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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.
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An electric quarter ton truck designed for use as a postal delivery vehicle was tested to characterize the state of the art of electric vehicles. Vehicle performance test results are presented. It is powered by a single-module, 54 volt industrial battery through a silicon controlled rectifier continuously adjustable controller with regenerative braking applied to a direct current compound wound motor.
Vehicle maximum speed, range at constant speed, range over stop-and-go driving schedules, maximum acceleration, gradeability, gradeability limit, road energy consumption, road power, indicated energy consumption, braking capability, battery charger efficiency, and battery characteristics were determined for a modified utility van powered by sixteen 6-volt batteries connected in series. A chopper controller actuated by a foot accelerator pedal changes the voltage applied to the 22-kilowatt (30-hp) series-wound drive motor. In addition to the conventional hydraulic braking system, the vehicle has hydraulic regenerative braking. Cycle tests and acceleration tests were conducted with and without hydraulic regeneration.
The EVA Change-of-Pace Coupe, is an electric passenger vehicle, to characterize the state-of-the-art of electric vehicles. The EVA Change-of-Pace Coupe is a four passenger sedan that has been coverted to an electric vehicle. It is powered by twenty 6 volt traction batteries through a silicon controlled rectifier chopper controller actuated by a foot throttle to change the voltage applied to the series wound, direct current motor. Braking is accomplished with a vacuum assist hydraulic braking system. Regenerative braking is also provided.
Cylindrical wound metallized film capacitors rated 2 micron F 500 VDC that had an energy density greater than 0.3 J/g, and flat flexible metallized film capacitors rated at 2 micron F 500 VDC that had an energy density greater than 0.1 J/g were developed. Polysulfone, polycarbonate, and polyvinylidene fluoride (PVF2) were investigated as dielectrics for the cylindrical units. PVF2 in 6.0 micron m thickness was employed in the final components of both types. Capacitance and dissipation factor measurements were made over the range 25 C to 100 C, and 10 Hz to 10 kHz. No pre-life-test burning was performed, and six of ten cylindrical units survived a 2500 hour AC plus DC lift test. Three of the four failures were infant mortality. All but two of the flat components survived 400 hours. Finished energy densities were 0.104 J/g at 500 V and 0.200 J/g at 700 V, the energy density being limited by the availability of thin PVF2 films.
Performance test results are presented for a four-passenger Austin A40 sedan that was converted to a heat-engine-alternator-and battery-powered hybrid. It is propelled by a conventional, gasoline-fueled, heat-engine-driven alternator and a traction pack powering a series-wound, 10 hp direct-current electric drive motor. The 16 hp gasoline engine drives the 7 kilowatt alternator, which provides electrical power to the drive motor or to the 96 volt traction battery through a rectifier. The propulsion battery consists of eight 12 volt batteries connected in series. The electric motor is coupled to a four-speed standard transmission, which drives the rear wheels. Power to the motor is controlled by a three-step foot throttle, which actuates relays that control armature current and field excitation. Conventional hydraulic brakes are used.
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.
A liquid-neon-cooled magnet has been designed to produce 30 teslas in steady operation. Its feasibility was established by a previously reported parametric study. To ensure the correctness of the heat transfer relationships used, supercritical neon heat transfer tests were made. Other tests made before the final design included tests on the effect of the magnetic field on pump motors; tensile-shear tests on the cryogenic adhesives; and simulated flow studies for the coolant. The magnet will be made of two pairs of coils, cooled by forced convection of supercritical neon. Heat from the supercritical neon will be rejected through heat exchangers which are made of roll-bonded copper panels and are submerged in a pool of saturated liquid neon. A partial mock-up coil was wound to identify the tooling required to wind the magnet. This was followed by winding a prototype pair of coils. The prototype winding established procedures for fabricating the final magnet and revealed slight changes needed in the final design.
Filament-wound, titanium-lined, fiber/epoxy pressure vessels were made using a very high-strength graphite fiber (3570-MPa typical fiber strength). The 0.254-mm-thick titanium liner was used to improve burst performance. The pressure vessels achieved an average burst performance of 241 kPa.cu m/kg, and the fatigue life of titanium liners with good welds (cycled to 50% of the average expected burst pressure) was in excess of 2000 cycles.
We are continuing to research the applications of acoustic emission testing for predicting burst pressure of filament-wound Kevlar 49/epoxy pressure vessels. This study has focused on three specific areas. The first area involves development of an experimental technique and the proper instrumentation to measure the energy given off by the acoustic emission transducer per acoustic emission burst. The second area concerns the design of a test fixture in which to mount the composite vessel so that the acoustic emission transducers are held against the outer surface of the composite. Included in this study area is the calibration of the entire test setup including couplant, transducer, electronics, and the instrument measuring the energy per burst. In the third and final area of this study, we consider the number, location, and sensitivity of the acoustic emission transducers used for proof testing composite pressure vessels.
