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Advanced Stirling Convertor Control Unit Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

Future NASA missions could include long-duration flyby, orbital, lander, or rover applications where generating power from sunlight may be limited. Radioisotope power systems (RPSs) provide a dependable power source for missions where inadequate sunlight or operational requirements make other power systems impractical. Over the past 16 years, NASA Glenn Research Center has been supporting the development of RPSs. The advanced Stirling radioisotope generator (ASRG) utilized a pair of advanced Stirling convertors (ASCs). Although flight development of the ASRG has been canceled, much of the technology and hardware continued development and testing to guide future activities. Specifically, a controller for the convertor(s) is an integral part of a Stirling-based RPS. For the ASRG design, the controller maintains stable operation of the convertors, regulates the alternating current produced by the linear alternator of the convertor, provides a specified direct-current output voltage for the spacecraft, and synchronizes the piston motion of the two convertors to minimize vibration as well as manage and maintain operation with a stable piston amplitude and hot-end temperature. It not only provides power to the spacecraft but also must regulate convertor operation to avoid damage to internal components and maintain safe thermal conditions after fueling. Lockheed Martin Coherent Technologies, Inc., has designed, developed, and tested an ASC control unit engineering development unit (ACU EDU) to support this effort. GRC used the ACU EDU as part of its nonnuclear representation of a RPS that also consists of a Dual advanced Stirling convertor simulator (DASCS), and associated support equipment to perform a test in the Radioisotope Power Systems System Integration Laboratory (RSIL). The RSIL was designed and built with flexibility to evaluate hardware utilizing RPS technology. The RSIL provides insight into the electrical interactions between as many as three radioisotope power generators, associated control strategies, and typical electric system loads. The first phase of testing included a DASCS that was developed by Johns Hopkins University Applied Physics Laboratory and simulates the operation and electrical behavior of a pair of ASCs in real time via a combination of hardware and software. Testing included the following spacecraft electrical energy storage configurations: capacitor, battery, and supercapacitor. Testing of the DASCS and ACU in each energy storage configuration included simulation of a typical mission profile and transient voltage and current data during load turnon and turnoff. Testing for these devices also included the initiation of several system faults such as short circuits, electrical bus overvoltage, undervoltage, and a "dead bus" recovery to restore normal power operations. The goal of this testing was to verify operation of the ACU(s) when connected to a spacecraft electrical bus. The results of these tests are presented here.

General↗

Attitude stability of a flexible solar electric spacecraft - A parametric study

The influence of large area solar array flexibility on the attitude control of a solar electric spacecraft is analyzed. The spacecraft consists of a rigid central body, two flexible roll-out solar arrays, and a cluster of three electric propulsion engines. Each engine has gimballing or translational capacity, or both, for attitude control purposes. A parametric stability study of various spacecraft configurations was made, using hybrid coordinate techniques in an eigenvalue analysis. Parameters varied were solar array aspect ratio, solar array first natural frequency, solar array rotation angle about the yaw axis, and sensor gain factors. Only the first six modes of solar array vibration were included in the study. The attitude response characteristics of the various spacecraft configurations were obtained by means of a digital computer simulation program of the system's equations of motion. The feasibility of using the thrusters for attitude control of electric propulsion spacecraft is demonstrated. It is also shown that although the dynamics effects of large-area flexible solar arrays can be harmful, changes in the control system parameters can insure stable attitude control.

