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Progression on the design and development of a 40 KW fuel cell system for on-site installation for providing both thermal and electrical power is reported. Development of the steam reformer fuel processor, power section, inverter, control system, and thermal management and water treatment systems is described.
An integrated cryogenic liquid oxygen, liquid methane (LOX/LCH4) reaction control system (RCS) was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. The RCS is a subsystem of the Integrated Cryogenic Propulsion Test Article (ICPTA), a pressure-fed LOX/LCH4 propulsion system composed of a single 2,800 lbf main engine, two 28 lbf RCS engines, and two 7 lbf RCS engines. Propellants are stored in four 48 inch diameter 5083 aluminum tanks that feed both the main engine and RCS engines in parallel. Helium stored cryogenically in a composite overwrapped pressure vessel (COPV) flows through a heat exchanger on the main engine before being used to pressurize the propellant tanks to a design operating pressure of 325 psi. The ICPTA is capable of simultaneous main engine and RCS operation. The RCS engines utilize a coil-on-plug (COP) ignition system designed for operation in a vacuum environment, eliminating corona discharge issues associated with a high voltage lead. There are two RCS pods on the ICPTA, with two engines on each pod. One of these two engines is a heritage flight engine from Project Morpheus. Its sea level nozzle was removed and replaced by an 85:1 nozzle machined using Inconel 718, resulting in a maximum thrust of 28 lbf under altitude conditions. The other engine is a scaled down version of the 28 lbf engine, designed to match the core and overall mixture ratios as well as other injector characteristics. This engine can produce a maximum thrust of 7 lbf with an 85:1 nozzle that was additively manufactured using Inconel 718. Both engines are film-cooled and capable of limited duration gas-gas and gas-liquid operation, as well as steady-state liquid-liquid operation. Each pod contains one of each version, such that two engines of the same thrust level can be fired as a couple on opposite pods. The RCS feed system is composed of symmetrical 3/8 inch lines that tap off of the main propellant manifold to send LOX and LCH4 outboard to the RCS pods. A Thermodynamic Vent System (TVS) is used to condition propellants at each pod by venting through an orifice and then routing the cold expansion products back through tubing that is welded along a large portion of the main RCS feed lines. Prior to final installation on the ICPTA, the RCS engines were tested in a small vacuum chamber at the Johnson Space Center (JSC) Energy Systems Test Area (ESTA) to verify functionality of the new COP ignition system and check out operation of the vacuum nozzles. After engine-level testing, the RCS engines were installed on the vehicle and a series of integrated hot-fire tests were performed at JSC consisting of various pulsing and steady-state firings as well as integrated main engine/RCS operation. The ICPTA was then integrated into the Plum Brook B-2 facility for vacuum and thermal/vacuum testing. Testing in the B-2 facility was composed of multiple thermal and pressure environments. The first set of tests were performed under ambient temperature and altitude pressure conditions. These tests consisted of a range of minimum impulse bit (MIB) pulsing sequences with low duty cycle, analogous to a coast phase in which the RCS is primarily used for station keeping. The primary goal of this sequence is to understand how propellant conditions were effected without an active TVS. In this scenario, consistent gas-gas operation is desirable since it results in a smaller MIB and more efficient propellant consumption. Multiple skin thermocouples are mounted on the feedlines, in addition to a submerged thermocouple on each commodity, in order to gather thermal data on the system. Higher duty cycle pulsing tests were then performed, analogous to an ascent or landing mission phase. The primary goal of this sequence was to examine how well the engines self-conditioned without active TVS when starting from a quiescent state. The TVS was then activated during some tests to demonstrate the capability to quickly condition the engines for higher pulsing demand scenarios. A thermocouple at the TVS outlet allows for the calculation of energy absorbed by the vented propellant. Lastly, tests with longer pulses and multiple engines firing either in sequence or simultaneously were run in order to gather transient system response data on waterhammer. Six total high-speed pressure transducers are installed on the RCS system, one sensor at the end of each propellant manifold line on the pods, and one at the tap-off location for each commodity. This will allow for the accurate characterization of waterhammer in the system under various propellant conditions and firing sequences. Other instrumentation for this test series includes nozzle throat thermocouples, chamber pressure measurement, heat soakback measurement, and tank wall plume impingement temperature measurement. The next set of tests were performed to demonstrate simultaneous main engine and RCS operation. Data from this test will be used to examine if there is any change to nominal operation of the RCS as a result of feed system interaction or other phenomenon. Some of these tests began under high vacuum conditions (target ambient pressure less than 1x10(exp -3) torr) and others began at altitude conditions. The last set of tests were performed with the B-2 cold wall active. Under these tests, many of the same low duty cycle MIB tests were repeated in order to characterize how propellant conditions changed with the lower heat leak. In this scenario the RCS manifold experiences much less heat leak, resulting in a change to how well the engines self-condition. As a result, an increase in maximum waterhammer pressures and a change in natural frequency of the system was expected due to higher density propellants. The lower heat leak should also result in a change to the MIB pulse profile, and data will be examined to understand how MIB repeatability is affected in the different operating environments. Parallel to the test efforts, a set of transient model development efforts were made to predict RCS performance. The primary effort was aimed at producing a SINDA/FLUINT model to predict propellant conditioning up to the engine inlet as a function of different environmental and operating parameters, with the goal of predicting chamber pressure, TVS performance, and propellant consumption over time. Preliminary results for this effort will be presented in comparison with test data. Additional modeling efforts were made using SINDA/FLUINT to predict waterhammer in the system since the software is capable of handling multiphase transient fluid dynamics. These results will be compared with the high-speed pressure transducer test data for validation purposes.
