Engineering topics

Tew, Roy C.

Publications and source records attributed to Tew, Roy C..

At least 19 records

NASA NTRS2008

Microfabrication of a Segmented-Involute-Foil Regenerator, Testing in a Sunpower Stirling Convertor and Supporting Modeling and Analysis

Under Phase II of a NASA Research Award contract, a prototype nickel segmented-involute-foil regenerator was microfabricated via LiGA and tested in the NASA/Sunpower oscillating-flow test rig. The resulting figure-of-merit was about twice that of the approx.90% porosity random-fiber material currently used in the small 50-100 W Stirling engines recently manufactured for NASA. That work was reported at the 2007 International Energy Conversion Engineering Conference in St. Louis, was also published as a NASA report, NASA/TM-2007-2149731, and has been more completely described in a recent NASA Contractor Report, NASA/CR-2007-2150062. Under a scaled-back version of the original Phase III plan, a new nickel segmentedinvolute- foil regenerator was microfabricated and has been tested in a Sunpower Frequency-Test-Bed (FTB) Stirling convertor. Testing in the FTB convertor produced about the same efficiency as testing with the original random-fiber regenerator. But the high thermal conductivity of the prototype nickel regenerator was responsible for a significant performance degradation. An efficiency improvement (by a 1.04 factor, according to computer predictions) could have been achieved if the regenerator been made from a low-conductivity material. Also the FTB convertor was not reoptimized to take full advantage of the microfabricated regenerator's low flow resistance; thus the efficiency would likely have been even higher had the FTB been completely reoptimized. This report discusses the regenerator microfabrication process, testing of the regenerator in the Stirling FTB convertor, and the supporting analysis. Results of the pre-test computational fluid dynamics (CFD) modeling of the effects of the regenerator-test-configuration diffusers (located at each end of the regenerator) is included. The report also includes recommendations for accomplishing further development of involute-foil regenerators from a higher-temperature material than nickel.

Ibrahim, Mounir B.↗

NASA NTRS2007

Fast Whole-Engine Stirling Analysis

An experimentally validated approach is described for fast axisymmetric Stirling engine simulations. These simulations include the entire displacer interior and demonstrate it is possible to model a complete engine cycle in less than an hour. The focus of this effort was to demonstrate it is possible to produce useful Stirling engine performance results in a time-frame short enough to impact design decisions. The combination of utilizing the latest 64-bit Opteron computer processors, fiber-optical Myrinet communications, dynamic meshing, and across zone partitioning has enabled solution times at least 240 times faster than previous attempts at simulating the axisymmetric Stirling engine. A comparison of the multidimensional results, calibrated one-dimensional results, and known experimental results is shown. This preliminary comparison demonstrates that axisymmetric simulations can be very accurate, but more work remains to improve the simulations through such means as modifying the thermal equilibrium regenerator models, adding fluid-structure interactions, including radiation effects, and incorporating mechanodynamics.

Dyson, Rodger W.↗

NASA NTRS2007

Stirling Analysis Comparison of Commercial vs. High-Order Methods

Recently, three-dimensional Stirling engine simulations have been accomplished utilizing commercial Computational Fluid Dynamics software. The validations reported can be somewhat inconclusive due to the lack of precise time accurate experimental results from engines, export control/ proprietary concerns, and the lack of variation in the methods utilized. The last issue may be addressed by solving the same flow problem with alternate methods. In this work, a comprehensive examination of the methods utilized in the commercial codes is compared with more recently developed high-order methods. Specifically, Lele's Compact scheme and Dyson s Ultra Hi-Fi method will be compared with the SIMPLE and PISO methods currently employed in CFD-ACE, FLUENT, CFX, and STAR-CD (all commercial codes which can in theory solve a three-dimensional Stirling model although sliding interfaces and their moving grids limit the effective time accuracy). We will initially look at one-dimensional flows since the current standard practice is to design and optimize Stirling engines with empirically corrected friction and heat transfer coefficients in an overall one-dimensional model. This comparison provides an idea of the range in which commercial CFD software for modeling Stirling engines may be expected to provide accurate results. In addition, this work provides a framework for improving current one-dimensional analysis codes.

Dyson, Rodger W.↗

NASA NTRS2006

Status of NASA's Advanced Radioisotope Power Conversion Technology Research and Development

NASA s Advanced Radioisotope Power Systems (RPS) development program is funding the advancement of next generation power conversion technologies that will enable future missions that have requirements that can not be met by either the ubiquitous photovoltaic systems or by current Radioisotope Power Systems (RPS). Requirements of advanced radioisotope power systems include high efficiency and high specific power (watts/kilogram) in order to meet mission requirements with less radioisotope fuel and lower mass. Other Advanced RPS development goals include long-life, reliability, and scalability so that these systems can meet requirements for a variety of future space applications including continual operation surface missions, outer-planetary missions, and solar probe. This paper provides an update on the Radioisotope Power Conversion Technology Project which awarded ten Phase I contracts for research and development of a variety of power conversion technologies consisting of Brayton, Stirling, thermoelectrics, and thermophotovoltaics. Three of the contracts continue during the current Phase II in the areas of thermoelectric and Stirling power conversion. The accomplishments to date of the contractors, project plans, and status will be summarized.

