SEARCH · Search NASA
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Spacecraft electric power transformation and control techniques enhancement, using DC to DC converter, voltage converter/regulator and solar array reorientation system
High temperature cobalt iron alloy for square loop and power transformer applications
Spacecraft historically have had sub-1kW(sub e), electrical requirements for GN&C, science, and communications: Galileo at 600W(sub e), and Cassini at 900W(sub e), for example. Because most missions have had the same order of magnitude power requirements, the Power Distribution Systems (PDS) use existing, space-qualified technology and are DC. As science payload and mission duration requirements increase, however, the required electrical power increases. Subsequently, this requires a change from a passive energy conversion (solar arrays and batteries) to dynamic (alternator, solar dynamic, etc.), because dynamic conversion has higher thermal and conversion efficiencies, has higher power densities, and scales more readily to higher power levels. Furthermore, increased power requirements and physical distribution lengths are best served with high-voltage, multi-phase AC to maintain distribution efficiency and minimize voltage drops. The generated AC-voltage must be stepped-up (or down) to interface with various subsystems or electrical hardware. Part of the trade-space design for AC distribution systems is volume and mass estimation of high-power transformers. The volume and mass are functions of the power rating, operating frequency, the ambient and allowable temperature rise, the types and amount of heat transfer available, the core material and shape, the required flux density in a core, the maximum current density, etc. McLyman has tabulated the performance of a number of transformers cores and derived a "cookbook" methodology to determine the volume of transformers, whereas Schawrze had derived an empirical method to estimate the mass of single-phase transformers. Based on the work of McLyman and Schwarze, it is the intent herein to derive an empirical solution to the volume and mass estimation of three-phase, laminated EI-core power transformers, having radiated and conducted heat transfer mechanisms available. Estimation of the mounting hardware, connectors, etc. is not included.
The principle features and special testing of a high voltage high power transformer designed and developed for space application are described. The transformer is operated in a series resonant inverter supplying beam power to a 30 cm mercury ion thruster. Electrical requirements include operation of 2.3 kW continuous power output, primary currents to 35 amps rms, and frequencies up to 20 kHz. High efficiency was obtained through detailed considerations of the tradeoffs available in core materials, wire selection, coil configurations and thermal control. A number of novel heat removal techniques are discussed which control the winding temperature using only the available conductive cooling.
The paper describes the principal features and special testing of a high-frequency high-power low-specific-weight (0.57 kg/kW) 2.3-kW electronic power transformer developed for space applications. The transformer is operated in a series resonant inverter supplying beam power to a 30-cm mercury ion thruster. High efficiency (above 98.5%) is obtained through careful detailed design. A number of unique heat removal techniques are discussed which control the winding temperature using only the available conductive cooling.
Noise lower than with sliprings. Rotary transformer transfers electric power across rotary joint. No wearing contacts, no contact noise, and no contamination from lubricants or wear debris. Because additional inductor not required, size and complexity of circuit reduced considerably.
Many future satellites and spacecraft with spun and despun configurations will require the transfer of power across rotating interfaces in lieu of slip-rings and/or flexures. This is particularly true of spacecraft that have to demonstrate a long life expectancy. The rotary transformer has the desirable characteristics of high reliability and low noise, which qualify it as a potential replacement for slip rings. Development of a rotary power transformer follows the successful completion of a task to develop rotary signal-level transformers for the Galileo Spacecraft Project. The physical configuration of a rotary power transformer has a significant effect on its magnetic and electrical characteristics and therefore impacts the design of the dc/ac inverter driver. Important characteristics addressed during this development effort include: operating frequency, efficiency, transformer gap size, leakage inductance, and leakage flux. A breadboard inverter and rotary transformer were designed, fabricated and tested.
Technology for design and fabrication of radically new type of conductioncooled high-power (25 kVA) lightweight transformer having outstanding thermal and electrical characteristics. Fulfills longstanding need for conduction-cooled transformers and magnetics with low internal thermal resistances. Development techniques limited to conductive heat transfer, since other techniques such as liquid cooling, forced liquid cooling, and evaporative cooling of transformers impractical in zero-gravity space environment. Transformer uniquely designed: mechanical structure also serves as thermal paths for conduction cooling of magnetic core and windings.
The electrical and mechanical design information and the electrical and thermal testing performed on the 440-208-V rms, 20-kHz, 25-kVa prototype node transformer are summarized. The calculated efficiency of the node transformer is 99.3 percent based on core loss and copper loss test data, and its maximum calculated load regulation is 0.7 percent. The node transformer has a weight of 19.7 lb and has a power density of 0.8 lb/kW. The hot-spot temperature rise is estimated to be 33 C above the cold plate mounting base. This proof-of-concept transformer design is a viable candidate for the space station Freedom application.
Both open and encapsulated varieties of high reliability, low weight, and high efficiency moderate and high voltage transformers were investigated to determine the advantages and limitations of their construction in the ranges of power and voltage required for operation in the hard vacuum environment of space. Topics covered include: (1) selection of the core material; (2) preliminary calculation of core dimensions; (3) selection of insulating materials including magnet wire insulation, coil forms, and layer and interwinding insulation; (4) coil design; (5) calculation of copper losses, core losses and efficiency; (6) calculation of temperature rise; and (7) optimization of design with changes in core selection or coil design as required to meet specifications.