In this age of shrinking military, civil, and commercial space budgets, an off-the-shelf solution is needed to provide a multimission approach to spacecraft control. A standard operational interface which can be applied to multiple spacecraft allows a common approach to ground and space operations. A trend for many space programs has been to reduce operational staff by applying autonomy to the spacecraft and to the ground stations. The Spacecraft Command Language (SCL) system developed by Interface and Control Systems, Inc. (ICS) provides an off-the-shelf solution for spacecraft operations. The SCL system is designed to provide a hyper-scripting interface which remains standard from program to program. The spacecraft and ground station hardware specifics are isolated to provide the maximum amount of portability from system to system. Uplink and downlink interfaces are also isolated to allow the system to perform independent of the communications protocols chosen. The SCL system can be used for both the ground stations and the spacecraft, or as a value added package for existing ground station environments. The SCL system provides an expanded stored commanding capability as well as a rule-based expert system on-board. The expert system allows reactive control on-board the spacecraft for functions such as electrical power systems (EPS), thermal control, etc. which have traditionally been performed on the ground. The SCL rule and scripting capability share a common syntax allowing control of scripts from rules and rules from scripts. Rather than telemeter over sampled data to the ground, the SCL system maintains a database on-board which is available for interrogation by the scripts and rules. The SCL knowledge base is constructed on the ground and uploaded to the spacecraft. The SCL system follows an open-systems approach allowing other tasks to communicate with SCL on the ground and in space. The SCL system was used on the Clementine program (launched January 25, 1994) and is required to have bidirectional communications with the guidance, navigation, and control (GNC) algorithms which were written as another task. Sequencing of the spacecraft maneuvers are handled by SCL, but the low-level thruster pulse commands are handled by the GNC software. Attitude information is reported back as telemetry, allowing the SCL expert system to inference on the changing data. The Clementine SCL flight software was largely reused from another Naval Center for Space Technology (NCST) satellite program. This paper details the SCL architecture and how an off-the-shelf solution makes sense for multimission spacecraft programs. The Clementine mission will be used as a case study in the application of the SCL to a 'fast track' program. The benefits of such a system in a 'better, cheaper, faster' climate will be discussed.
A system level design and analysis has been conducted on an Earth Observation Satellite (EOS) system using the Interactive Design and Evaluation of Advanced Spacecraft (IDEAS) computer-aided design and analysis program. The IDEAS program consists of about 40 user-friendly technical modules and an interactive graphics display. The reflector support system and feed mast of the EOS spacecraft are constructed with box-truss structural concept, a lattice configuration which can be packaged for delivery in a single Shuttle flight and deployed in orbit. The deployed spacecraft consists of a 120-m by 60-m parabolic focal axis. The spacecraft was modeled for structural, thermal, and control systems analysis and structural elements were designed. On-orbit dynamic and thermal loading analyses were conducted; spacecraft weights and developmental and first unit costs were determined.
