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NASA NTRSDate not supplied

Modeling and Analysis of Stirling Power Convertors

Modeling and Analysis of Stirling Power Convertors Luis A. Rodriguez1 Steven M. Geng, Terry V. Reid, Scott D. Wilson NASA Glenn Research Center, Cleveland, OH, 44135, USA NASA Glenn’s Thermal Energy Conversion Branch is supporting the development of the next generation free-piston Stirling power convertors. American Superconductor (AMSC) and Sunpower Inc. are the two firms under contract to develop the Flexure Isotope Stirling Convertor (FISC) and the Sunpower Robust Stirling Convertor (SRSC), respectively. To comprehend and forecast convertor performance, Sage, ANSYS® Maxwell, and ANSYS® Fluent were used to model the Stirling thermodynamic cycle, alternator electromagnetics, and piston and displacer dynamics. I. Introduction Stirling convertors are being developed by NASA as a potential steady source of electrical power for NASA’s future scientific space missions. Currently, NASA Glenn Research Center has two corporations under contract, American Superconductor (AMSC) and Sunpower Inc., for the development of the next generation of free-piston Stirling convertors for dynamic radioisotope power systems. AMSC is developing the Flexure Isotope Stirling Convertor (FISC), which uses flexures to prevent side motion and rubbing of the piston. Similarly, Sunpower Inc, is developing the Sunpower Robust Stirling Convertor (SRSC). The SRSC uses gas bearings to prevent radial contact of the moving piston. As convertor development continues, it is increasingly important to understand and predict the interactions of components in the system, how they respond to one another, and how they perform as a response to changes in operating conditions. A suitable and enlightening way to demonstrate and foresee these interactions is with the use of accurate modeling software. Sage, ANSYS® Maxwell, and ANSYS® Fluent are the current modeling tools used by NASA to analytically determine convertor performance. Sage is a one-dimensional object-oriented commercial software package used for modeling and optimizing Stirling convertors for Dynamic Radioisotope Power Systems (DRPS) and it is one of the most accurate Stirling convertor codes in use by NASA. This code is the successor to GLIMPS (Globally-Implicit Stirling Cycle Simulation) and GLOP (GLIMPS Optimization) software created by Gedeon Associates [1]. Model input parameters are typically material/gas type, component physical dimensions, temperatures, frequency, charge pressure, and number of time/space nodes. Sage is used to model both the FISC’s and SRSC’s Stirling cycle thermodynamics and piston/displacer dynamics. Performance maps were created and analyzed for both power systems to better understand the relationship between the following conditions: cold-end temperature, hot-end temperature, piston/displacer amplitudes, pressure drop, and thermal input power. The synergy between these conditions will help determine parameter sensitivity. ANSYS® Maxwell was used to create a three-dimensional (3-D) axisymmetric model for both FISC and SRSC alternators. The significant physical components included in each model are the magnets, magnet carrier, outer/inner laminations, and the coil. Inputs to the model are piston amplitude, piston frequency, alternator load, coil resistance, tuning capacitance, and specific material properties. The alternator models calculate terminal voltage, current, piston/current phase, voltage/current phase, coil inductance, terminal power and efficiency. The RI2 losses, core (hysteresis and eddy) losses, and magnet/can eddy losses are also a part of the final results. ANSYS® Fluent is used to build 3-D computational fluid dynamic (CFD) models to examine the Stirling cycle thermodynamics for both the FISC and SRSC systems. Three-dimensional Computer Aided Design (CAD) models were used to create the physical components of each convertor. Steady-state simulations were conducted for hardware testing, prediction of environmental losses during testing, and generation of radiation look-up tables. The model inputs to the aforementioned analysis are the material properties and boundary thermal conditions. The steady-state model calculates temperature and heat flow distributions. Transient 3-D calculations were also part of the CFD analysis. In this study a physically reduced version of the FISC is used to obtain a prediction of available engine power. For the gas bearing SRSC, the transient effort is used to obtain a prediction of bearing pad performance and its sensitivity to micro-channel geometric variation. The model inputs to the transient simulations are the piston amplitude, displacer amplitude, frequency, displacer/piston phase angle, dynamic deforming CFD grid, temperature boundary conditions, and user defined files describing motion profile of piston/displacer. The results of the model are temperature distributions, heat distributions, and PV power produced at pre-determined conditions.

