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Modular heat exchanger with integral heat pipe transports heat from source to Stirling engine. Alternative to heat exchangers depending on integrities of thousands of brazed joints, contains only 40 brazed tubes.
As part of the Civil Space Technology Initiative (CSTI) Advanced Technology program, a conceptual design of the Stirling space engine (SSE) was generated. The overall goal of the CSTI high capacity power element is to develop the technology base needed to meet the long duration, high capacity power requirements for future NASA space missions. The free-piston Stirling engine (FPSE) was chosen as the growth option in the CSTI program. A major goal during the conceptual design of the SSE was to reduce the number of critical joints. One area of concern was the heat exchanger assemblies that typically have the majority of critical joints. The solution proposed in the SSE conceptual design used 40 modular heat exchangers. Each module has its own integral heat pipe to transport heat from the heat source to the engine. A demonstration of the modular concept was undertaken before committing to the detailed design of the SSE heat exchangers. An existing FPSE was modified as a test bed for modular heat exchanger evaluation. The engine incorporated three heat exchanger modules, each having a sodium filled heat pipe. The thermal loading of these modules was intended to be similar to the conditions projected for the SSE modules. The engine was assembled and tests are underway. The design and fabrication of the heat exchanger modules and the engine used for these tests were described. Evaluation of the individual heat pipes before installation in the engine is described. The initial test results with the modules in operation on the engine were presented. Future tests involving the engine were outlined.
As part of the Civil Space Technology Initiative (CSTI) Advanced Technology program, a conceptual design of the Stirling space engibe (SSE) was generated to develop the technology base needed to meet the long duration, high capacity power requirements for future NASA space missions. The free-piston Stirling engine (FPSE) was chosen as the growth option in the CSTI program. An existing FPSE was modified as a test bed for a modular heat exchanger evaluation. Evaluation of the individual heat pipes before installation in the engine is described.
An empirical modification of an existing integral energy turbulent boundary layer method is proposed in order to improve the estimates of local heat transfer in converging-diverging nozzles and consequently, provide better assessments of the total or integrated heat transfer. The method involves the use of a modified momentum-heat analogy which includes an acceleration term comprising the nozzle geometry and free stream velocity. The original and modified theories are applied to heat transfer data from previous studies which used heated air in 30 deg - 15 deg, 45 deg - 15 deg, and 60 deg - 15 deg water-cooled nozzles.
Integral heat sink material space suit for body temperature control
The conceptual design of a free-piston Stirling Space Engine (SSE) intended for space power applications has been generated. The engine was designed to produce 25 kW of electric power with heat supplied by a nuclear reactor. A novel heat exchanger module was designed to reduce the number of critical joints in the heat exchanger assembly while also incorporating a heat pipe as the link between the engine and the heat source. Two inexpensive verification tests are proposed. The SSE heat exchanger module is described and the operating conditions for the module are outlined. The design process of the heat exchanger modules, including the sodium heat pipe, is briefly described. Similarities between the proposed SSE heat exchanger modules and the LeRC test modules for two test engines are presented. The benefits and weaknesses of using a sodium heat pipe to transport heat to a Stirling engine are discussed. Similarly, the problems encountered when using a true heat pipe, as opposed to a more simple reflux boiler, are described. The instruments incorporated into the modules and the test program are also outlined.
The conceptual design of a free-piston Stirling Space Engine (SSE) intended for space power applications has been generated. The engine was designed to produce 25 kW of electric power with heat supplied by a nuclear reactor. A novel heat exchanger module was designed to reduce the number of critical joints in the heat exchanger assembly while also incorporating a heat pipe as the link between the engine and the heat source. Two inexpensive verification tests are proposed. The SSE heat exchanger module is described and the operating conditions for the module are outlined. The design process of the heat exchanger modules, including the sodium heat pipe, is briefly described. Similarities between the proposed SSE heat exchanger modules and the LeRC test modules for two test engines are presented. The benefits and weaknesses of using a sodium heat pipe to transport heat to a Stirling engine are discussed. Similarly, the problems encountered when using a true heat pipe, as opposed to a more simple reflux boiler, are described. The instruments incorporated into the modules and the test program are also outlined.