A multilayered approach to the symbolic control of complex electromechanical assemblies, such as spaceborne thermal, power, and life subsystems, is discussed. An example of this approach is given in some recent tests of the Thermal Expert System (TEXSYS) in control of the Boeing Aerospace Thermal Bus System (BATBS), a prototype two-phase Space Station Freedom thermal bus. The BATBS hardware requires read-update-act cycles of under a minute, and it is subject to dynamic reconfiguration while operating. These performance requirements are addressed by layering model-based expert system software on a conventional numerical data acquisition and control system. TEXSYS test results demonstrate both nominal control and fault recovery actions with the BATBS. Dynamic modification of the symbolic model used in this approach is compared to that of a classical numerical adaptive controller.
Entry trajectory control effects on thermal protection system weight of space shuttle
A system level design and analysis has been conducted on an Earth Observation Satellite (EOS) system using the Interactive Design and Evaluation of Advanced Spacecraft (IDEAS) computer-aided design and analysis program. The IDEAS program consists of about 40 user-friendly technical modules and an interactive graphics display. The reflector support system and feed mast of the EOS spacecraft are constructed with a box-truss structural concept, a lattice configuration which can be packaged for delivery in a single Shuttle flight and deployed in orbit. The deployed spacecraft consists of a 120-m by 60-m parabolic reflector, a 120-m-long support structure, and a 30-m feed arc beam on the focal axis. The spacecraft was modeled for structural, thermal, and control systems analysis and structural elements were designed. On-orbit dynamic and thermal loading analyses were conducted and spacecraft weights were determined.
With the era of full utilization of the ISS now upon us, this presentation will discuss some of the highest-priority areas for two-phase flow systems with thermal control applications. These priorities are guided by recommendations of a 2011 NRC Decadal Survey report, Recapturing a Future for Space Exploration, Life and Physical Sciences for a New Era as well as an internal NASA exercise in response to the NRC report conducted in early 2012. Many of these proposals are already in various stages of development, while others are still conceptual.
Effects on Skylab of thermal control coating degradation by service module reaction control system rocket exhaust
Program objectives, components and subsystems operations of the Small Astronomy Satellite-3 are briefly described. A control system description is given covering the attitude control, the attitude detection system, the telemetry system, the command system, the power system and thermal control. Launch operations and in-orbit operations are also touched upon.
Two observatories under consideration in the 2020 decadal survey include coronagraphs for characterizing the atmospheric composition of exoplanets. The telescope in those observatories must provide a wavefront that is stable to the picometer level for the coronagraph to provide enough starlight rejection to capture light reflected off of an Earth-like exoplanet. Therefore, picometer dimensional stability and control are required for these missions. Analysis indicates the thermal environment around the primary mirror must be stable to milliKelvin for the primary mirror’s thermally induced wavefront error to be stable to picometers. Marshall Space Flight Center (MSFC) partnered with L3-Harris Corporation to design and build a 1.5mthermal control system capable of milliKelvin stability. MSFC tested this thermal control system in the X-Ray and Cryogenic Facility’s large chamber to characterize how well the system controlled a 1.5m ULE® mirror.
Topics covered include: A Multifunctional Space Environment Simulation Facility for Accelerated Spacecraft Materials Testing; Exposure of Spacecraft Surface Coatings in a Simulated GEO Radiation Environment; Gravity-Offloading System for Large-Displacement Ground Testing of Spacecraft Mechanisms; Microscopic Shutters Controlled by cRIO in Sounding Rocket; Application of a Physics-Based Stabilization Criterion to Flight System Thermal Testing; Upgrade of a Thermal Vacuum Chamber for 20 Kelvin Operations; A New Approach to Improve the Uniformity of Solar Simulator; A Perfect Space Simulation Storm; A Planetary Environmental Simulator/Test Facility; Collimation Mirror Segment Refurbishment inside ESA s Large Space; Space Simulation of the CBERS 3 and 4 Satellite Thermal Model in the New Brazilian 6x8m Thermal Vacuum Chamber; The Certification of Environmental Chambers for Testing Flight Hardware; Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Wallops Flight Facility: Current and Future Test Capabilities for Suborbital and Orbital Projects; Force Limited Vibration Testing of JWST NIRSpec Instrument Using Strain Gages; Investigation of Acoustic Field Uniformity in Direct Field Acoustic Testing; Recent Developments in Direct Field Acoustic Testing; Assembly, Integration and Test Centre in Malaysia: Integration between Building Construction Works and Equipment Installation; Complex Ground Support Equipment for Satellite Thermal Vacuum Test; Effect of Charging Electron Exposure on 1064nm Transmission through Bare Sapphire Optics and SiO2 over HfO2 AR-Coated Sapphire Optics; Environmental Testing Activities and Capabilities for Turkish Space Industry; Integrated Circuit Reliability Simulation in Space Environments; Micrometeoroid Impacts and Optical Scatter in Space Environment; Overcoming Unintended Consequences of Ambient Pressure Thermal Cycling Environmental Tests; Performance and Functionality Improvements to Next Generation Thermal Vacuum Control System; Robotic Lunar Lander Development Project: Three-Dimensional Dynamic Stability Testing and Analysis; Thermal Physical Properties of Thermal Coatings for Spacecraft in Wide Range of Environmental Conditions: Experimental and Theoretical Study; Molecular Contamination Generated in Thermal Vacuum Chambers; Preventing Cross Contamination of Hardware in Thermal Vacuum Chambers; Towards Validation of Particulate Transport Code; Updated Trends in Materials' Outgassing Technology; Electrical Power and Data Acquisition Setup for the CBER 3 and 4 Satellite TBT; Method of Obtaining High Resolution Intrinsic Wire Boom Damping Parameters for Multi-Body Dynamics Simulations; and Thermal Vacuum Testing with Scalable Software Developed In-House.