Luis A Rodriguez↗
NASA NTRS2013

Scheduling Operations for Massive Heterogeneous Clusters

High-performance computing (HPC) programming has become increasingly difficult with the advent of hybrid supercomputers consisting of multicore CPUs and accelerator boards such as the GPU. Manual tuning of software to achieve high performance on this type of machine has been performed by programmers. This is needlessly difficult and prone to being invalidated by new hardware, new software, or changes in the underlying code. A system was developed for task-based representation of programs, which when coupled with a scheduler and runtime system, allows for many benefits, including higher performance and utilization of computational resources, easier programming and porting, and adaptations of code during runtime. The system consists of a method of representing computer algorithms as a series of data-dependent tasks. The series forms a graph, which can be scheduled for execution on many nodes of a supercomputer efficiently by a computer algorithm. The schedule is executed by a dispatch component, which is tailored to understand all of the hardware types that may be available within the system. The scheduler is informed by a cluster mapping tool, which generates a topology of available resources and their strengths and communication costs. Software is decoupled from its hardware, which aids in porting to future architectures. A computer algorithm schedules all operations, which for systems of high complexity (i.e., most NASA codes), cannot be performed optimally by a human. The system aids in reducing repetitive code, such as communication code, and aids in the reduction of redundant code across projects. It adds new features to code automatically, such as recovering from a lost node or the ability to modify the code while running. In this project, the innovators at the time of this reporting intend to develop two distinct technologies that build upon each other and both of which serve as building blocks for more efficient HPC usage. First is the scheduling and dynamic execution framework, and the second is scalable linear algebra libraries that are built directly on the former.

Humphrey, John↗
NASA NTRS1973

Study and design of cryogenic propellant acquisition systems. Volume 1: Design studies

An in-depth study and selection of practical propellant surface tension acquisition system designs for two specific future cryogenic space vehicles, an advanced cryogenic space shuttle auxiliary propulsion system and an advanced space propulsion module is reported. A supporting laboratory scale experimental program was also conducted to provide design information critical to concept finalization and selection. Designs using localized pressure isolated surface tension screen devices were selected for each application and preliminary designs were generated. Based on these designs, large scale acquisition prototype hardware was designed and fabricated to be compatible with available NASA-MSFC feed system hardware.

Burge, G. W.↗
NASA NTRS1982

A method for determining the flight readiness of the integrated Space Shuttle system

The Space Shuttle Dynamic Integrated Test (DIT) system is described. The DIT is an open-loop system which makes no attempt to simulate Shuttle sensors, and by which the Shuttle redundancy management system is left unmodified. Open-loop operation is shown to inherently require less computing capacity during a test than the closed-loop alternative. DIT tests have generated a high degree of confidence in the Shuttle hardware, allowing the identification of such problems as a sluggish main fuel valve, which caused a countdown hold seconds before the simulated T-zero, and Main Engine Controller software malfunctions. Attention is given to the combination and substitution of sensor data, the modification of nominal flight software, and the preparation of simulation data. It is noted that greater performance would have been achieved if the interface with DIT had been a design requirement from the outset of Space Shuttle development.

Bacon, I.↗
NASA NTRS1982

The software-implemented fault tolerance /SIFT/ approach to fault tolerant computing

SIFT is an experimental computer designed for highly reliable flight-control service in advanced air transports. Its development was intended to integrate and demonstrate the latest techniques in fault-tolerant computing. During its development, several new problems of some generality were uncovered and solved. The technology developed for the validation of its design is seen as being perhaps as important as the design itself. The SIFT design is described, as is the way in which the design and its validation were shaped by the requirements of its intended application. Attention is also given to reliability and fault tolerance. The most significant feature of the hardware design is the absence of elements that can generate multiple faults, such as shared clocks or data buses. It is noted that the software is realized in only 800 lines of code, of which 80% are in a high-level language.

