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This presentation describes recent activities in materials research for high voltage power transmission cables/busbar for future electric aircraft. It also describes current high voltage (>1 KV) materials test capabilities at NASA-GRC and high voltage, multi-stress test chamber build-up concepts for cable/coupon testing.
Internal embedment stress measurements were performed, using tiny ferrite core transformers, whose voltage output was calibrated versus pressure by the manufacturer. Comparative internal strain measurements were made by attaching conventional strain gages to the same type of resistors and encapsulating these in various potting compounds. Both types of determinations were carried out while temperature cycling from 77 C to -50 C.
Testing high voltage (HV) electronic parts (greater than 300 V) for sudden event effects (SEE) caused by cosmic rays in the space environment, consisting of energetic heavy-ions, and neutron radiation in the upper atmosphere is a crucial step towards using these parts in spacecraft and aircraft. Due to the nature of cosmic radiation and neutrons, electronic parts are tested for SEE without any packaging and/or shielding over the top of the device. In the case of commercial HV parts, the top of the packaging is etched off and then a thin dielectric coating is placed over the part in order to avoid electrical arcing between the device surface and wire bonds and other components. Even though the effects of the thin dielectric layer on SEE testing can be accounted for, the dielectric layer significantly hinders post testing failure analysis. Replicating the test capability of state-of-the-art packaging while eliminating the need for post radiation test processing of the die surface (that obscures failure analysis) is the goal. To that end, a new packaging concept for HV parts has been developed that requires no dielectric coating over the part. Testing of prototype packages used with Schottky diodes (rated at 1200V) has shown no electrical arcing during testing and leakage currents during reverse bias testing are within the manufactures specifications.
Nondestructive high voltage test techniques (mostly electrical methods) are studied to prevent total or catastrophic breakdown of insulation systems under applied high voltage in space. Emphasis is on the phenomenon of partial breakdown or partial discharge (P.D.) as a symptom of insulation quality, notably partial discharge testing under D.C. applied voltage. Many of the electronic parts and high voltage instruments in space experience D.C. applied stress in service, and application of A.C. voltage to any portion thereof would be prohibited. Suggestions include: investigation of the ramp test method for D.C. partial discharge measurements; testing of actual flight-type insulation specimen; perfect plotting resin samples with controlled defects for test; several types of plotting resins and recommendations of the better ones from the electrical characteristics; thermal and elastic properties are also considered; testing of commercial capaciters; and approximate acceptance/rejection/rerating criteria for sample test elements for space use, based on D.C. partial discharge.
High voltage is applied to an arc gap adjacent to a test specimen to develop a succession of high frequency arc discharges. Those high frequency arc discharges generate pulses of ultrasonic energy within the test specimen without requiring the arc discharges to contact that test specimen and without requiring a coupling medium. Those pulses can be used for detection of flaws and measurements of certain properties and stresses within the test specimen.
Adjustable electronic load in solar-cell-array test instrument uses ten power MOSFET's and eight resistors. Two gate-control voltages adjusting load are derived from single, manually-operated, ganged potentiometer control. Third adjustable resistor adjusts relative turn-on points of two groups of transistors.
High voltage solar arrays are necessary for direct-drive solar electric propulsion, which has many advantages, including simplicity and high efficiency. Even when direct-drive is not used, the use of high voltage solar arrays leads to power transmission and conversion efficiencies in electric propulsion Power Management and Distribution. Nevertheless, high voltage solar arrays may lead to temporary power disruptions, through the so-called primary electrostatic discharges, and may permanently damage arrays, through the so-called permanent sustained discharges between array strings. Design guidance is needed to prevent these solar array discharges, and to prevent high power drains through coupling between the electric propulsion devices and the high voltage solar arrays. While most electric propulsion systems may operate outside of Low Earth Orbit, the plasmas produced by their thrusters may interact with the high voltage solar arrays in many ways similarly to Low Earth Orbit plasmas. A brief description of previous experiences with high voltage electric propulsion systems will be given in this paper. There are two new official NASA documents available free through the NASA Standards website to help in designing and testing high voltage solar arrays for electric propulsion. They are NASA-STD-4005, the Low Earth Orbit Spacecraft Charging Design Standard, and NASA-HDBK-4006, the Low Earth Orbit Spacecraft Charging Design Handbook. Taken together, they can both educate the high voltage array designer in the engineering and science of spacecraft charging in the presence of dense plasmas and provide techniques for designing and testing high voltage solar arrays to prevent electrical discharges and power drains.
Overview of materials research activities for high voltage electric aircraft propulsion power transmission cables. The overview includes briefing materials research in CNT/Cu composite conductors, micro- multilayered multifunctional electrical insulation (MMEI) and development of high voltage testing capabilities.
