Power converter module and assembly
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Materials technology for Stirling space power converters
This program was conducted in support of the NASA LeRC development of the Stirling power converter (SPC) for space power applications. The objectives of this contract were: (1) to perform a technology review and analyses to support the evaluation of materials issues for the SPC; (2) to evaluate liquid metal compatibility issues of the SPC; (3) to evaluate and define a transient liquid phase diffusion bonding (TLPDB) process for the SPC joints to the Udimet 720 heater head; and (4) to evaluate alternative (to the TLPDB) joining techniques. In the technology review, several aspects of the current Stirling design were examined including the power converter assembly process, materials joining, gas bearings, and heat exchangers. The supporting analyses included GLIMPS power converter simulation in support of the materials studies, and system level analysis in support of the technology review. The liquid metal compatibility study evaluated process parameters for use in the Stirling power converter. The alternative joining techniques study looked at the applicability of various joining techniques to the Stirling power converter requirements.
Baggenstoss, William↗
Assessment of Selected CERES Electronic Component Survivability under Simulated Overvoltage Conditions
In August, 1998 a Clouds and the Earth's Radiant Energy System (CERES) instrument telemetry housekeeping parameter generated a yellow warning message that indicated an on-board + 15V Data Acquisition Assembly (DAA) power converter deregulation anomaly. An exhaustive investigation was undertaken to understand this anomaly and the long-term consequences which have severely reduced CERES operations on the Tropical Rainfall Measuring Mission (TRMM) spacecraft. Among investigations performed were ground tests that approximated the on-board electronic circuitry using a small quantity of flight identical components exposed to maximum spacecraft bus over-voltage conditions. These components include monolithic integrated microcircuits that perform analog signal conditioning on instrument sensor signals and an analog- to-digital converter (ADC) for the entire DAA. All microcircuit packages have either a bipolar silicon design with internal current limiting protections or have a complementary metal oxide semiconductor (CMOS) design with bias protections. Ground tests that have been running for approximately 8 months have indicated that these components are capable of withstanding as much as twice their input supply voltage ratings without noticeable performance degradation. These data provide CERES operators with confidence of being able to continue science operations over the remaining life of the TRMM mission. This paper will discuss this anomaly and some possible causes, a simulator of affected electronics, test results, prognosis for future CERES operations, and conclusions.
Chapman, John J.↗
CTS-type variable conductance heat pipes for SEP FM/PPU
The development effort for, and the fabrication and testing of, six CTS-type variable conductance heat pipes is described. The heat pipes are constructed of stainless steel, use methanol as a working fluid, and a nitrogen/helium mixture as the control gas. The wicking structure consists of interior wall grooves, a metal-felt diametral slab wick, and two wire-mesh arteries. The heat pipes are used to cool two Functional Model/Power Processing Units in a Solar Electric Propulsion prototype BIMOD thruster subsystem assembly. The Power Processing Units convert the electric power from a spacecraft solar array system to the voltages required to operate the electric thrusters which are part of the BIMOD assembly.
Antoniuk, D.↗
Modifications to CTVS TV cameras for space shuttle compatibility and evaluation
Five all solid state cockpit television system (CTVS) cameras, built to USAF requirements for high performance type F-16 aircraft, were modified and tested for possible use in the closed circuit television system on the space shuttle orbiter. The 400 HZ power supply in the electronics unit assembly was replaced with two DC/DC converters to enable operation from 28VDC spacecraft-type power sources. Nonessential circuit functions were deleted to minimize input power requirements. The normal 31 mm focal length lense assemblies were replaced with wider field-of-view 19 mm focal length lenses. Base plates for and housings were redesigned to facilitate mounting and heat-sinking of the camera in the space environment and short length (14") adapter cables were designed, fabricated, and tested to meet requirements for cameras configured to mount on the astronauts helmet/visor assembly. Technical requirements, design implementation, environmental tests, Modifications prodedures, and reliability/quality efforts are discussed. Schematics are included.