Industrial facilities are seeking new strategies that help in providing savings mechanisms for demand charges. Demand charges are the charges incurred by industrial facilities as a result of power usage. Thermal energy storage has advanced significantly with lots of new applications, garnering the interest of many industrial facilities. These applications could be used to shave the industrial facilities’ peak electric demand and reduce their demand charges. This paper aims to demonstrate the efficacy of thermal energy storage in reducing demand charges and highlight new developments in the integration of smart control systems with thermal energy storage. The study compares energy consumption and peak demand for a facility equipped with and without thermal energy storage tanks using a fixed schedule for charging and discharging. Additionally, the paper examines the impact of incorporating a smart controller to determine when to charge and discharge the tank based on the facility’s real-time power usage and a given setpoint. The results indicate cost savings from the use of thermal energy storage tanks under two proposed scenarios, reflected in the reduced cost of power consumption for the studied facility. The incorporation of a smart controller with the thermal energy storage tank in the facility studied could provide estimated savings of 3.3% per year of power consumption charges, without considering the contribution of any incentives. The estimated savings provided by the fixed schedule scenario are 2.7% per year.
An equation representing man's thermal balance under water is considered. The equation states that the body thermal loading from metabolic heat production and artificial heat input must be offset by respiratory and environmental heat exchange to maintain a constant body temperature. Critical body regions are affected by cold-water thermal stress. A model of the thermoregulatory system may be divided into the physical-controlled system and the dynamic controlling system. The thermal model is simulated by computer programs.
This paper describes the NASA/MSFC thermal control activities performed in support of the European design and development of the Spacelab environmental control system (ECS) and the integration of the ECS with experiments and with the Shuttle Orbiter. Thermal interfaces with the Orbiter are reviewed, including payload bay temperature profiles for the long module and pallet Spacelab configuration for the on-orbit mission phase. Thermal designs and predicted thermal performance are also reviewed for the module air cooling systems and specific experiment interfaces, such as the experiment dedicated heat exchanger and rack cooling.
Real time image processing techniques, combined with multitasking computational capabilities are used to establish thermal imaging as a multimode sensor for systems control during crystal growth. Whereas certain regions of the high temperature scene are presently unusable for quantitative determination of temperature, the anomalous information thus obtained is found to serve as a potentially low noise source of other important systems control output. Using this approach, the light emission/reflection characteristics of the crystal, meniscus and melt system are used to infer the crystal diameter and a linear regression algorithm is employed to determine the local diameter trend. This data is utilized as input for closed loop control of crystal shape. No performance penalty in thermal imaging speed is paid for this added functionality. Approach to secondary (diameter) sensor design and systems control structure is discussed. Preliminary experimental results are presented.
Heat transfer, and thermal control characteristics of diffuse bladed louver system for spacecraft
The Portable Life Support System (PLSS) provides a suitable environment for the astronaut in the Extravehicular Mobility Unit (EMU), and the heat rejection system controls the thermal conditions in the space suit. The current PLSS sublimates water to the space environment; therefore, the system loses mass. Since additional supplies of fluid must be available on the Space Shuttle, NASA desires a closed heat rejecting system. This document presents the embodiment design for a radiative plate heat rejection system without mass transfer to the space environment. This project will transform the concept variant into a design complete with material selection, dimensions of the system, layouts of the heat rejection system, suggestions for manufacturing, and financial viability.