Marsh, E. L.↗

Space Nuclear Propulsion for Deep Space Science Missions

The use of nuclear thermal propulsion (NTP) 1 and nuclear electric propulsion (NEP) 2 systems on deep space science missions to the outer planets and into the interstellar medium 3 can yield significant spacecraft system and mission performance benefits and improvements relative to the use of conventional chemical propulsion systems. Several recent and ongoing programs are developing the technologies and systems required to realize a near-term deep space nuclear propulsion capability. NTP provides improved propulsion efficiencies compared to chemical propulsion, while also providing substantial thrust. This combination of high thrust and increased specific impulse (I_sp) provides high acceleration and extended thrusting periods, enabling greatly reduced trip-times on certain types of missions compared to various propulsive alternatives. For examples, compared to a baseline mission using chemical propulsion, NTP-powered missions to Jupiter or Uranus could deliver approximately 2.4-3.6 times more payload (in the case of Jupiter, the payload delivery is significantly larger than the Juno spacecraft). In this comparison, the higher end of the payload advantage is obtained when the trip time is held equal for the NTP-powered vehicle and a vehicle using a chemical propulsion departure stage. NTP systems are presently under development by multiple government agencies. NASA’s Space Nuclear Propulsion (SNP) project aims to demonstrate a hydrogen-fed NTP engine at 900 s specific impulse (I_sp) and approximately 10-15 klb_f of thrust. DARPA’s Demonstration Rocket for Agile Cislunar Operations (DRACO) program is targeting a demonstration of an NTP system in the cislunar space between the Earth and the Moon. An appropriately phased development plan that applies the development of the reactor technology for an NTP engine in this performance class and leverages mature, existing liquid rocket component hardware provides a path to a lower cost propulsion system that can be realized on a shorter development schedule. NEP, with high Isp in the 2,000-8,000 s range, can also provide advantages over chemical propulsion, including a much greater payload delivery mass and the flexibility for planners to trade between delivered mass and a wider window of mission trajectory options. Electric propulsion (EP) systems have demonstrated great utility, performing notably on the Dawn mission to enable rendezvous and orbital insertion at two separate bodies, Vesta and Ceres. An NEP-powered vehicle would have a similar capability to visit multiple bodies, loitering at each before moving to the next. A 10 kW_e NEP system provides a power- rich environment on the spacecraft that is simply not possible using present radioisotope power systems, giving mission planners more scientific instrument and communication hardware options. Several programs and projects are presently developing NEP systems and subsystems in the 10 kW_e power range, leveraging past reactor work and recent nuclear power generation risk-reduction demonstration activities such as the Demonstration Using Flattop Fission (DUFF) and the Kilopower Reactor Using Stirling TechnologY (KRUSTY). The goal of the Air Force Research Laboratory’s Joint Energy Technology Supplying On-Orbit Nuclear Power (JETSON) program is an in-space demonstration vehicle that has a 10 kW_e -class fission power source. These past and present efforts can be combined with the ongoing development of 10 kW_e -class electric propulsion systems (notably the NEXT-C ion thruster or the Hall-effect thrusters for Power and Propulsion Element of the Lunar Gateway) to provide a pathway to a low-cost, reliable NEP system for deep space science application.

Kurt A. Polzin↗

Space Nuclear Propulsion for Deep Space Science Missions

The use of nuclear thermal propulsion (NTP) 1 and nuclear electric propulsion (NEP) 2 systems on deep space science missions to the outer planets and into the interstellar medium 3 can yield significant spacecraft system and mission performance benefits and improvements relative to the use of conventional chemical propulsion systems. Several recent and ongoing programs are developing the technologies and systems required to realize a near-term deep space nuclear propulsion capability. NTP provides improved propulsion efficiencies compared to chemical propulsion, while also providing substantial thrust. This combination of high thrust and increased specific impulse (I_sp) provides high acceleration and extended thrusting periods, enabling greatly reduced trip-times on certain types of missions compared to various propulsive alternatives. For examples, compared to a baseline mission using chemical propulsion, NTP-powered missions to Jupiter or Uranus could deliver approximately 2.4-3.6 times more payload (in the case of Jupiter, the payload delivery is significantly larger than the Juno spacecraft). In this comparison, the higher end of the payload advantage is obtained when the trip time is held equal for the NTP-powered vehicle and a vehicle using a chemical propulsion departure stage. NTP systems are presently under development by multiple government agencies. NASA’s Space Nuclear Propulsion (SNP) project aims to demonstrate a hydrogen-fed NTP engine at 900 s specific impulse (I_sp) and approximately 10-15 klb_f of thrust. DARPA’s Demonstration Rocket for Agile Cislunar Operations (DRACO) program is targeting a demonstration of an NTP system in the cislunar space between the Earth and the Moon. An appropriately phased development plan that applies the development of the reactor technology for an NTP engine in this performance class and leverages mature, existing liquid rocket component hardware provides a path to a lower cost propulsion system that can be realized on a shorter development schedule. NEP, with high Isp in the 2,000-8,000 s range, can also provide advantages over chemical propulsion, including a much greater payload delivery mass and the flexibility for planners to trade between delivered mass and a wider window of mission trajectory options. Electric propulsion (EP) systems have demonstrated great utility, performing notably on the Dawn mission to enable rendezvous and orbital insertion at two separate bodies, Vesta and Ceres. An NEP-powered vehicle would have a similar capability to visit multiple bodies, loitering at each before moving to the next. A 10 kW_e NEP system provides a power- rich environment on the spacecraft that is simply not possible using present radioisotope power systems, giving mission planners more scientific instrument and communication hardware options. Several programs and projects are presently developing NEP systems and subsystems in the 10 kW_e power range, leveraging past reactor work and recent nuclear power generation risk-reduction demonstration activities such as the Demonstration Using Flattop Fission (DUFF) and the Kilopower Reactor Using Stirling TechnologY (KRUSTY). The goal of the Air Force Research Laboratory’s Joint Energy Technology Supplying On-Orbit Nuclear Power (JETSON) program is an in-space demonstration vehicle that has a 10 kW_e -class fission power source. These past and present efforts can be combined with the ongoing development of 10 kW_e -class electric propulsion systems (notably the NEXT-C ion thruster or the Hall-effect thrusters for Power and Propulsion Element of the Lunar Gateway) to provide a pathway to a low-cost, reliable NEP system for deep space science application.