Hoagland, K.↗
Lunar base thermoelectric power station study
Under NASA's Project Prometheus, the Nuclear Systems Program, the Jet Propulsion Laboratory, Pratt & Whitney Rocketdyne, and Teledyne Energy Systems have teamed with a number of universities, under the Segmented Thermoelectric Multicouple Converter (STMC) program, to develop the next generation of advanced thermoelectric converters for space reactor power systems. Work on the STMC converter assembly has progressed to the point where the lower temperature stage of the segmented multicouple converter assembly is ready for laboratory testing and the upper stage materials have been identified and their properties are being characterized. One aspect of the program involves mission application studies to help define the potential benefits from the use of these STMC technologies for designated NASA missions such as the lunar base power station where kilowatts of power are required to maintain a permanent manned presence on the surface of the moon. A modular 50 kWe thermoelectric power station concept was developed to address a specific set of requirements developed for this mission. Previous lunar lander concepts had proposed the use of lunar regolith as in-situ radiation shielding material for a reactor power station with a one kilometer exclusion zone radius to minimize astronaut radiation dose rate levels. In the present concept, we will examine the benefits and requirements for a hermetically-sealed reactor thermoelectric power station module suspended within a man-made lunar surface cavity. The concept appears to maximize the shielding capabilities of the lunar regolith while minimizing its handling requirements. Both thermal and nuclear radiation levels from operation of the station, at its 100-m exclusion zone radius, were evaluated and found to be acceptable. Site preparation activities are reviewed and well as transport issues for this concept. The goal of the study was to review the entire life cycle of the unit to assess its technical problems and technology needs in all areas to support the development, deployment, operation and disposal of the unit.
space power↗
Advanced Electric Distribution, Switching, and Conversion Technology for Power Control
The Electrical Power Control Unit currently under development by Sundstrand Aerospace for use on the Fluids Combustion Facility of the International Space Station is the precursor of modular power distribution and conversion concepts for future spacecraft and aircraft applications. This unit combines modular current-limiting flexible remote power controllers and paralleled power converters into one package. Each unit includes three 1-kW, current-limiting power converter modules designed for a variable-ratio load sharing capability. The flexible remote power controllers can be used in parallel to match load requirements and can be programmed for an initial ON or OFF state on powerup. The unit contains an integral cold plate. The modularity and hybridization of the Electrical Power Control Unit sets the course for future spacecraft electrical power systems, both large and small. In such systems, the basic hybridized converter and flexible remote power controller building blocks could be configured to match power distribution and conversion capabilities to load requirements. In addition, the flexible remote power controllers could be configured in assemblies to feed multiple individual loads and could be used in parallel to meet the specific current requirements of each of those loads. Ultimately, the Electrical Power Control Unit design concept could evolve to a common switch module hybrid, or family of hybrids, for both converter and switchgear applications. By assembling hybrids of a common current rating and voltage class in parallel, researchers could readily adapt these units for multiple applications. The Electrical Power Control Unit concept has the potential to be scaled to larger and smaller ratings for both small and large spacecraft and for aircraft where high-power density, remote power controllers or power converters are required and a common replacement part is desired for multiples of a base current rating.
Soltis, James V.↗
Space Station Freedom secondary power wiring requirements
Secondary power is produced by DDCU's (direct current to direct current converter units) and routed to and through secondary power distribution assemblies (SPDA's) to loads or tertiary distribution assemblies. This presentation outlines requirements of Space Station Freedom (SSF) EEE (electrical, electronic, and electromechanical) parts wire and the approved electrical wire and cable. The SSF PDRD (Program Definition and Requirements Document) language problems and resolution are reviewed. The cable routing to and from the SPDA's is presented as diagrams and the wire recommendations and characteristics are given.
Sawyer, C. R.↗
Battery Reinitialization of the Photovoltaic Module of the International Space Station
The photovoltaic (PV) module on the International Space Station (ISS) has been operating since November 2000 and supporting electric power demands of the ISS and its crew of three. The PV module contains photovoltaic arrays that convert solar energy to electrical power and an integrated equipment assembly (IEA) that houses electrical hardware and batteries for electric power regulation and storage. Each PV module contains two independent power channels for fault tolerance. Each power channel contains three batteries in parallel to meet its performance requirements and for fault tolerance. Each battery consists of 76 Ni-Hydrogen (Ni-H2) cells in series. These 76 cells are contained in two orbital replaceable units (ORU) that are connected in series. On-orbit data are monitored and trended to ensure that all hardware is operating normally. Review of on-orbit data showed that while five batteries are operating very well, one is showing signs of mismatched ORUs. The cell pressure in the two ORUs differs by an amount that exceeds the recommended range. The reason for this abnormal behavior may be that the two ORUs have different use history. An assessment was performed and it was determined that capacity of this battery would be limited by the lower pressure ORU. Steps are being taken to reduce this pressure differential before battery capacity drops to the point of affecting its ability to meet performance requirements. As a first step, a battery reinitialization procedure was developed to reduce this pressure differential. The procedure was successfully carried out on-orbit and the pressure differential was reduced to the recommended range. This paper describes the battery performance and the consequences of mismatched ORUs that make a battery. The paper also describes the reinitialization procedure, how it was performed on orbit, and battery performance after the reinitialization. On-orbit data monitoring and trending is an ongoing activity and it will continue as ISS assembly progresses.
