Engineering topics

Hamley, John A.

Publications and source records attributed to Hamley, John A..

At least 37 records · Page 2

NASA NTRS1994

Development of a Power Electronics Unit for the Space Station Plasma Contactor

A hollow cathode plasma contactor has been baselined as a charge control device for the Space Station (SS) to prevent deleterious interactions of coated structural components with the ambient plasma. NASA LeRC Work Package 4 initiated the development of a plasma contactor system comprised of a Power Electronics Unit (PEU), an Expellant Management Unit (EMU), a command and data interface, and a Plasma Contactor Unit (PCU). A breadboard PEU was designed and fabricated. The breadboard PEU contains a cathode heater and discharge power supply, which were required to operate the PCU, a control and auxiliary power converter, an EMU interface, a command and telemetry interface, and a controller. The cathode heater and discharge supplies utilized a push-pull topology with a switching frequency of 20 kHz and pulse-width-modulated (PWM) control. A pulse ignition circuit derived from that used in arcjet power processors was incorporated in the discharge supply for discharge ignition. An 8088 based microcontroller was utilized in the breadboard model to provide a flexible platform for controller development with a simple command/data interface incorporating a direct connection to SS Mulitplexer/Demultiplexer (MDM) analog and digital I/O cards. Incorporating this in the flight model would eliminate the hardware and software overhead associated with a 1553 serial interface. The PEU autonomously operated the plasma contactor based on command inputs and was successfully integrated with a prototype plasma contactor unit demonstrating reliable ignition of the discharge and steady-state operation.

Hamley, John A.↗

NASA NTRS1994

Performance evaluation of the Russian SPT-100 thruster at NASA LeRC

Performance measurements of a Russian flight-model SPT-100 thruster were obtained as part of a comprehensive program to evaluate engineering issues pertinent to integration with Western spacecraft. Power processing was provided by a US Government developed laboratory power conditioner. When received the thruster had been subjected to only a few hours of acceptance testing by the manufacturer. Accumulated operating time during this study totalled 148 h and included operation of both cathodes. Cathode flow fraction was controlled both manually and using the flow splitter contained within the supplied xenon flow controller. Data were obtained at current levels ranging from 3 A to 5 A and thruster voltages ranging from 200 V to 300 V. Testing centered on the design power of 1.35 kW with a discharge current of 4.5 A. The effects of facility pressure on thruster operation were examined by varying the pressure via injection of xenon into the vacuum chamber. The facility pressure had a significant effect on thruster performance and stability at the conditions tested. Periods of current instabilities were noted throughout the testing period and became more frequent as testing progressed. Performance during periods of stability agreed with previous data obtained in Russian laboratories.

Sankovic, John M.↗

NASA NTRS1993

Plasma contactor development for Space Station

Plasma contactors have been baselined for the Space Station (SS) to control the electrical potentials of surfaces to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and, in particular, the technology development effort on ion thrustor systems. The plasma contactor subsystems include the plasma contactor unit, a power electronics unit, and an expellant management unit. Under this pre-flight development program these will all be brought to breadboard or engineering model status. Development efforts for the plasma contactor include optimizing the design and configuration of the contactor, validating its required lifetime, and characterizing the contactor plume and electromagnetic interference. The plasma contactor unit design selected for the SS is an enclosed keeper, xenon hollow cathode plasma source. This paper discusses the test results and development status of the plasma contactor unit subsystem for the SS.

Patterson, Michael J.↗

NASA NTRS1993

Plasma contactor technology for Space Station Freedom

Hollow cathode plasma contactors have been baselined for Space Station Freedom to control the electrical potentials of surfaces to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and in particular the technology development effort on ion thruster systems. Specific efforts include optimizing the design and configuration of the contactor, validating its required lifetime, and characterizing the contactor plume and electromagnetic interference. The plasma contactor subsystems include the plasma contactor unit, a power electronics unit, and an expellant management unit. Under this program these will all be brought to breadboard and engineering model development status. New test facilities have been developed, and existing facilities have been augmented, to support characterizations and life testing of contactor components and systems. This paper discusses the magnitude, scope, and status of the plasma contactor hardware development program now under way and preliminary test results on system components.