Wong, Wayne A.↗

NASA NTRS2006

An Initial Non-Equilibrium Porous-Media Model for CFD Simulation of Stirling Regenerators

The objective of this paper is to define empirical parameters for an initial thermal non-equilibrium porous-media model for use in Computational Fluid Dynamics (CFD) codes for simulation of Stirling regenerators. The two codes currently used at Glenn Research Center for Stirling modeling are Fluent and CFD-ACE. The codes porous-media models are equilibrium models, which assume solid matrix and fluid are in thermal equilibrium. This is believed to be a poor assumption for Stirling regenerators; Stirling 1-D regenerator models, used in Stirling design, use non-equilibrium regenerator models and suggest regenerator matrix and gas average temperatures can differ by several degrees at a given axial location and time during the cycle. Experimentally based information was used to define: hydrodynamic dispersion, permeability, inertial coefficient, fluid effective thermal conductivity, and fluid-solid heat transfer coefficient. Solid effective thermal conductivity was also estimated. Determination of model parameters was based on planned use in a CFD model of Infinia's Stirling Technology Demonstration Converter (TDC), which uses a random-fiber regenerator matrix. Emphasis is on use of available data to define empirical parameters needed in a thermal non-equilibrium porous media model for Stirling regenerator simulation. Such a model has not yet been implemented by the authors or their associates.

Tew, Roy C.↗

NASA NTRS2006

Experimental and Computational Analysis of Unidirectional Flow Through Stirling Engine Heater Head

A high efficiency Stirling Radioisotope Generator (SRG) is being developed for possible use in long-duration space science missions. NASA s advanced technology goals for next generation Stirling convertors include increasing the Carnot efficiency and percent of Carnot efficiency. To help achieve these goals, a multi-dimensional Computational Fluid Dynamics (CFD) code is being developed to numerically model unsteady fluid flow and heat transfer phenomena of the oscillating working gas inside Stirling convertors. In the absence of transient pressure drop data for the zero mean oscillating multi-dimensional flows present in the Technology Demonstration Convertors on test at NASA Glenn Research Center, unidirectional flow pressure drop test data is used to compare against 2D and 3D computational solutions. This study focuses on tracking pressure drop and mass flow rate data for unidirectional flow though a Stirling heater head using a commercial CFD code (CFD-ACE). The commercial CFD code uses a porous-media model which is dependent on permeability and the inertial coefficient present in the linear and nonlinear terms of the Darcy-Forchheimer equation. Permeability and inertial coefficient were calculated from unidirectional flow test data. CFD simulations of the unidirectional flow test were validated using the porous-media model input parameters which increased simulation accuracy by 14 percent on average.

Wilson, Scott D.↗

NASA NTRS2006

Fast Whole-Engine Stirling Analysis

This presentation discusses the simulation approach to whole-engine for physical consistency, REV regenerator modeling, grid layering for smoothness, and quality, conjugate heat transfer method adjustment, high-speed low cost parallel cluster, and debugging.

Dyson, Rodger W.↗

NASA NTRS2006

Stirling Analysis Comparison of Commercial VS. High-Order Methods

The conclusions are: Low Reynold s number, wall bounded flow allows economical use of large eddy simulation for turbulent transition modeling. UHF and Compact comparable at conjugate heat transfer. UHF much better for turbulence modeling Modern methods much more efficient than those currently available commercially.

Dyson, Rodger W.↗

NASA NTRS2005

Fast Whole-Engine Stirling Analysis

Dyson, Rodger W.↗

NASA NTRS2005

On the Need for Multidimensional Stirling Simulations

Given the cost and complication of simulating Stirling convertors, do we really need multidimensional modeling when one-dimensional capabilities exist? This paper provides a comprehensive description of when and why multidimensional simulation is needed.