Hajela, Gyan↗
Microwave power transmission system studies. Volume 4: Sections 9 through 14 with appendices
The microwave rectifier technology, approaches to the receiving antenna, topology of rectenna circuits, assembly and construction, ROM cost estimates are discussed. Analyses and cost estimates for the equipment required to transmit the ground power to an external user. Noise and harmonic considerations are presented for both the amplitron and klystron and interference limits are identified and evaluated. The risk assessment discussion is discussed wherein technology risks are rated and ranked with regard to their importance in impacting the microwave power transmission system. The system analyses and evaluation are included of parametric studies of system relationships pertaining to geometry, materials, specific cost, specific weight, efficiency, converter packing, frequency selection, power distribution, power density, power output magnitude, power source, transportation and assembly. Capital costs per kW and energy costs as a function of rate of return, power source and transportation costs as well as build cycle time are presented. The critical technology and ground test program are discussed along with ROM costs and schedule. The orbital test program with associated critical technology and ground based program based on full implementation of the defined objectives is discussed.
Maynard, O. E.↗
Space processing applications payload equipment study. Volume 2D: SPA supplemental power and heat rejection kit
The design and application of a supplementary power and heat rejection kit for the Spacelab are discussed. Two subsystems of electric power and thermal control were analyzed to define the requirements for the power and heat rejection kit (PHRK). Twelve exemplary experiments were defined and power timelines were developed. From these timeline, the experiment requirements for sustained power, peak power, and energy were determined. The electrical power subsystem of the PHRK will consist of two fuel cells, oxygen and hydrogen reactant tank assemblies, water storage tanks, plumbing, cabling, and inverters to convert the nominal 28 volt dc fuel cell output to ac power.
Hammel, R. L.↗
Reconditioning of Batteries on the International Space Station
Primary source of electric power for the International Space Station (ISS) is the photovoltaic module (PVM). At assembly complete stage, the ISS will be served by 4 PVMs. Each PVM contains two independent power channels such that one failure will result in loss of only one power channel. During early stages of assembly, the ISS is served by only one PVM designated as P6. Solar arrays are used to convert solar flux into electrical power. Nickel hydrogen batteries are used to store electrical power for use during periods when the solar input is not adequate to support channel loads. Batteries are operated per established procedures that ensure that they are maintained within specified temperature limits, charge current is controlled to conform to a specified charge profile, and battery voltages are maintained within specified limits. Both power channels on the PVM P6 have been operating flawlessly since December 2000 with 100 percent power availability. All components, including batteries, are monitored regularly to ensure that they are operating within specified limits and to trend their wear out and age effects. The paper briefly describes the battery trend data. Batteries have started to show some effects of aging and a battery reconditioning procedure is being evaluated at this time. Reconditioning is expected to reduce cell voltage divergence and provide data that can be used to update the state of charge (SOC) computation in the software to account for battery age. During reconditioning, each battery, one at a time, will be discharged per a specified procedure and then returned to a full state of charge. The paper describes the reconditioning procedure and the expected benefits. The reconditioning procedures have been thoroughly coordinated by all affected technical teams and approved by all required boards. The reconditioning is tentatively scheduled for September 2004.
Hajela, Gyan↗
Load converter interactions with the secondary system in the Space Station Freedom power management and distribution DC test bed
The NASA LeRC in Cleveland, Ohio, is responsible for the design, development, and assembly of the Space Station Freedom (SSF) Electrical Power System (EPS). In order to identify and understand system level issues during the SSF Program design and development phases, a system Power Management and Distribution (PMAD) DC test bed was assembled. Some of the objectives of this test bed facility are the evaluation of, system efficiency, power quality, system stability, and system protection and reconfiguration schemes. In order to provide a realistic operating scenario, dc Load Converter Units are used in the PMAD dc test bed to characterize the user interface with the power system. These units are dc to dc converters that provide the final system regulation before power is delivered to the load. This final regulation is required on the actual space station because the majority of user loads will require voltage levels different from the secondary bus voltage. This paper describes the testing of load converters in an end to end system environment (from solar array to loads) where their interactions and compatibility with other system components are considered. Some of the system effects of interest that are presented include load converters transient behavior interactions with protective current limiting switchgear, load converters ripple effects, and the effects of load converter constant power behavior with protective features such as foldback.