Patterson, Michael J.↗

NASA NTRS1993

A soft-start circuit for arcjet ignition

The reduced propellant flow rates associated with high performance arcjets have placed new emphasis on electrode erosion, especially at startup. A soft-start current profile was defined which limited current overshoot during the initial 30 to 50 ms of operation, and maintained significantly lower than the nominal arc current for the first eight seconds of operation. A 2-5 kW arcjet PPU was modified to provide this current profile, and a 500 cycle test using simulated fully decomposed hydrazine was conducted to determine the electrode erosion during startup. Electrode geometry and mass flow rates were selected based on requirements for a 600 sec specific impulse (mission average) arcjet system. The flow rate was varied throughout the test to simulate the blow down of a flight propellant system. Electrode damage was negligible at flow rates above 33 mg/s, and minor chamfering of the constrictor occurred at flow rates of 33 to 30 mg/s, corresponding to flow rates expected in the last 40 percent of the mission. The soft-start current profile significantly reduced electrode damage when compared to state-of-the-art starting techniques.

Hamley, John A.↗

NASA NTRS1993

A Soft-Start Circuit for Arcjet Ignition

The reduced propellant flow rates associated with high performance arcjets have placed new emphasis on electrode erosion, especially at startup. A soft-start current profile was defined which limited current overshoot during the initial 30 to 50 ms of operation, and maintained significantly lower than the nominal arc current for the first eight seconds of operation. A 2-5 kW arcjet PPU was modified to provide this current profile, and a 500 cycle test using simulated fully decomposed hydrazine was conducted to determine the electrode erosion during startup. Electrode geometry and mass flow rates were selected based on requirements for a 600 second specific impulse mission average arcjet system. The flow rate was varied throughout the test to simulate the blow down of a flight propellant system. Electrode damage was negligible at flow rates above 33 mg/s, and minor chamfering of the constrictor occurred at flow rates of 33 to 30 mg/s, corresponding to flow rates expected in the last 40 percent of the mission. Constrictor diameter remained unchanged and the thruster remained operable at the completion of the test. The soft-start current profile significantly reduced electrode damage when compared to state of the art starting techniques.

Hamley, John A.↗

NASA NTRS1993

Plasma contactor technology for Space Station Freedom

Hollow cathode plasma contactors were baselined for Space Station Freedom (SSF) to control the electrical potentials of surfaces to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and in particular the technology development effort on ion thruster systems. Specific efforts include optimizing the design and configuration of the contactor, validating its required lifetime, and characterizing the contactor plume and electromagnetic interference. The plasma contact or subsystems include the plasma contact or unit, a power electronics unit, and an expellant management unit. Under this program these will all be brought to breadboard and engineering model development status. New test facilities were developed, and existing facilities were augmented, to support characterizations and life testing of contactor components and systems. The magnitude, scope, and status of the plasma contactor hardware development program now underway and preliminary test results on system components are discussed.

Patterson, Michael J.↗

NASA NTRS1992

Ion Thruster Development at NASA Lewis Research Center

Recent ion propulsion technology efforts at NASA's Lewis Research Center including development of kW-class xenon ion thrusters, high power xenon and krypton ion thrusters, and power processors are reviewed. Thruster physical characteristics, performance data, life projections, and power processor component technology are summarized. The ion propulsion technology program is structured to address a broad set of mission applications from satellite stationkeeping and repositioning to primary propulsion using solar or nuclear power systems.

Sovey, James S.↗

NASA NTRS1992

Dependence of hydrogen arcjet operation on electrode geometry

The dependence of 2 kW hydrogen arcjet performance on cathode to anode electrode spacing was evaluated at specific impulses of 900 and 1000 s. Less than 2 absolute percent change in efficiency was measured for the spacings tested which did not repeat the 14 absolute percent variation reported in earlier work with similar electrode designs. A different nozzle configuration was used to quantify the variation in hydrogen arcjet performance over an extended range of electrode spacing. Electrode gap variation resulted in less than 3 absolute percent change in efficiency. These null results suggested that electrode spacing is decoupled from hydrogen arcjet performance considerations over the ranges tested. Initial studies were conducted on hydrogen arcjet ignition. The dependence of breakdown voltage on mass flow rate and hydrogen arcjet ignition on rates of pulse repetition and pulse voltage rise were also included for comparison with previous results obtained using simulated hydrazine.