Kurt A. Polzin↗

Subscale Hardware-In-The-Loop Results for Hybrid Electric Turbofan Controls Use Cases

NASA is investigating hybrid electric turbine engine systems for commercial transport aircraft due to the potentially significant improvements hybrid electric technology offers in performance, fuel consumption, and operational and design flexibility. Recently, the technology has been tested at full scale in partnership with industry and advanced to Technology Readiness Level 4. This presentation will focus on a recent subscale hardware-in-the-loop test of an open source turbofan engine model developed by NASA. The Advanced Geared Turbofan 30,000 lbf – electrified (AGTF30-e) engine is used as a reference model to demonstrate control system design and use cases for an example mild hybrid electric system with no large-scale energy storage. This model is run in real-time in NASA’s Hybrid Propulsion Emulation Rig (HyPER) and is used to drive an emulation of the turbomachinery system using subscale electric machines. This dynamic scaled shaft emulation interacts with a subscale (<100 kW) hybrid system consisting of electric machines, motor controllers, and a programmable electronic load. Specific use cases demonstrated include the use of Turbine Electrified Energy Management to improve operation during transients, megawatt-scale power extraction from the AGTF30-e, and power transfer between engine spools. Results related to the effectiveness of hybrid systems are qualitatively compared to results from industry testing.

Hybrid↗

Advanced eLectrical Bus (ALBus) CubeSat: From Build to Flight

The Advanced eLectrical Bus (ALBus) CubeSat project is a technology demonstration mission of a 3-U CubeSat with an advanced, digitally controlled electrical power system capability and novel use of Shape Memory Alloy (SMA) technology for reliable deployable solar array mechanisms. The objective of the project was to advance the state of power management and distribution (PMAD) capabilities to enable future missions requiring flexible and reliable power systems with higher output power capabilities. The goals of the mission were to demonstrate 100W distribution to a target electrical load, respond to continuous and fast transient power requirements, and show reliable deployment of solar arrays and antennas utilizing re-settable SMA mechanisms. The power distribution function of the ALBus PMAD system is unique in the total power to target load capability. Power is distributed from batteries to provide 100W of power directly to a resistive load. The deployable solar arrays utilize NASA Glenn Research Center’s Nickel-Titanium-Palladium-Platinum high-temperature SMAs for the retention and release mechanism, and a super-elastic binary NiTi alloy for the hinge component. The deployable solar array hinge design features the utilization of SMA material properties for a dual purpose. First, the hinge uses the super-elastic SMA properties to provide the spring force to deploy the arrays. Second, the electrical conductivity properties of the SMA enables the design to provide clean conduits for power transfer from the deployable arrays to the power management system. This eliminates the need for electrical harnesses between the arrays and the PMAD system in the ALBus system design. The uniqueness of the SMA retention and release mechanism design is the ability to reset the mechanism and reuse the same hardware. This allow functional tests of the mechanisms before flight with no degradation of performance and flying the hardware that is tested. The project launched as part of the CubeSat Launch Initiative Educational Launch of Nanosatellites (ELaNa) XIX mission on Rocket Lab’s Electron in December 2018. This paper summarizes the final launched design of ALBus and lessons learned from the technology and overall project from development through flight.

Deboshri Sadhukhan↗

Investigation of fluctuations in angular velocity in magnetic memory devices

The fluctuations in the angular velocity of individual assemblies of a precision mechanical system were analyzed. The system was composed of an electric motor and a magnetic drum which were connected by a flexible coupling. A dynamic model was constructed which took into account the absence of torsion in the rigid shafts of the electric motor drive rotor and the magnetic drum. The motion was described by Lagrange differential equations of the second kind. Curves are developed to show the nature of amplitude fluctuation of the magnetic drum angular velocity at a specific excitation frequency. Additional curves show the amplitudes of fluctuation of the magnetic drum angular velocity compared to the quantity of damping at specific frequencies.

