Implicit Aerothermodynamic Navier-Stokes code with Thermochemical Surface Conditions) code and CMA (Charring Material Thermal Response and Ablation) Program for heating analysis and heat shield material sizing. These two codes are interfaced using a loosely coupled technique. The flowfield and convective heat transfer coefficients are computed by the GIANTS code with a species balance condition for an ablating surface, and the time dependent in-depth conduction with surface blowing is simulated by the CMA code with a complete surface energy balance condition. In this study, SLA-561V has been selected as heat shield material. The solutions, including the minimum heat shield thicknesses over aeroshell forebody, pyrolysis gas blowing rates, surface heat fluxes and temperature distributions, flowfield, and in-depth temperature history of SLA-561V, are presented and discussed in detail.
Analytical and experimental studies of rocket- booster base flow
A coupled, trajectory-based flowfield and material thermal-response analysis is presented for the European Space Agency proposed Rosetta comet nucleus sample return vehicle. The probe returns to earth along a hyperbolic trajectory with an entry velocity of 16.5 km/s and requires an ablative heat shield on the forebody. Combined radiative and convective ablating flowfield analyses were performed for the significant heating portion of the shallow ballistic entry trajectory. Both quasisteady ablation and fully transient analyses were performed for a heat shield composed of carbon-phenolic ablative material. Quasisteady analysis was performed using the two-dimensional axisymmetric codes RASLE and BLIMPK. Transient computational results were obtained from the one-dimensional ablation/conduction code CMA. Results are presented for heating, temperature, and ablation rate distributions over the probe forebody for various trajectory points. Comparison of transient and quasisteady results indicates that, for the heating pulse encountered by this probe, the quasisteady approach is conservative from the standpoint of predicted surface recession.
Feasibility of outer mold line (OML) heat exchangers for electrified aircraft is computationally explored for three different aircraft concepts within The High-efficiency Electrified Aircraft Thermal Research (HEATheR) project. OML surface temperature limits were selected based on aluminum-alloy and carbon-fiber composite materials commonly used in transport aircraft. Heat flux distribution over the aircraft OML at the surface temperature limit was evaluated with computational fluid dynamics (CFD) analysis. The candidate OML locations and the size for the implementation of the OML-based heat exchanger is down-selected using this initial analysis and other considerations including the concern for structural integrity and proximity to heat-generating electrical components. The sensitivity of the heat transfer analysis to the computational grid, aircraft angle of attack, surface temperature, and the interaction of individual OML heat exchanger patches were investigated.
Heating equipment to control radiation hazards, and for improved space vehicle design
A heat pump is a device which elevates the temperature of a heat flow by a means of an energy input. By doing this, the heat pump can cause heat to transfer faster from a warm region to a cool region, or it can cause heat to flow from a cool region to a warmer region. The second case is the one which finds vast commercial applications such as air conditioning, heating, and refrigeration. Aerospace applications of heat pumps include both cases. The NASA Johnson Space Center is currently developing a Life Support Systems Integration Facility (LSSIF, previously SIRF) to provide system-level integration, operational test experience, and performance data that will enable NASA to develop flight-certified hardware for future planetary missions. A high lift heat pump is a significant part of the TCS hardware development associated with the LSSIF. The high lift heat pump program discussed here is being performed in three phases. In Phase 1, the objective is to develop heat pump concepts for a lunar base, a lunar lander, and for a ground development unit for the SIRF. In Phase 2, the design of the SIRF ground test unit is being performed, including identification and evaluation of safety and reliability issues. In Phase 3, the SIRF unit will be manufactured, tested, and delivered to the NASA Johnson Space Center.