Pencil, Eric J.↗

NASA NTRS1992

Dependence of hydrogen arcjet operation on electrode geometry

The dependence of 2kW hydrogen arcjet performance on cathode to anode electrode spacing was evaluated at specific impulses of 900 and 1000 s. Less than 2 absolute percent change in efficiency was measured for the spacings tested which did not repeat the 14 absolute percent variation reported in earlier work with similar electrode designs. A different nozzle configuration was used to quantify the variation in hydrogen arcjet performance over an extended range of electrode spacing. Electrode gap variation resulted in less than 3 absolute percent change in efficiency. These null results suggested that electrode spacing is decoupled from hydrogen arcjet ignition. The dependence of breakdown voltage on mass flow rate and electrode agreed with Paschen curves for hydrogen. Preliminary characterization of the dependence of hydrogen arcjet ignition on rates of pulse repetition and pulse voltage rise were also included for comparison with previous results obtained using simulated hydrazine.

Pencil, Eric J.↗

NASA NTRS1992

The evolutionary development of high specific impulse electric thruster technology

Electric propulsion flight and technology demonstrations conducted in the USA, Europe, Japan, China, and USSR are reviewed with reference to the major flight qualified electric propulsion systems. These include resistojets, ion thrusters, ablative pulsed plasma thrusters, stationary plasma thrusters, pulsed magnetoplasmic thrusters, and arcjets. Evolutionary mission applications are presented for high specific impulse electric thruster systems. The current status of arcjet, ion, and magnetoplasmadynamic thrusters and their associated power processor technologies are summarized.

Sovey, James S.↗

NASA NTRS1992

The evolutionary development of high specific impulse electric thruster technology

Electric propulsion flight and technology demonstrations conducted primarily by Europe, Japan, China, the U.S., and the USSR are reviewed. Evolutionary mission applications for high specific impulse electric thruster systems are discussed, and the status of arcjet, ion, and magnetoplasmadynamic thrusters and associated power processor technologies are summarized.

Sovey, James S.↗

NASA NTRS1992

The 10 kW power electronics for hydrogen arcjets

A combination of emerging mission considerations such as 'launch on schedule', resource limitations, and the development of higher power spacecraft busses has resulted in renewed interest in high power hydrogen arcjet systems with specific impulses greater than 1000 s for Earth-space orbit transfer and maneuver applications. Solar electric propulsion systems with about 10 kW of power appear to offer payload benefits at acceptable trip times. This work outlines the design and development of 10 kW hydrogen arcjet power electronics and results of arcjet integration testing. The power electronics incorporated a full bridge switching topology similar to that employed in state of the art 5 kW power electronics, and the output filter included an output current averaging inductor with an integral pulse generation winding for arcjet ignition. Phase shifted, pulse width modulation with current mode control was used to regulate the current delivered to arcjet, and a low inductance power stage minimized switching transients. Hybrid power Metal Oxide Semiconductor Field Effect Transistors were used to minimize conduction losses. Switching losses were minimized using a fast response, optically isolated, totem-pole gate drive circuit. The input bus voltage for the unit was 150 V, with a maximum output voltage of 225 V. The switching frequency of 20 kHz was a compromise between mass savings and higher efficiency. Power conversion efficiencies in excess of 0.94 were demonstrated, along with steady state load current regulation of 1 percent. The power electronics were successfully integrated with a 10 kW laboratory hydrogen arcjet, and reliable, nondestructive starts and transitions to steady state operation were demonstrated. The estimated specific mass for a flight packaged unit was 2 kg/kW.

Hamley, John A.↗

NASA NTRS1991

Power electronics for low power arcjets

In anticipation of the needs of future light-weight low-power spacecraft, arcjet power electronics in the 100- to 400-W operating range were developed. Power topologies similar to those in the higher 2-kW and 5- to 30-kW power range were implemented, including a four-transistor bridge-switching circuit, current-mode pulse-width modulated control, and an output current averaging inductor with an integral pulse generation winding. Reduction of switching transients was accomplished using a low inductance power distribution network, and no passive snubber circuits were necessary for power switch protection. Phase shift control of the power bridge was accomplished using an improved pulse width modulation to phase shift converter circuit. These features, along with conservative magnetics designs, allowed power conversion efficiencies of greater than 92.5 percent to be achieved into resistive loads over the entire operating range of the converter.