The Heat Pipe Stirling Engine (HP-1000), a free-piston Stirling engine incorporating three heat exchanger modules, each having a sodium filled heat pipe, has been tested at the NASA-Lewis Research Center as part of the Civil Space Technology Initiative (CSTI). The heat exchanger modules were designed to reduce the number of potential flow leak paths in the heat exchanger assembly and incorporate a heat pipe as the link between the heat source and the engine. An existing RE-1000 free-piston Stirling engine was modified to operate using the heat exchanger modules. This paper describes heat exchanger module and engine performance during baseline testing. Condenser temperature profiles, brake power, and efficiency are presented and discussed.
The baseline concept is introduced for the 'integral heat exchanger' (IHX) which is the interface of the two-phase thermal bus with the heat-rejecting radiator panels. A direct bus-to-radiator heat-pipe integral connection replaces the present interface hardware to reduce the weight and complexity of the heat-exchange mechanism. The IHX is presented in detail and compared to the baseline system assuming certain values for heat rejection, mass per unit width, condenser capacity, contact conductance, and assembly mass. The spreadsheet comparison can be used to examine a variety of parameters such as radiator length and configuration. The IHX is shown to permit the reduction of panel size and system mass in response to better conductance and packaging efficiency. The IHX is found to be a suitable heat-rejection system for the Space Station Freedom because it uses present technology and eliminates the interface mechanisms.
Transient performance tests of an integrated heat pipe-thermal storage system have been conducted. This system was developed as a part of an Organic Rankine Cycle-Solar Dynamic Power System receiver for future power systems. The integrated system consists of potassium heat pipe elements that incorporate thermal energy storage canisters within the vapor space and an organic fluid (toluene) heater tube used as the condenser region of the heat pipe. The transient performance tests determined the operating characteristics and power input limits of the integrated heat pipe-thermal storage unit under conditions corresponding to re-acquisition of the sun during emergence from eclipse conditions and to the initial start-up of the solar dynamic power system. The tests demonstrated that the heat pipe-thermal storage element is not limited under conditions corresponding to emergence from eclipse during normal orbital operations and the heat pipe will successfully start-up from the frozen condition with full input power at the onset. Details of the test procedures and results of the tests are presented in this paper.
The major design and performance test subtasks in the development of small (200 to 1,000 whr) integral heat pipe/thermal energy storage devices for use with thermally driven spacecraft cryo-coolers are described. The design of the integral heat pipe/thermal energy storage device was based on a quasi steady resistance heat transfer, lumped capacitance model. Design considerations for the heat pipe and thermal storage annuli are presented. The thermomechanical stress and insulation system design for the device are reviewed. Experimental correlations are described, as are the plans for the further development of the concept.
Laboratory and flight performance tests of integral heating units for food preparation
An integrated heat pipe-thermal storage system was developed as part of the Organic Rankine Cycle Solar Dynamic Power System solar receiver for space station application. The solar receiver incorporates potassium heat pipe elements to absorb and transfer the solar energy within the receiver cavity. The heat pipes contain thermal energy storage (TES) canisters within the vapor space with a toluene heater tube used as the condenser region of the heat pipe. During the insolation period of the earth orbit, solar energy is delivered to the heat pipe. Part of this thermal energy is delivered to the heater tube and the balance is stored in the TES units. During the eclipse period of earth orbit, the stored energy in the TES units is transferred by the potassium vapor to the toluene heater tube. A developmental heat pipe element was constructed that contains axial arteries and a distribution wick connecting the toluene heater and the TES units to the solar insolation surface of the heat pipe. Tests were conducted to demonstrate the heat pipe, TES units, and the heater tube operation. The heat pipe element was operated at design input power of 4.8 kW. Thermal cycle tests were conducted to demonstrate the successful charge and discharge of the TES units. Axial power flux levels up to 15 watts/sq cm were demonstrated and transient tests were conducted on the heat pipe element. Details of the heat pipe development and test procedures are presented.