A heat pipe cooled reactor is one of several candidate reactor cores being considered for advanced space power and propulsion systems to support future space exploration applications. Long life heat pipe modules, with designs verified through a combination of theoretical analysis and experimental lifetime evaluations, would be necessary to establish the viability of any of these candidates, including the heat pipe reactor option. A hardware-based program was initiated to establish the infrastructure necessary to build heat pipe modules. This effort, initiated by Los Alamos National Laboratory and referred to as the Safe Affordable Fission Engine (SAFE) project, set out to fabricate and perform non-nuclear testing on a modular heat pipe reactor prototype that can provide 100 kilowatt from the core to an energy conversion system at 700 C. Prototypic heat pipe hardware was designed, fabricated, filled, closed-out and acceptance tested.
The objective of this project was to investigate the feasibility of constructing a heat pump suitable for use as a heat rejection device in applications such as a lunar base. In this situation, direct heat rejection through the use of radiators is not possible at a temperature suitable for lde support systems. Initial analysis of a heat pump of this type called for a temperature lift of approximately 378 deg. K, which is considerably higher than is commonly called for in HVAC and refrigeration applications where heat pumps are most often employed. Also because of the variation of the rejection temperature (from 100 to 381 deg. K), extreme flexibility in the configuration and operation of the heat pump is required. A three-stage compression cycle using a refrigerant such as CFC-11 or HCFC-123 was formulated with operation possible with one, two or three stages of compression. Also, to meet the redundancy requirements, compression was divided up over multiple compressors in each stage. A control scheme was devised that allowed these multiple compressors to be operated as required so that the heat pump could perform with variable heat loads and rejection conditions. A prototype heat pump was designed and constructed to investigate the key elements of the high-lift heat pump concept. Control software was written and implemented in the prototype to allow fully automatic operation. The heat pump was capable of operation over a wide range of rejection temperatures and cooling loads, while maintaining cooling water temperature well within the required specification of 40 deg. C +/- 1.7 deg. C. This performance was verified through testing.
A 6.4-cm-diameter scale model of the Jovian entry vehicle is tested in an electric-arc-driven shock tube and a 5-cm-diameter sphere model is tested in a combustion-driven shock tube and in an electric-arc-driven shock tunnel. The radiative heat-transfer rate and pressure on the front and the base regions are measured in the absence of ablation with sensors imbedded in the models in a stream consisting of 10% hydrogen in a bath of either neon or argon. The measured radiative heat-transfer rates and pressures range to about 22 kW/sq cm and 12 atm, respectively, at the front stagnation point. The ratio of the radiative heat-transfer rate at the base stagnation point to that at the front stagnation point is found to be about 1/4 for the sphere at Mach 1.8, about 1/30 for the sphere at Mach 4.8, and about 1/6 for the scale model at Mach 1.7. The present experimental results agree well with the theoretical predictions of Park, thus indicating that Park's theory is valid.
Short duration technique providing simulation of thermodynamic properties and composition of exhaust products of liquid and solid propellant rocket engines
Short duration technique providing simulation of thermodynamic properties and composition of exhaust products of liquid and solid propellant rocket engines
A coupled, trajectory based flowfield and material thermal response analysis is presented for the European Space Agency (ESA) proposed Rosetta comet nucleus sample return vehicle. The probe returns to Earth along a hyperbolic trajectory with an entry velocity of 16.5 km/sec and requires an ablative heat shield on the forebody. Combined radiative and convective, ablating flowfield analyses were performed for the significant heating portion of the shallow ballistic entry trajectory. Both quasi-steady ablation and fully transient analyses were performed for a heat shield composed of carbon-phenolic ablative material. Quasi-steady analysis was performed using the two-dimensional, axisymmetric codes RASLE and BLIMPK. Transient computational results were obtained from the one-dimensional ablation/conduction code, CMA. Results are presented for heating, temperature and ablation rate distributions over the probe forebody for various trajectory points. Comparison of transient and quasi-steady results indicates that, for the heating pulse encountered by this probe, the quasi-static approach is conservative from the standpoint of predicted surface recession.