Meshkis, Y. A.↗

An Innovation for the Energy Industry

REDOX is an economical energy storage system which promises major reductions in the cost of storing electrical energy. The system is based upon the conversion of chemical energy into electrical energy. 75 percent of the energy used to charge the system is returned. It is flexible and the energy may be stored for long periods. It was developed by Lewis Research Center, who transferred the technology to SOHIO for further development and possible commercialization. Redox could eliminate the use of high quality generator levels and would be particularly valuable to utilities which generate power from coal or nuclear energy.

Source record↗

The walking robot project

A walking robot was designed, analyzed, and tested as an intelligent, mobile, and a terrain adaptive system. The robot's design was an application of existing technologies. The design of the six legs modified and combines well understood mechanisms and was optimized for performance, flexibility, and simplicity. The body design incorporated two tripods for walking stability and ease of turning. The electrical hardware design used modularity and distributed processing to drive the motors. The software design used feedback to coordinate the system and simple keystrokes to give commands. The walking machine can be easily adapted to hostile environments such as high radiation zones and alien terrain. The primary goal of the leg design was to create a leg capable of supporting a robot's body and electrical hardware while walking or performing desired tasks, namely those required for planetary exploration. The leg designers intent was to study the maximum amount of flexibility and maneuverability achievable by the simplest and lightest leg design. The main constraints for the leg design were leg kinematics, ease of assembly, degrees of freedom, number of motors, overall size, and weight.

Williams, P.↗

Multiple beam microwave systems for the solar power satellite

An antenna optimization technique is applied to the environmental requirements pertaining to SPS (solar power satellite) systems to create high efficiency, multiple beams from a single antenna. Effects of rectenna spacings, subarray sizing, multiple beam degradations, antenna electrical and mechanical errors, and satellite motion are investigated. Advantages of multiple beam SPS systems include operational flexibility, lower power per rectenna, fewer satellites, smaller rectennas, and adherence to a 0.01 mW/sq cm environmental guidelines for sidelobe levels. These advantages suggest multiple beam systems are attractive alternatives to the present single beam system.

Arndt, G. D.↗

Operational Integration Assessment (OIA) of Midterm UAM Operations: Class C Airspace Tabletop Exercise and Integration Checkpoint

The National Aeronautics and Space Administration (NASA), in collaboration with the Federal Aviation Administration (FAA), is conducting research into evolving today’s air traffic management system towards a more automated and operationally flexible airspace to accommodate Urban Air Mobility (UAM) operations at scale. UAM operations, enabled by electric Vertical Takeoff and Landing (eVTOL) aircraft, may change the role of aviation in the movement of people and goods and provide practical, cost-effective air transport in metropolitan areas. FAA UAM Concept of Operations v2.0 describes three evolutionary stages of UAM operations: Initial, Midterm, and Mature State operations. Midterm operations are comprised of many complex changes to the national airspace system (NAS). The Operational Integration Assessment (OIA) was created as a capability to address the need to study the progression and identify interdependencies of those changes that may occur during the midterm UAM operations timeframe. The OIA includes a series of tabletop exercises and integration checkpoints planned to explore various use cases from end-to-end, evaluated by NASA’s Air Traffic Management eXploration (ATM-X) project in partnership with the FAA’s William J. Hughes Technical Center (WJHTC) and industry partners. The use cases were exercised in an immersive, integrated live-virtual-constructive (LVC) airspace simulation environment, called the NASA/FAA Laboratory Integrated Test Environment (NFLITE), as part of an effort to learn how UAM operations can scale beyond the as-is NAS and through the transition to higher-tempo and highly automated operations of the future. This document describes the events of the tabletop exercise held from January 24-26, 2023, at the National Airspace Research & Technology Park (NARTP) in Egg Harbor Township, New Jersey, adjacent to the WJHTC and the subsequent integration checkpoint performed on March 28, 2023,at NASA Langley Research Center (LaRC) in Hampton, Virginia.

UAM↗

Exploration of the Versatile Electrically Augmented Turbine Engine Gearbox Concept

Integration of electric machines with the shafts of gas turbine engines is implied in various electrified aircraft propulsion concepts. This includes implementation of the Turbine Electrified Energy Management (TEEM) concept, a motivator for the Versatile Electrically Augmented Turbine Engine (VEATE) gearbox. The VEATE gearbox is a mechanical power transmission concept that seeks to interface electric machines with a gas turbine engine in a synergistic manner. It enables a hybrid electro-mechanical approach for managing power in a gas turbine engine. It is hypothesized that the mechanical design of the VEATE gearbox could be leveraged to enhance the versatility of the present electrical hardware. The VEATE gearbox concept is first introduced and applied to an electrified two-spool advanced geared turbofan meant for powering a single-aisle commercial aircraft. A modeling approach for the gearbox is presented and studies are conducted to investigate the potential application to TEEM and power extraction. There is evidence that the VEATE gearbox could help to reduce the size of the TEEM power system, provide flexibility in power extraction implementation, and exhibit fail-safe design attributes.