In 1998, a new failure mode for space solar arrays was discovered. A flowchart for this failure mode is presented. Since the discovery of this arc failure mode, many tactics have been used to defeat it. The arc thresholds and arc mitigation strategies must be determined in vacuum-plasma tank testing on Earth. Results from these tests must then be extrapolated to the space plasma environment. Thus, the test conditions on Earth must be adequate to reproduce the important aspects of the phenomenon in space. At Glenn Research Center, we have been testing solar arrays for their arc thresholds and sustained arcing thresholds. In this paper, we detail the test conditions for a specific set of tests-those aimed at qualifying the Boeing Solar Tile solar arrays to operate in space at very high voltages (300 V or more).
NASA Lewis Research Center is presently developing a 60 GHz traveling wave tube for satellite cross-link communications. The operating voltage for this new tube is - 20 kV. There is concern about the high voltage insulation system and NASA is planning a space station high voltage experiment that will demonstrate both the 60 GHz communications and high voltage electronics technology. The experiment interfaces, requirements, conceptual design, technology issues and safety issues are determined. A block diagram of the high voltage power supply test facility was generated. It includes the high voltage power supply, the 60 GHz traveling wave tube, the communications package, the antenna package, a high voltage diagnostics package and a command and data processor system. The interfaces with the space station and the attached payload accommodations equipment were determined. A brief description of the different subsystems and a discussion of the technology development needs are presented.
A battery charge regulator based on the series-connected boost regulator (SCBR) technology has been developed for high-voltage spacecraft applications. The SCBR regulates the solar array power during insolation to prevent battery overcharge or undercharge conditions. It can also be used to provide regulated battery output voltage to spacecraft loads if necessary. This technology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. The high-voltage SCBR shown in the photograph has demonstrated power densities of over 1000 watts per kilogram (W/kg). Using four 150-W dc-dc converter modules, it can process 2500 W of power at 120 Vdc with a minimum input voltage of 90 Vdc. Efficiency of the SCBR was 94 to 98 percent over the entire operational range. Internally, the unit is made of two separate SCBR s, each with its own analog control circuitry, to demonstrate the modularity of the technology. The analog controllers regulate the output current and incorporate the output voltage limit with active current sharing between the two units. They also include voltage and current telemetry, on/off control, and baseplate temperature sensors. For peak power tracking, the SCBR was connected to a LabView-based data acquisition system for telemetry and control. A digital control algorithm for tracking the peak power point of a solar array was developed using the principle of matching the source impedance with the load impedance for maximum energy transfer. The algorithm was successfully demonstrated in a simulated spacecraft electrical system at the Boeing PhantomWorks High Voltage Test Facility in Seattle, Washington. The system consists of a 42-string, high-voltage solar array simulator, a 77-cell, 80-ampere-hour (A-hr) nickel-hydrogen battery, and a constant power-load module. The SCBR and the LabView control algorithm successfully tracked the solar array peak power point through various load transients, including sunlight discharge transients when the total load exceeded the maximum solar array output power.
One of NASA'S agency-wide goals is the commercial development of space. To further this goal NASA is implementing a policy whereby U.S. firms are encouraged to utilize NASA facilities to develop and test concepts having commercial potential. Goddard, in keeping with this policy, will make the facilities and capabilities described in this document available to private entities at a reduced cost and on a noninterference basis with internal NASA programs. Some of these facilities include: (1) the Vibration Test Facility; (2) the Battery Test Facility; (3) the Large Area Pulsed Solar Simulator Facility; (4) the High Voltage Testing Facility; (5) the Magnetic Field Component Test Facility; (6) the Spacecraft Magnetic Test Facility; (7) the High Capacity Centrifuge Facility; (8) the Acoustic Test Facility; (9) the Electromagnetic Interference Test Facility; (10) the Space Simulation Test Facility; (11) the Static/Dynamic Balance Facility; (12) the High Speed Centrifuge Facility; (13) the Optical Thin Film Deposition Facility; (14) the Gold Plating Facility; (15) the Paint Formulation and Application Laboratory; (16) the Propulsion Research Laboratory; (17) the Wallops Range Facility; (18) the Optical Instrument Assembly and Test Facility; (19) the Massively Parallel Processor Facility; (20) the X-Ray Diffraction and Scanning Auger Microscopy/Spectroscopy Laboratory; (21) the Parts Analysis Laboratory; (22) the Radiation Test Facility; (23) the Ainsworth Vacuum Balance Facility; (24) the Metallography Laboratory; (25) the Scanning Electron Microscope Laboratory; (26) the Organic Analysis Laboratory; (27) the Outgassing Test Facility; and (28) the Fatigue, Fracture Mechanics and Mechanical Testing Laboratory.