Dyson, Rodger W.↗

NASA NTRS2005

Stirling Analysis Comparison of Commercial Versus High-Order Methods

Recently, three-dimensional Stirling engine simulations have been accomplished utilizing commercial Computational Fluid Dynamics software. The validations reported can be somewhat inconclusive due to the lack of precise time accurate experimental results from engines, export control/proprietary concerns, and the lack of variation in the methods utilized. The last issue may be addressed by solving the same flow problem with alternate methods. In this work, a comprehensive examination of the methods utilized in the commercial codes is compared with more recently developed high-order methods. Specifically, Lele's compact scheme and Dyson's Ultra Hi-Fi method will be compared with the SIMPLE and PISO methods currently employed in CFD-ACE, FLUENT, CFX, and STAR-CD (all commercial codes which can in theory solve a three-dimensional Stirling model with sliding interfaces and their moving grids limit the effective time accuracy). We will initially look at one-dimensional flows since the current standard practice is to design and optimize Stirling engines with empirically corrected friction and heat transfer coefficients in an overall one-dimensional model. This comparison provides an idea of the range in which commercial CFD software for modeling Stirling engines may be expected to provide accurate results. In addition, this work provides a framework for improving current one-dimensional analysis codes.

Dyson, Rodger W.↗

NASA NTRS2005

Overview 2004 of NASA Stirling-Convertor CFD-Model Development and Regenerator R&D Efforts

This paper reports on accomplishments in 2004 in development of Stirling-convertor CFD model at NASA GRC and via a NASA grant, a Stirling regenerator-research effort being conducted via a NASA grant (a follow-on effort to an earlier DOE contract), and a regenerator-microfabrication contract for development of a "next-generation Stirling regenerator." Cleveland State University is the lead organization for all three grant/contractual efforts, with the University of Minnesota and Gedeor Associates as subcontractors. Also, the Stirling Technology Co. and Sunpower, Inc. are both involved in all three efforts, either as funded or unfunded participants. International Mezzo Technologies of Baton Rouge, LA is the regenerator fabricator for the regenerator-microfabrication contract. Results of the efforts in these three areas are summarized.

Tew, Roy C.↗

NASA NTRS2004

Overview 2004 of NASA-Stirling Convertor CFD Model Development and Regenerator R and D Efforts

This paper reports on accomplishments in 2004 in (1) development of Stirling-convertor CFD models at NASA Glenn and via a NASA grant, (2) a Stirling regenerator-research effort being conducted via a NASA grant (a follow-on effort to an earlier DOE contract), and (3) a regenerator-microfabrication contract for development of a "next-generation Stirling regenerator." Cleveland State University is the lead organization for all three grant/contractual efforts, with the University of Minnesota and Gedeon Associates as subcontractors. Also, the Stirling Technology Company and Sunpower, Inc. are both involved in all three efforts, either as funded or unfunded participants. International Mezzo Technologies of Baton Rouge, Louisiana is the regenerator fabricator for the regenerator-microfabrication contract. Results of the efforts in these three areas are summarized.

Tew, Roy C.↗

NASA NTRS2004

Review of Computational Stirling Analysis Methods

Nuclear thermal to electric power conversion carries the promise of longer duration missions and higher scientific data transmission rates back to Earth for both Mars rovers and deep space missions. A free-piston Stirling convertor is a candidate technology that is considered an efficient and reliable power conversion device for such purposes. While already very efficient, it is believed that better Stirling engines can be developed if the losses inherent its current designs could be better understood. However, they are difficult to instrument and so efforts are underway to simulate a complete Stirling engine numerically. This has only recently been attempted and a review of the methods leading up to and including such computational analysis is presented. And finally it is proposed that the quality and depth of Stirling loss understanding may be improved by utilizing the higher fidelity and efficiency of recently developed numerical methods. One such method, the Ultra HI-Fl technique is presented in detail.

Dyson, Rodger W.↗

NASA NTRS2004

Multi-d CFD Modeling of a Free-piston Stirling Convertor at NASA Glenn

A high efficiency Stirling Radioisotope Generator (SRG) is being developed for possible use in long duration space science missions. NASA s advanced technology goals for next generation Stirling convertors include increasing the Carnot efficiency and percent of Carnot efficiency. To help achieve these goals, a multidimensional Computational Fluid Dynamics (CFD) code is being developed to numerically model unsteady fluid flow and heat transfer phenomena of the oscillating working gas inside Stirling convertors. Simulations of the Stirling convertors for the SRG will help characterize the thermodynamic losses resulting from fluid flow and heat transfer between the working gas and solid walls. The current CFD simulation represents approximated 2-dimensional convertor geometry. The simulation solves the Navier Stokes equations for an ideal helium gas oscillating at low speeds. The current simulation results are discussed.