Versatile Electrically Augmented Turbine Engine Ge↗

JSC space base/power module studies

Users of the Orbiter/Spacelab combination will require both higher electrical power and longer duration than is available with the current baseline system. Present Orbiter/Spacelab mission capability is primarily constrained by the hydrogen and oxygen available to generate power in the Orbiter fuel cells. It is also necessary to assure that considerable attitude or point flexibility is retained to assure efficient operation of the Orbiter radiator cooling system. Beyond these early limitations, it is foreseen that orbital operations will eventually need even greater quantities of the basic space utilities: electrical power; heat rejection; and attitude control. Such operations, forecasted for the mid to late 1980's, will be best accommodated by a module stored in orbit that can furnish these to a docked Orbiter/Spacelab or other vehicles. The Orbital Service Module concept to provide for these services is presented.

Craig, J. W.↗

NASA Electric Propulsion Program

The described NASA program is to provide the technology base to meet the U.S. future needs in the area of low thrust, high specific impulse propulsion. An electric propulsion system will be needed to augment the Shuttle-IUS Space Transportation System for space missions involving the exploration of the solar system. Plans exist in this connection for comet and asteroid rendezvous, a Saturn and a Mercury orbiter, and a Mars surface sample return. An analysis has shown that electric propulsion can be used to obtain larger payloads, shorter trip times, more mission flexibility, and less complicated trajectories. In addition, electric propulsion has also potential uses for earth orbital missions. Attention is given to the auxiliary propulsion technology program which is to develop a one millipound electron bombardment thrust system, a baseline program concerned with a 3 kilowatt thrust system, ion thruster research, magnetoplasmadynamic thruster research and evaluation, and the use of a mass driver as a reaction mass propulsion system.

Hudson, W. R.↗

Toward an electrical power utility for space exploration

Plans for space exploration depend on today's technology programs addressing the novel requirements of space-based enterprise. The requirements for electrical power will be formidable: megawatts in magnitude, reliability for multi-year missions and the flexibility to adapt to needs unanticipated at design time. The reasons for considering the power management and distribution in the various systems from a total mission perspective, rather than simply extrapolating current spacecraft design practice, are discussed. A utility approach to electric power being developed at the Lewis Research Center is described. It integrates requirements from a broad selection of current development programs with studies in which both space and terrestrial technologies are conceptually applied to exploration mission scenarios.

Bercaw, Robert W.↗

PHOBOS Exploration using Two Small Solar Electric Propulsion (SEP) Spacecraft

Phobos Surveyor Mission concept provides an innovative low cost, highly reliable approach to exploring the inner solar system 1/16/2013 3 Dual manifest launch. Use only flight proven, well characterize commercial off-the-shelf components. Flexible mission architecture allows for a slew of unique measurements.

Solar Electric Propulsion (SEP)↗

Power and Propulsion System Design for Near-Earth Object Robotic Exploration

Near-Earth Objects (NEOs) are exciting targets for exploration; they are relatively easy to reach but relatively little is known about them. With solar electric propulsion, a vast number of interesting NEOs can be reached within a few years and with extensive flexibility in launch date. An additional advantage of electric propulsion for these missions is that a spacecraft can be small, enabling a fleet of explorers launched on a single vehicle or as secondary payloads. Commercial, flight-proven Hall thruster systems have great appeal based on their performance and low cost risk, but one issue with these systems is that the power processing units (PPUs) are designed for regulated spacecraft power architectures which are not attractive for small NEO missions. In this study we consider the integrated design of power and propulsion systems that utilize the capabilities of existing PPUs in an unregulated power architecture. Models for solar array and engine performance are combined with low-thrust trajectory analyses to bound spacecraft design parameters for a large class of NEO missions, then detailed array performance models are used to examine the array output voltage and current over a bounded mission set. Operational relationships between the power and electric propulsion systems are discussed, and it is shown that both the SPT-100 and BPT-4000 PPUs can perform missions over a solar range of 0.7 AU to 1.5 AU - encompassing NEOs, Venus, and Mars - within their operable input voltage ranges. A number of design trades to control the array voltage are available, including cell string layout, array offpointing during mission operations, and power draw by the Hall thruster system.

Near Earth Object (NEO)↗