Lebron, Ramon C.↗
Load converter interactions with the secondary system in the Space Station Freedom power management and distribution dc test bed
The NASA LeRC in Cleveland, Ohio, is responsible for the design, development, and assembly of the Space Station Freedom (SSF) Electrical Power System (EPS). In order to identify and understand system level issues during the SSF program design and development phases, a system Power Management and Distribution (PMAD) dc test bed was assembled. Some of the objectives of this test bed facility are the evaluation of, system efficiency, power quality, system stability, and system protection and reconfiguration schemes. In order to provide a realistic operating scenario, dc Load Converter Units are used in the PMAD dc test bed to characterize the user interface with the power system. These units are dc to dc converters that provide the final system regulation before power is delivered to the load. This final regulation is required on the actual space station because the majority of user loads will require voltage levels different from the secondary bus voltage. This paper describes the testing of load converters in an end to end system environment (from solar array to loads) where their interactions and compatibility with other system components are considered. Some of the system effects of interest that are presented include load converters transient behavior interactions with protective current limiting switchgear, load converters ripple effects, and the effects of load converter constant power behavior with protective features such as foldback.
Lebron, Ramon C.↗
Preliminary design study of an alternate heat source assembly for a Brayton isotope power system
Results are presented for a study of the preliminary design of an alternate heat source assembly (HSA) intended for use in the Brayton isotope power system (BIPS). The BIPS converts thermal energy emitted by a radioactive heat source into electrical energy by means of a closed Brayton cycle. A heat source heat exchanger configuration was selected and optimized. The design consists of a 10 turn helically wound Hastelloy X tube. Thermal analyses were performed for various operating conditions to ensure that post impact containment shell (PICS) temperatures remain within specified limits. These limits are essentially satisfied for all modes of operation except for the emergency cooling system for which the PICS temperatures are too high. Neon was found to be the best choice for a fill gas for auxiliary cooling system operation. Low cycle fatigue life, natural frequency, and dynamic loading requirements can be met with minor modifications to the existing HSA.
Strumpf, H. J.↗
Portable Fan Assembly for the International Space Station
NASA/ Marshall Space Flight Center (NASA/MSFC) is responsible for the design and fabrication of a Portable Fan Assembly (PFA) for the International Space Station (ISS). The PFA will be used to enhance ventilation inside the ISS modules as needed for crew comfort and for rack rotation. The PFA consists of the fan on-orbit replaceable unit (ORU) and two noise suppression packages (silencers). The fan ORU will have a mechanical interface with the Seat Track Equipment Anchor Assembly, in addition to the power supply module which includes a DC-DC converter, on/standby switch, speed control, power cable and connector. This paper provides a brief development history, including the criteria used for the fan, and a detailed description of the PFA operational configurations. Space Station requirements as well as fan performance characteristics are also discussed.
Jenkins, Arthur A.↗
Comparison of advanced engines for parabolic dish solar thermal power plants
A paraboloidal dish solar thermal power plant produces electrical energy by a two-step conversion process. The collector subsystem is composed of a two-axis tracking paraboloidal concentrator and a cavity receiver. The concentrator focuses intercepted sunlight (direct, normal insolation) into a cavity receiver whose aperture encircles the focal point of the concentrator. At the internal wall of the receiver the electromagnetic radiation is converted to thermal energy. A heat engine/generator assembly then converts the thermal energy captured by the receiver to electricity. Developmental activity has been concentrated on small power modules which employ 11- to 12-meter diameter dishes to generate nominal power levels of approximately 20 kWe. A comparison of advanced heat engines for the dish power module is presented in terms of the performance potential of each engine with its requirements for advanced technology development. Three advanced engine possibilities are the Brayton (gas turbine), Brayton/Rankine combined cycle, and Stirling engines.
Fujita, T.↗
Description of the PMAD DC test bed architecture and integration sequence
NASA-LEWIS is responsible for the development, fabrication, and assembly of the electric power system (EPS) for the Space Station Freedom (SSF). The SSF power system is radically different from previous spacecraft power systems in both the size and complexity of the system. Unlike past spacecraft power systems, the SSF EPS will grow and be maintained on orbit and must be flexible to meet challenging user power needs. The SSF power system is also unique in comparison with terrestrial power systems because it is dominated by power electronic converters which regulate and control the power. A description is provided of the Power Management and Distribution DC Testbed which was assembled to support the design and early evaluation of the SSF EPS. A description of the integration process used in the assembly sequence is also given along with a description of the support facility.
Beach, R. F.↗