Goldberg, J.↗
NASA NTRS1983

A system for load isolation and precision pointing

A system capable of satisfying the accuracy and stability requirements dictated by Shuttle-borne payloads utilizing large optics has been under joint NASA/Sperry development. This device, denoted the Annular Suspension and Pointing System, employs a unique combination of conventional gimbals and magnetic bearing actuators, thereby providing for the complete isolation of the payload from its external environment, as well as for extremely accurate and stable pointing (equal to about 0.01 arcsec). This effort has been pursued through the fabrication and laboratory evaluation of engineering model hardware. Results from these tests have been instrumental in generating high fidelity computer simulations of this load isolation and precision pointing system, and in permitting confident predictions of the system's on-orbit performance. The applicability of this system to the Solar Optical Telescope mission has been examined using the computer simulation. The worst case pointing error predicted for this payload while subjected to vernier reaction control system thruster firings and crew motions aboard the Shuttle was approximately 0.006 arcsec.

Keckler, C. R.↗
NASA NTRS1990

Measurement and analysis of workload effects on fault latency in real-time systems

The authors demonstrate the need to address fault latency in highly reliable real-time control computer systems. It is noted that the effectiveness of all known recovery mechanisms is greatly reduced in the presence of multiple latent faults. The presence of multiple latent faults increases the possibility of multiple errors, which could result in coverage failure. The authors present experimental evidence indicating that the duration of fault latency is dependent on workload. A synthetic workload generator is used to vary the workload, and a hardware fault injector is applied to inject transient faults of varying durations. This method makes it possible to derive the distribution of fault latency duration. Experimental results obtained from the fault-tolerant multiprocessor at the NASA Airlab are presented and discussed.

Woodbury, Michael H.↗
NASA NTRS1992

Defining contamination control requirements for non-human research on Space Station Freedom

The use of non-human biological specimens for life sciences research on Space Station Freedom has generated concerns about spacecraft internal contamination, crew safety and hardware utility. Various NASA organizations convened to discuss the concerns and determine how they should be addressed. This paper will present the issues raised at this meeting, the process by which safety concerns were identified, and the means by which contamination control requirements for all biological payloads were recommended for incorporation into Space Station Freedom safety requirements. The microbiological, toxicological and particulate contamination criteria for long-term spaceflight will be based on realistic assessment of risk and hardware will be designed to meet established contamination criteria while facilitating crew operations, thereby meeting the needs of the investigator.

Corbin, Barbara J.↗
NASA NTRS1996

Optical System Design for the Next Generation Space Telescope

This report provides considerations and suggested approaches for design of the Optical Telescope Assembly and the segmented primary mirror of a Next Generation Space Telescope (NGST). Based on prior studies and hardware development, we provide data and design information on low-risk materials and hardware configurations most likely to meet low weight, low temperature and long-life requirements of the nominal 8-meter aperture NGST. We also provide preliminary data for cost and performance trades, and recommendations for technology development and demonstration required to support the system design effort.

Solomon, Leonard H.↗
NASA NTRS2000

Solid-Liquid Interface Characterization Hardware: Advanced Technology Development (ATD)

This ATD has the goal of enabling the integration of three separate measurement techniques to characterize the solid-liquid interface of directionally solidified materials in real-time. Arrays of film-based metal thermocouple elements are under development along with compact Seebeck furnaces suitable for interfacing with separately developed X-ray Transmission Microscopes. Results of applying film arrays to furnace profiling are shown, demonstrating their ability to identify a previously undetected hardware flaw in the development of a second-generation compact furnace. Results of real-time furnace profiling also confirmed that the compact furnace design effectively isolates the temperature profiles in two halves of the furnace, a necessary feature. This isolation had only been inferred previously from the characteristics of Seebeck data reported. Results from a 24-thermocouple array successfully monitoring heating and isothermal cooling of a tin sample are shown. The importance of non-intrusion by the arrays, as well as furnace design, on the profiling of temperature gradients is illustrated with example measurements. Further developments underway for effectively combining all three measurements are assessed in terms of improved x-ray transmission, increased magnification, integral arrays with minimum intrusion, integral scales for velocity measurements and other features being incorporated into the third generation Seebeck furnace under construction.