Wilson, Scott D.↗

NASA NTRS2004

NASA Multidimensional Stirling Convertor Code Developed

A high-efficiency Stirling Radioisotope Generator (SRG) for use on potential NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company, and the NASA Glenn Research Center. These missions may include providing spacecraft onboard electric power for deep space missions or power for unmanned Mars rovers. Glenn is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall power system. Performance and mass improvement goals have been established for second- and third-generation Stirling radioisotope power systems. Multiple efforts are underway to achieve these goals, both in house at Glenn and under various grants and contracts. These efforts include the development of a multidimensional Stirling computational fluid dynamics code, high-temperature materials, advanced controllers, an end-to-end system dynamics model, low-vibration techniques, advanced regenerators, and a lightweight convertor. Under a NASA grant, Cleveland State University (CSU) and its subcontractors, the University of Minnesota (UMN) and Gedeon Associates, have developed a twodimensional computer simulation of a CSUmod Stirling convertor. The CFD-ACE commercial software developed by CFD Research Corp. of Huntsville, Alabama, is being used. The CSUmod is a scaled version of the Stirling Technology Demonstrator Convertor (TDC), which was designed and fabricated by the Stirling Technology Company and is being tested by NASA. The schematic illustrates the structure of this model. Modeled are the fluid-flow and heat-transfer phenomena that occur in the expansion space, the heater, the regenerator, the cooler, the compression space, the surrounding walls, and the moving piston and displacer. In addition, the overall heat transfer, the indicated power, and the efficiency can be calculated. The CSUmod model is being converted to a two-dimensional model of the TDC at NASA Glenn. Validation of the multidimensional Stirling code is an important part of the grant effort. UMN has been generating data in an oscillating-flow test facility using two different test sections: a 90 turn and a cooler/regenerator/heater test section. CSU has created computational fluid dynamics models of both these test sections and has been making comparisons with the data, then improving their models to improve the agreement with the test data. CSU has also been using data available in the literature for code validation. UMN is now preparing to begin fabrication of a new 180 turn test section that will be more representative of certain portions of the Stirling engine geometry. Simulations to almost periodic steady state with the two-dimensional CSUmod model indicate that, to reach periodic steady state on a single 2-GHz desktop computer, 75 to 100 complete simulation cycles would be required and between 1 and 2 months of computer time. Therefore, Glenn has purchased the first 8 computers, of a 64-computer cluster, to be run in parallel to accelerate the simulation. On the basis of CFD Research Corp.'s experience with running the parallelized version of CFD-ACE on their clusters, we estimate that the complete 64-computer cluster will reduce simulation computing time by a factor of about 40. Plans are to continue development of these multidimensional Stirling codes and to use them to study the fluid-flow and heat-transfer phenomena that occur inside Stirling convertors. This is expected to lead to improved thermodynamic loss understanding, onedimensional design and performance codes, and engine performance.

Tew, Roy C.↗

NASA NTRS2004

How to Overcome Numerical Challenges to Modeling Stirling Engines

Nuclear thermal to electric power conversion carries the promise of longer duration missions and higher scientific data transmission rates back to Earth for a range of missions, including both Mars rovers and deep space missions. A free-piston Stirling convertor is a candidate technology that is considered an efficient and reliable power conversion device for such purposes. While already very efficient, it is believed that better Stirling engines can be developed if the losses inherent in current designs could be better understood. However, they are difficult to instrument and so efforts are underway to simulate a complete Stirling engine numerically. This has only recently been attempted and a review of the methods leading up to and including such computational analysis is presented. And finally it is proposed that the quality and depth of Stirling loss understanding may be improved by utilizing the higher fidelity and efficiency of recently developed numerical methods. One such method, the Ultra HI-FI technique is presented in detail.

Dyson, Rodger W.↗

NASA NTRS2002

Overview of NASA Multi-dimensional Stirling Convertor Code Development and Validation Effort

A NASA grant has been awarded to Cleveland State University (CSU) to develop a multi-dimensional (multi-D) Stirling computer code with the goals of improving loss predictions and identifying component areas for improvements. The University of Minnesota (UMN) and Gedeon Associates are teamed with CSU. Development of test rigs at UMN and CSU and validation of the code against test data are part of the effort. The one-dimensional (1-D) Stirling codes used for design and performance prediction do not rigorously model regions of the working space where abrupt changes in flow area occur (such as manifolds and other transitions between components). Certain hardware experiences have demonstrated large performance gains by varying manifolds and heat exchanger designs to improve flow distributions in the heat exchangers. 1-D codes were not able to predict these performance gains. An accurate multi-D code should improve understanding of the effects of area changes along the main flow axis, sensitivity of performance to slight changes in internal geometry, and, in general, the understanding of various internal thermodynamic losses. The commercial CFD-ACE code has been chosen for development of the multi-D code. This 2-D/3-D code has highly developed pre- and post-processors, and moving boundary capability. Preliminary attempts at validation of CFD-ACE models of MIT gas spring and "two space" test rigs were encouraging. Also, CSU's simulations of the UMN oscillating-flow fig compare well with flow visualization results from UMN. A complementary Department of Energy (DOE) Regenerator Research effort is aiding in development of regenerator matrix models that will be used in the multi-D Stirling code. This paper reports on the progress and challenges of this

Tew, Roy C.↗