A scale model of the Jovian entry vehicle of 6.4 cm diameter is tested in an electric-arc-driven shock tube while a sphere model of 5 cm diameter is tested in a combustion-driven shock tube and an electric-arc-driven shock tunnel. The radiative heat-transfer rate and pressure on the front and the base regions are measured in the absence of ablation with sensors imbedded in the models in a stream consisting of 10% hydrogen in a bath of either neon or argon. The measured radiative heat-transfer rates and pressures are up to about 22 kW/sq cm and 12 atm, respectively, at the front stagnation point. The ratio of the base-to-stagnation-point radiative heat-transfer rates is found to be about 1/4 for the sphere at Mach 1.8, about 1/30 for the sphere at Mach 4.8, and about 1/6 for the scale model at Mach 1.7. When the effects of model geometry and Mach number are accounted for, the present experimental results agree well with the theoretical prediction of Park.
Establishing and maintaining a sustained presence on the lunar and/or Martian surfaces will require a diverse portfolio of surface elements (e.g., habitation, mobility, power generation, etc.). Many of these systems generate excess heat that must be rejected across a wide range of magnitudes, temperatures, and duty cycles and under variable environmental conditions. To identify the most promising heat rejection approaches for this diverse portfolio, a heat rejection trade study was conducted to evaluate the performance of different technology approaches across a spectrum of surface environments and heat-load requirements. The trade study consisted of three stages: (1) development of a parametric-based modeling framework, (2) creation of a database of heat rejection technologies, surface elements, and environmental conditions for the Moon and Mars, and (3) execution of a quantitative analysis of various heat rejection technologies across different operating conditions and surface elements. The modeling framework is developed in Python and Excel to prioritize small model size and hence low computational cost to enable large parametric sweeps while avoiding the reliance on proprietary software. Individual heat rejection processes are represented as simple Excel models, and a centralized Python script interfaces with the models to coordinate the parametric study. These simple sizing models were developed to take heat load requirements and environmental parameters as inputs and compute mass, power, and volume as outputs. Rather than assess each heat rejection technology separately for each surface element, a unified parametric space was developed to evaluate all technologies across all elements. This parametric space includes factors related to heat load (e.g., magnitude or temperature) and environment (e.g., surface temperature, sky temperature, solar flux). This effort generated a database containing information on over 60 heat rejection technologies and 30 surface elements. For each surface element, the expected heat rejection requirements were documented and analyzed to determine the most common needs shared across all elements. Environmental conditions at various lunar and Martian latitudes were also established for worst-case hot and worst-case cold scenarios. High-fidelity heat rejection models are currently under development. Preliminary trades between heat rejection technologies including radiators, venting technologies, convective coolers, and more have been conducted to identify promising options. This presentation will summarize the preliminary trade results and provide an overview and discussion of the expected heat loads and thermal environments for sustained surface operations on the Moon and Mars.
During development of the 25-O space shuttle model, several test firings were made in a vacuum chamber at simulated altitude conditions in order to verify satisfactory ignition and operation of the model in a high altitude environment. In conjunction with these firings, heating rate and pressure measurements were obtained at several locations in the orbiter base region on a piggy-back basis. Data obtained during these experiments are summarized, the 25-O space shuttle model is described.
A study of various aspects of Adjustable Speed Drives (ASD) is presented. A summary of the relative merits of different ASD systems presently in vogue is discussed. The advantages of using microcomputer based ASDs is now widely understood and accepted. Of the three most popular drive systems, namely the Induction Motor Drive, Switched Reluctance Motor Drive and Brushless DC Motor Drive, any one may be chosen. The choice would depend on the nature of the application and its requirements. The suitability of the above mentioned drive systems for a photovoltaic array driven ASD for an aerospace application are discussed. The discussion is based on the experience of the authors, various researchers and industry. In chapter 2 a PV array power supply scheme has been proposed, this scheme will have an enhanced reliability in addition to the other known advantages of the case where a stand alone PV array is feeding the heat pump. In chapter 3 the results of computer simulation of PV array driven induction motor drive system have been included. A discussion on these preliminary simulation results have also been included in this chapter. Chapter 4 includes a brief discussion on various control techniques for three phase induction motors. A discussion on different power devices and their various performance characteristics is given in Chapter 5.