Peters, Palmer N.↗
NASA NTRS2009

Oxygen Generation System Laptop Bus Controller Flight Software

The Oxygen Generation System Laptop Bus Controller Flight Software was developed to allow the International Space Station (ISS) program to activate specific components of the Oxygen Generation System (OGS) to perform a checkout of key hardware operation in a microgravity environment, as well as to perform preventative maintenance operations of system valves during a long period of what would otherwise be hardware dormancy. The software provides direct connectivity to the OGS Firmware Controller with pre-programmed tasks operated by on-orbit astronauts to exercise OGS valves and motors. The software is used to manipulate the pump, separator, and valves to alleviate the concerns of hardware problems due to long-term inactivity and to allow for operational verification of microgravity-sensitive components early enough so that, if problems are found, they can be addressed before the hardware is required for operation on-orbit. The decision was made to use existing on-orbit IBM ThinkPad A31p laptops and MIL-STD-1553B interface cards as the hardware configuration. The software at the time of this reporting was developed and tested for use under the Windows 2000 Professional operating system to ensure compatibility with the existing on-orbit computer systems.

Rowe, Chad↗
NASA NTRS2005

Joint Test Protocol for Validation of Alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel

Headquarters National Aeronautics and Space Administration (NASA) chartered the Acquisition Pollution Prevention (AP2) Office to coordinate agency activities affecting pollution prevention issues identified during system and component acquisition and sustainment processes. The primary objectives of the AP2 Office are to: (1) Reduce or eliminate the use of hazardous materials (HazMats) or hazardous processes at manufacturing, remanufacturing, and sustainment locations. (2) A void duplication of effort in actions required to reduce or eliminate HazMats through joint center cooperation and technology sharing. This project will identify, evaluate and approve alternative surface preparation technologies for use at NASA and Air Force Space Command (AFSPC) installations. Materials and processes will be evaluated with the goal of selecting those processes that will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination and reduce the amount of hazardous waste generated. This Joint Test Protocol (JTP) contains the critical requirements and tests necessary to qualify alternative Low-Emission Surface Preparation/Depainting Technologies for Structural Steel Applications. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of NASA and Air Force Space Command (AFSPC) participants. The Field Test Plan (FTP), entitled Joint Test Protocol for Validation of Alternative Low Emission Surface Preparation/Depainting Technologies for Structural Steel, prepared by ITB, defines the field evaluation and testing requirements for validating alternative surface preparation/depainting technologies and supplements the JTP.

Lewis, Pattie↗
NASA NTRS2011

Gas Dynamic Spray Technology Demonstration Project Management

The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are sUbject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by Air Force Space Command (AFSPC) and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GOS) technology (also known as Cold Spray) was evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GOS coatings also have no VOCs and are environmentally preferable coatings. The primary objective of this effort was to demonstrate GDS technology as a repair method for TSCs. The aim was that successful completion of this project would result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations to improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗
NASA NTRS2008

Joint Test Plan for Gas Dynamic Spray Technology Demonstration

Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Lewis, Pattie↗
NASA NTRS2015

Design and Stability of an On-Orbit Attitude Control System Using Reaction Control Thrusters

Principles for the design and stability of a spacecraft on-orbit attitude control system employing on-off Reaction Control System (RCS) thrusters is presented. Both the vehicle dynamics and the control system actuators are inherently nonlinear, hence traditional linear control system design approaches are not directly applicable. This paper has three main aspects: It summarizes key RCS control System design principles from the Space Shuttle and Space Station programs, it demonstrates a new approach to develop a linear model of a phase plane control system using describing functions, and applies each of these to the initial development of the NASA's next generation of upper stage vehicles. Topics addressed include thruster hardware specifications, phase plane design and stability, jet selection approaches, filter design metrics, and automaneuver logic.