This paper presents the results of the systems level thermal modeling for a conceptual Chemical Heat Integrated Power Source (CHIPS). This proposed system offers a combined thermal and electrical power source to support survival of spacecraft operating in extreme low temperature lunar environments, without the use of radioisotope-based sources. A conceptual design study has been completed for this system, that uses heat generated by an exothermic chemical reaction in place of radioisotope or electrical heat sources. The goal of the study was to evaluate the feasibility of such a system through thermodynamic and chemical analysis and thermal modeling, and to identify technology gaps to inform a technology development and maturation plan. The specific technical objectives focused on delivery of 90 to 100 Wth thermal power and 30 to 40 We electrical power for 336 hours to a representative Commercial Lunar Payload Services (CLPS) lander, to support lunar surface survival and limited operations through a lunar night. The total system mass was targeted at ≤50 kg. A highly exothermic chemical reaction system is used to generate on-board electrical power for spacecraft systems, and thermal power to maintain critical spacecraft/lander systems within their allowable flight temperature (AFTs). Based on the very high energy content of the chemical reaction system, a much higher amount of heat per unit mass can be delivered to the spacecraft, relative to a rechargeable lithium-ion battery and electrical heater(s). Since radioisotope heaters or generators are not used, the system will be orders of magnitude lower in cost than a radioisotope heating/power unit, without the attendant regulatory complexities. As part of the CHIPS concept, a fraction of the thermal power generated is converted to electrical power via an appropriate thermal-to-electric converter technology (such as a free piston Stirling converter or a thermoelectric generator module), to provide power to critical loads. This approach is ideally suited to support operation of commercial landers (e.g., via the CLPS program). In most cases, these landers are only designed to operate during a portion of the lunar day, with no provision for survival through the lunar night. By supporting lunar night survival, a mission can be extended through the lunar night and at least into another lunar day, thus turning a nominal eight-day mission into a 36-day mission. Therefore, the current system demonstration will focus on scalability to support at least 336 hours (one lunar night) of continuous thermal and electrical power generation. Although initially targeted to support lunar equatorial landings, the technology is extensible to missions at the lunar poles, other extreme environments in the Solar System or even air-independent applications on Earth (e.g., ocean exploration).
Thermally-driven, nonmechanical compressor uses container filled with compressed praseodymium cerium oxide powder (PrCeOx) to provide high-pressure flow of oxygen gas for driving closed-cycle Joule-Thomson-expansion refrigeration unit. Integrated heat switch/oxide sorption compressor has no moving parts except check valves, which control flow of oxygen gas between compressor and closed-cycle Joule-Thomson refrigeration system. Oxygen expelled from sorbent at high pressure by evacuating heat-switch gap and turning on heater.
An innovative thermal management solution was conceptualized, built and tested for the X57 Maxwell electric airplane. A combination of commercial CFD codes and bespoke thermal modeling tools were employed to rapidly develop a structurally-integral power electronics heat sink. A structurally-integrated heat sink was devised for the GIMC-SCEPTOR high lift motor controller. The nacelle-conforming sink is designed to dissipate heat from the power electronics assembly while simultaneously acting as the mechanical load path between the wing structure and high lift motor.
A process for producing an integral adsorbent-heat exchanger apparatus useful in ammonia refrigerant heat pump systems. In one embodiment, the process wets an activated carbon particles-solvent mixture with a binder-solvent mixture, presses the binder wetted activated carbon mixture on a metal tube surface and thereafter pyrolyzes the mixture to form a bonded activated carbon matrix adjoined to the tube surface. The integral apparatus can be easily and inexpensively produced by the process in large quantities.
An integrated thermal energy storage (TES) system, developed as a part of an organic Rankine cycle solar dynamic power system is described, and the results of the performance verification tests of this TES system are presented. The integrated system consists of potassium heat-pipe elements that incorporate TES canisters within the vapor space, along with an organic fluid heater tube used as the condenser region of the heat pipe. The heat pipe assembly was operated through the range of design conditions from the nominal design input of 4.8 kW to a maximum of 5.7 kW. The performance verification tests show that the system meets the functional requirements of absorbing the solar energy reflected by the concentrator, transporting the energy to the organic Rankine heater, providing thermal storage for the eclipse phase, and allowing uniform discharge from the thermal storage to the heater.