Corona discharges arise due to ionization of air or gas subject to high electric fields. The free electrons and ions contained in these discharges interact with molecules of insulating materials, resulting in chemical changes and destroying the electrical insulating properties. The paper describes some results of measurements aimed at determining corona pulse waveforms, their repetition rate, and amplitude distribution during various randomly-sampled identical time periods of a 60-Hz high-voltage wave. Described are properties of positive and negative corona impulses generated from typical conductors at various test high voltages. A possible method for calculating the energies, densities, and electromagnetic interferences by making use of these results is suggested.
Design and test of high voltage power supply for satellite application
The High Voltage Testing Laboratory at NASA Glenn Research Center is equipped with a pulsed electroacoustic (PEA) analyzer to study space charge phenomena in dielectric materials. Dielectric materials such as those used in high voltage insulation systems are of great interest due to their crucial role in withstanding high voltages and avoiding electrical breakdown in electrified aircraft power systems. Current research is underway for the development of novel lightweight electrical insulation and the thorough evaluation of these materials is required. The PEA instrumentation at NASA GRC is a nondestructive method to evaluate the space charge phenomena which can give a unique insight on the feasibility and lifetime of material systems. The instrumentation capability and initial results are reported here.
Two polymeric coatings have been developed for the Propulsive Small Expendable Deployer System (ProSEDS) mission. ProSEDS is designed to provide an on-orbit demonstration of the electrodynamic propulsion capabilities of tethers in space. The ProSEDS experiment will be a secondary payload on a Delta II unmanned expendable booster scheduled for launch in August 2000. A 5-km conductive tether is attached to the Delta 11 second stage and collects current from the low Earth orbit (LEO) plasma to facilitate de-orbit of the spent stage. The conductive tether is attached to a 10-km non-conductive tether, the other end of which is attached to an endmass containing several scientific instruments. A bare metal tether would have the best conductivity but thermal concerns preclude this design. A conductive polymer developed by Triton Systems has been optimized for conductivity and thermo-optical properties. The current design for the ProSEDS conductive tether is seven strands of 28 AWG aluminum wire individually coated with 8.7 micrometers (0.35 mil) of an atomic oxygen-resistant conductive polymer composed of a mixture of 87% Clear Oxygen-Resistant polymer (COR) and 13% polyanaline (PANi), wrapped around a braided Kevlar (TM) 49 core. Extensive testing has been performed at the Marshall Space Flight Center (MSFC) to qualify this material for flight on ProSEDS. Atomic oxygen exposure was performed, with solar absorptance and infrared emittance measured before and after exposure. Conductivity was measured before and after atomic oxygen exposure. High voltage tests, up to 1500 V, of the current collecting ability of the COR/PANi have been completed. Approximately 160 meters of the conductive tether closest to the Delta 11 second stage is insulated to prevent any electron reconnection to the tether from the plasma contactor. The insulation is composed of polyimide overcoated with TOR-BP, another polymeric coating developed by Triton for this mission. TOR-BP acts as both insulator and a protective coating against atomic oxygen erosion. The insulation has been tested to withstand 5000 V.
The Bureau of Mines, U.S. Department of the Interior, is reviewing explosion protection methods for use in gassy coal mines. This performance criteria guideline is an evaluation of three explosion protection methods of machines electrically powered with voltages up to 15,000 volts ac. A sufficient amount of basic research has been accomplished to verify that the explosion proof and pressurized enclosure methods can provide adequate explosion protection with the present state of the art up to 15,000 volts ac. This routine application of the potted enclosure as a stand alone protection method requires further investigation or development in order to clarify performance criteria and verification certification requirements. An extensive literature search, a series of high voltage tests, and a design evaluation of the three explosion protection methods indicate that the explosion proof, pressurized, and potted enclosures can all be used to enclose up to 15,000 volts ac.
Real concerns of spacecraft charging and experience with solar array augmented electrostatic discharge arcs on spacecraft have minimized the use of high voltages on large solar arrays despite numerous vehicle system mass and efficiency advantages. Boeing's solar tile (patent pending) allows high voltage to be generated at the array without the mass and efficiency losses of electronic conversion. Direct drive electric propulsion and higher power payloads (lower spacecraft weight) will benefit from this design. As future power demand grows, spacecraft designers must use higher voltage to minimize transmission loss and power cable mass for very large area arrays. This paper will describe the design and discuss the successful test of Boeing's 500-Volt Solar Tile in NASA Glenn's Tenney chamber in the Space Plasma Interaction Facility. The work was sponsored by NASA's Space Solar Power Exploratory Research and Technology (SERT) Program and will result in updated high voltage solar array design guidelines being published.