The effect of a preload cycle on the structural performance of three graphite/epoxy composite laminates was studied. The layups studied were a laminate typical of general purpose structures (L1), a laminate representative of a filament wound tank (L2), and a laminate representative of turboengine fan blades. The effects of three sizes of simulated initial defects were studied. The tests developed static strength data, fatigue to failure data, and residual static data after application of a predetermined number of fatigue cycles. For L1 specimens, there was a slight trend for the static strength to be greater for preloaded specimens. After application of cyclic loading, however, the influence of preloading was insignificant. In L2 and L3 specimens there was no consistent difference in the static or fatigue results between preloaded and nonpreloaded specimens.
The purpose of this experiment is to localize celestial sources of X-rays to a precision of 5 to 20 arcsec, so that they may be identified with optical or radio counterparts. We also study their angular size and structure, to elucidate the X-ray emission mechanism. Four grids, wound with nickel alloy wires, are aligned to produce a modulated X-ray signal when the spacecraft rotation carries the collimator field of view across an X-ray source. An image dissector star camera and rate integrating gyroscopes are used to deduce the celestial position from which a peak X-ray signal arises. On-orbit performance and thermal stability have been very good. Based on the first six weeks of quick look data, we have the following results: the location of an X-ray burst source within a globular cluster; the location of 4U1608-52, a unique object which shows bursting, transient, and steady X-ray behavior and is also an optical source; the location of the X-ray transient H1705-25, which provided Anglo-Australian astronomers the basis for an optical identification with a nova-like object; the location of the X-ray transient H1743-32 in the galactic center; and a precise measurement of the angular extent of the Crab Nebula.
Manufacturing technique produces high quality metalized-film cylindrical capacitors of energy density greater than 0.1 J/g uncased, using either 24-gage polyvinylidene flouride or 14-gage polycarbonate film. Components are wound wrinkle-free on hollow PTFE cores, using winding machine that applies constant dynamically controlled tension to film during winding operation.
The aerodynamic design, structural design, fabrication, and structural testing is described for a 60 foot long filament wound, fiberglass/epoxy resin matrix wind turbine rotor blade for a 125 foot diameter, 100 kW wind energy conversion system. One blade was fabricated which met all aerodynamic shape requirements and was structurally capable of operating under all specified design conditions. The feasibility of filament winding large rotor blades was demonstrated.
A flexible solar array strip is formed by providing printed circuitry between flexible layers of a nonconductive material, depositing solder pads on the printed circuitry, and storing the resulting substrate on a drum from which it is then withdrawn and advanced along a linear path. Solderless solar cells are serially transported into engagement with the pads and are infrared radiation to melt the solder and attach the cells to the circuitry. Excess flux is cleaned from the solar cells which are then encapsulated in a protective coating. The resulting array is then wound on a drum.
A machine is described for attaching solar cells to a flexable substrate on which printed circuitry has been deposited. The strip is fed through: (1) a station in which solar cells are elevated into engagement with solder pads for the printed circuitry and thereafter heated by an infrared lamp; (2) a station at which flux and solder residue is removed; (3) a station at which electrical performance of the soldered cells is determined; (4) a station at which an encapsulating resin is deposited on the cells; (5) a station at which the encapsulated solar cells are examined for electrical performance; and (6) a final station at which the resulting array is wound on a takeup drum.
The effects of initial defects on the fatigue and fracture response of graphite-epoxy composite laminates are presented. The structural laminates investigated were a typical angle ply laminate, a polar/hoop wound pressure vessel laminate, and a typical engine fan blade laminate. Defects investigated were full and half penetration circular holes, full and half penetration slits, and countersink holes. The effects of the defect size and type on the static fracture strength, fatigue performance, and residual static strength are shown as well as the results of loadings on damage propagation in composite laminates. The data obtained were used to define proof test levels as a qualification procedure in composite structure subjected to cyclic loading.
The proposed Earth Radiation Budget Satellite System (ERBSS) of the 1980's will include a wide field-of-view (WFOV) fixed axes earth radiator discriminator consisting of a shortwave channel and a total (unfiltered) channel. The broadband spectral isolation required for the shortwave channel is achieved by use of a hemispherical fused silica (Suprasil W) dome filter placed in front of a wire wound thermopile radiation detector. A description is presented of the thermal response of the single-fused silica dome filter in the ERBSS WFOV shortwave channel conceptual design and the impact of that response on the channel measurement. Results from design definition and performance analysis studies are included. Problems associated with achieving the desired levels of confidence in a high accuracy filtered, WFOV radiometer are discussed. Design approaches, ground calibration, and data reduction techniques which minimize measurement uncertainties are explained.
The authors have measured thermal and mechanical properties of several composites of S-2 glass fiber in a room-temperature-curable epoxy matrix. The filament-wound composites ranged from 50 to 70 vol% fiber. The composites had generally good to excellent mechanical properties, particularly in view of the moderate cost of the material. However, the composites showed rapid increases in transverse thermal expansion above 50 C, and this property must be carefully considered if any use above that temperature is contemplated.