Hall, Robert A.↗
NASA NTRS2017

Microbial Characteristics of ISS Environmental Surfaces

The microbiome of environmental surfaces from the International Space Station were characterized in order to examine the relationship to crew and hardware maintenance. The Microbial Observatory (ISS-MO) experiment generated a microbial census of ISS environments using advanced molecular microbial community analyses along with traditional culture-based methods. Since the “omics” methodologies generated an extensive microbial census, significant insights into spaceflight-induced changes in the populations of beneficial and/or potentially harmful microbes were gained. Surface samples were collected from several ISS surface locations from three flight opportunities, and were returned to Earth via the Soyuz TMA-14M or the Space X Dragon capsule. In addition to cultivation methods, viable microbial burden, iTag-based sequencing, and metagenome analyses were carried out. The cultivable microbial bioburden differed by location and sampling event. Exploring the ISS environmental microbiome revealed presence of opportunistic pathogens and antibiotic resistant microbes. Genes involved in ATP binding cassette transporters, two component systems, and beta-lactam resistance were among a diverse set of metabolic and genetic information processing pathways. Whole genome sequencing (WGS) of 50 ISS strains exhibiting resistance to various antibiotics was carried out. The antibiotic resistant genes deduced from the WGS were compared with the resistomes generated directly from the gene pool of the environmental samples. Two unique Aspergillus fumigatus strains isolated from the ISS were characterized and compared to the experimentally established clinical isolates Af293 and CEA10. A virulence assessment in a neutrophil-deficient larval zebrafish model of invasive aspergillosis indicated that both ISSFT-021 and IF1SW-F4 were significantly more lethal compared to Af293 and CEA10. The findings from this Environmental “Omics” project should be exploited to enhance human health and well-being of a closed system. In other words, the ISS-MO research aims to "translate" findings in fundamental research into medical practice (pathogen detection) and meaningful health outcomes (countermeasure development).

Perry, Jay↗
NASA NTRS2005

Lessons Learned From Developing Three Generations of Remote Sensing Science Data Processing Systems

The Biospheric Information Systems Branch at NASA s Goddard Space Flight Center has developed three generations of Science Investigator-led Processing Systems for use with various remote sensing instruments. The first system is used for data from the MODIS instruments flown on NASA s Earth Observing Systems @OS) Terra and Aqua Spacecraft launched in 1999 and 2002 respectively. The second generation is for the Ozone Measuring Instrument flying on the EOS Aura spacecraft launched in 2004. We are now developing a third generation of the system for evaluation science data processing for the Ozone Mapping and Profiler Suite (OMPS) to be flown by the NPOESS Preparatory Project (NPP) in 2006. The initial system was based on large scale proprietary hardware, operating and database systems. The current OMI system and the OMPS system being developed are based on commodity hardware, the LINUX Operating System and on PostgreSQL, an Open Source RDBMS. The new system distributes its data archive across multiple server hosts and processes jobs on multiple processor boxes. We have created several instances of this system, including one for operational processing, one for testing and reprocessing and one for applications development and scientific analysis. Prior to receiving the first data from OMI we applied the system to reprocessing information from the Solar Backscatter Ultraviolet (SBUV) and Total Ozone Mapping Spectrometer (TOMS) instruments flown from 1978 until now. The system was able to process 25 years (108,000 orbits) of data and produce 800,000 files (400 GiB) of level 2 and level 3 products in less than a week. We will describe the lessons we have learned and tradeoffs between system design, hardware, operating systems, operational staffing, user support and operational procedures. During each generational phase, the system has become more generic and reusable. While the system is not currently shrink wrapped we believe it is to the point where it could be readily adopted, with substantial cost savings, for other similar tasks.

Tilmes, Curt↗
NASA NTRS2009

Testing and Functions of the J2X Gas Generator

The Ares I, NASA s new solid rocket based crew launch vehicle, is a two stage in line rocket that has made its waytothe forefront of NASA s endeavors. The Ares I s Upper Stage (US) will be propelled by a J-2X engine which is fueled by liquid hydrogen and liquid oxygen. The J-2X is a variation based on two of its predecessor s, the J-2 and J-2S engines. ET50 is providing the design support for hardware required to run tests on the J-2X Gas Generator (GG) that increases the delivery pressure of the supplied combustion fuels that the engine burns. The test area will be running a series of tests using different lengths and curved segments of pipe and different sized nozzles to determine the configuration that best satisfies the thrust, heat, and stability requirements for the engine. I have had to research the configurations that are being tested and gain an understanding of the purpose of the tests. I then had to research the parts that would be used in the test configurations. I was taken to see parts similar to the ones used in the test configurations and was allowed to review drawings and dimensions used for those parts. My job over this summer has been to use the knowledge I have gained to design, model, and create drawings for the un-fabricated parts that are necessary for the J-2X Workhorse Gas Generator Phase IIcTest.

Miller, Nicholas↗