Compilation of information on design procedures, electrical properties, and fabrication. Guide provides information on design procedures; magnetic and insulating material electrical properties; impregnating, encapsulating and processing techniques.
Transformer core made of thin layers of insulating material interspersed with thin layers of ferromagnetic material. Flux-linking conductors made of thinner nonferromagnetic-conductor/insulator multilayers wrapped around core. Transformers have geometric features finer than those of transformers made in customary way by machining and mechanical pressing. In addition, some thin-film materials exhibit magnetic-flux-carrying capabilities superior to those of customary bulk transformer materials. Suitable for low-cost, high-yield mass production.
This paper examines various sources of error in MIT's improved top oil temperature rise over ambient temperature model and estimation process. The sources of error are the current parameter estimation technique, quantization noise, and post-processing of the transformer data. Results from this paper will show that an output error parameter estimation technique should be selected to replace the current least squares estimation technique. The output error technique obtained accurate predictions of transformer behavior, revealed the best error covariance, obtained consistent parameter estimates, and provided for valid and sensible parameters. This paper will also show that the output error technique should be used to minimize errors attributed to post-processing (decimation) of the transformer data. Models used in this paper are validated using data from a large transformer in service.
Rotary transformer originally developed for spacecraft transfers electrical power from stationary primary winding to rotating secondary without sliding contacts and very little leakage of electromagnetic radiation. Transformer has two stationary primary windings connected in parallel. Secondary, mounted on a shaft that extends out of housing, rotates between two windings of primary. Shaft of secondary is composed of electrically conducting inner and outer parts separated by an insulator. Electrical contact is made from secondary winding, through shaft, to external leads.
A design study was made on a rotary transformer for transferring electrical power across a rotating spacecraft interface. The analysis was performed for a 100 KW, 20 KHz unit having a ""pancake'' geometry. The rotary transformer had a radial (vertical) gap and consisted of 4-25 KW modules. It was assumed that the power conditioning comprised of a Schwarz resonant circuit with a 20 KHz switching frequency. The rotary transformer, mechanical and structural design, heat rejection system and drive mechanism which provide a complete power transfer device were examined. The rotary transformer losses, efficiency, weight and size were compared with an axial (axial symmetric) gap transformer having the same performance requirements and input characteristics which was designed as part of a previous program. The ""pancake'' geometry results in a heavier rotary transformer primarily because of inefficient use of the core material. It is shown that the radial gap rotary transformer is a feasible approach for the transfer of electrical power across a rotating interface and can be implemented using presently available technology.
A power supply for a quadrupole mass spectrometer which operates using an RF signal. The RF signal is controllable via a feedback loop. The feedback loop is from the output, through a comparator, and compared to a digital signal. An air core transformer is used to minimize the weight. The air core transformer is driven via two out of phase sawtooth signals which drive opposite ends of the transformer.
Improvements in individual piezoelectric transformer (PT) performance and the combination of these PTs in a unique modular topology under a Phase I contract with the NASA Glenn Research Center have enabled for the first time the simultaneous achievement of both high voltage and high power at much higher levels than previously obtained with any PT. Feasibility was demonstrated by a prototype transformer (called a Tap-Soner), which is shown in the preceding photograph as part of a direct-current to direct-current (dc-dc) converter having two outputs rated at 1.5 kV/5 W and 4.5 kV/20 W. The power density of 3.5 W/cm3 is significantly lower than for magnetic transformers with the same voltage and power output. This development, which is being done under a Small Business Innovation Research (SBIR) contract by Face Electronics, LC (Norfolk, VA), is based on improvements in the materials and design of Face's basic patented Transoner-T3 PT, shown in the left in the following figure. The T3 PT is most simply described as a resonant multilayer transducer where electrical energy at the input section is efficiently mechanically coupled to the output section, which then vibrates in a fundamental longitudinal mode to generate a high gain in voltage. The piezoelectric material used is a modified lead-zirconium-titanate-based ceramic. One of the significant improvements in PT design was the incorporation of a symmetrical double input layer, shown on the right in the following figure, which eliminated the lossy bending vibration modes characteristic of a single input layer. The performance of the improved PT was optimized to 1.5 kV/5 W. The next step was devising a way to combine the individual PTs in a modular circuit topology needed to achieve the desired high voltage and power output. Since the optimum performance of the individual PT occurs at resonance, the most efficient operation of the modular transformer was achieved by using a separate drive circuit for each PT. The output section consists of a separate output rectifier for each PT connected in series.
Simple fixed-inductance/fixed-capacitance tank circuit modified for fine adjustment of resonant frequency by addition of small inductance with potentiometer across it. Additional winding built into full winding as integral part or added externally. Technique provides quick way of tuning reactance out of power-transformer circuit to maximize power transfer or to adjust frequency of oscillator. Applications include rotary transformers, servo amplifiers, and analog computer modules.