Hamley, John A.↗

NASA NTRS1991

Power electronics for low power arcjets

In anticipation of the needs of future light-weight, low-power spacecraft, arcjet power electronics in the 100 to 400 W operating range were developed. Limited spacecraft power and thermal control capacity of these small spacecraft emphasized the need for high efficiency. Power topologies similar to those in the higher 2 kW and 5 to 30 kW power range were implemented, including a four transistor bridge switching circuit, current mode pulse-width modulated control, and an output current averaging inductor with an integral pulse generation winding. Reduction of switching transients was accomplished using a low inductance power distribution network, and no passive snubber circuits were necessary for power switch protection. Phase shift control of the power bridge was accomplished using an improved pulse width modulation to phase shift converter circuit. These features, along with conservative magnetics designs allowed power conversion efficiencies of greater than 92.5 percent to be achieved into resistive loads over the entire operating range of the converter. Electromagnetic compatibility requirements were not considered in this work, and control power for the converter was derived from AC mains. Addition of input filters and control power converters would result in an efficiency of on the order of 90 percent for a flight unit. Due to the developmental nature of arcjet systems at this power level, the exact nature of the thruster/power processor interface was not quantified. Output regulation and current ripple requirements of 1 and 20 percent respectively, as well as starting techniques, were derived from the characteristics of the 2 kW system but an open circuit voltage in excess of 175 V was specified. Arcjet integration tests were performed, resulting in successful starts and stable arcjet operation at power levels as low as 240 W with simulated hydrazine propellants.

Hamley, John A.↗

NASA NTRS1991

Hydrogen arcjet technology

During the 1960's, a substantial research effort was centered on the development of arcjets for space propulsion applications. The majority of the work was at the 30 kW power level with some work at 1-2 kW. At the end of the research effort, the hydrogen arcjet had demonstrated over 700 hours of life in a continuous endurance test at 30 kW, at a specific impulse over 1000 s, and at an efficiency of 0.41. Another high power design demonstrated 500 h life with an efficiency of over 0.50 at the same specific impulse and power levels. At lower power levels, a life of 150 hours was demonstrated at 2 kW with an efficiency of 0.31 and a specific impulse of 935 s. Lack of a space power source hindered arcjet acceptance and research ceased. Over three decades after the first research began, renewed interest exists for hydrogen arcjets. The new approach includes concurrent development of the power processing technology with the arcjet thruster. Performance data were recently obtained over a power range of 0.3-30 kW. The 2 kW performance has been repeated; however, the present high power performance is lower than that obtained in the 1960's at 30 kW, and lifetimes of present thrusters have not yet been demonstrated. Laboratory power processing units have been developed and operated with hydrogen arcjets for the 0.1 kW to 5 kW power range. A 10 kW power processing unit is under development and has been operated at design power into a resistive load.

Sankovic, John M.↗

NASA NTRS1990

Arcjet load characteristics

Experiments were conducted to define the interface characteristics and constraints of 1 kW class arcjets run on simulated decomposition products of hydrazine and power processors. The impacts of power supply output current ripple on arcjet performance were assessed by variation of the ripple frequency from 100 Hz to 100 kHz with 10 percent peak-to-peak ripple amplitude at 1.2 kW. Ripple had no significant effects on thrust, specific impulse or efficiency. The impact of output ripple on thruster lifetime was not assessed. The static and dynamic impedances of the arcjet were quantitied with two thrusters of nearly identical configuration. Superposition of an AC component on the DC arc current was used to characterize the dynamic impedance as a function of flow rate and DC current level. A mathematical model was formulated from these data. Both the static and dynamic impedance magnitude were found to be dependent on mass flow rate. The amplitude of the AC component was found to have little effect on the dynamic impedance. Reducing the DC level from 10 to 8 amps led to a large change in the magnitude of the dynamic impedance with no observable phase change. The impedance data compared favorably between the two thrusters.

Hamley, John A.↗

NASA NTRS1990

Arcjet load characteristics

Experiments were conducted to define the interface characteristics and constraints of 1 kW class arcjets run on simulated decomposition products of hydrazine and power processors. The impacts of power supply output current ripple on arcjet performance were assessed by variation of the ripple frequency from 100 Hz to 100 kHz with 10 percent peak-to-peak ripple amplitude at 1.2 kW. Ripple had no significant effects on thrust, specific impulse or efficiency. The impact of output ripple on thruster lifetime was not assessed. The static and dynamic impedances of the arcjet were quantified with two thrusters of nearly identical configuration. Superposition of an AC component on the DC arc current was used to characterize the dynamic impedance as a function of flow rate and DC current level. A mathematical model was formulated from these data. Both the static and dynamic impedance magnitude were found to be dependent on mass flow rate. The amplitude of the AC component was found to have little effect on the dynamic impedance. Reducing the DC level from 10 to 8 amps led to a large change in the magnitude of the dynamic impedance with no observable phase change. The impedance data compared favorably between the two thrusters.

Hamley, John A.↗