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Development and Integration of a Thermal Management Simulation for a Quadrotor Parallel Hybrid Propulsion System

This paper details the development of a propulsion system simulation for a six-passenger parallel hybrid quadrotor and utilizes the Numerical Propulsion System Simulation (NPSS) along with the NPSS Power System Library as the development environment. This simulation integrates an engine power plant with an electrical generation and distribution system and includes the required thermal management system. The thermal management system is comprised of liquid cooling loops that reject the heat load through air to coolant heat exchangers and utilizes a map-based performance estimation method. This method is developed within NPSS and detailed in this paper. The full system model is designed to predict system weight, range, and performance through a proposed mission profile. Results of the paper show an all-engine system maintains the best range, while a mostly electric system that utilizes an engine as a backup or a conditional power contributor offers range benefit.

Vertical lift and take off vehicle↗

Exploring the Model Design Space for Battery Health Management

Battery Health Management (BHM) is a core enabling technology for the success and widespread adoption of the emerging electric vehicles of today. Although battery chemistries have been studied in detail in literature, an accurate run-time battery life prediction algorithm has eluded us. Current reliability-based techniques are insufficient to manage the use of such batteries when they are an active power source with frequently varying loads in uncertain environments. The amount of usable charge of a battery for a given discharge profile is not only dependent on the starting state-of-charge (SOC), but also other factors like battery health and the discharge or load profile imposed. This paper presents a Particle Filter (PF) based BHM framework with plug-and-play modules for battery models and uncertainty management. The batteries are modeled at three different levels of granularity with associated uncertainty distributions, encoding the basic electrochemical processes of a Lithium-polymer battery. The effects of different choices in the model design space are explored in the context of prediction performance in an electric unmanned aerial vehicle (UAV) application with emulated flight profiles.

Saha, Bhaskar↗

Space Transportation Infrastructure Supported By Propellant Depots

A space transportation infrastructure is described that utilizes propellant depots to support all foreseeable missions in the Earth-Moon vicinity and deep space out to Mars. The infrastructure utilizes current expendable launch vehicles such as the Delta IV Heavy, Atlas V, and Falcon 9, for all crew, cargo, and propellant launches to orbit. Propellant launches are made to a Low-Earth-Orbit (LEO) Depot and an Earth-Moon Lagrange Point 1 (L1) Depot to support new reusable in-space transportation vehicles. The LEO Depot supports missions to Geosynchronous Earth Orbit (GEO) for satellite servicing, and to L1 for L1 Depot missions. The L1 Depot supports Lunar, Earth-Sun L2 (ESL2), Asteroid, and Mars missions. A Mars Orbital Depot is also described to support ongoing Mars missions. New concepts for vehicle designs are presented that can be launched on current 5-meter diameter expendable launch vehicles. These new reusable vehicle concepts include a LEO Depot, L1 Depot, and Mars Orbital Depot based on International Space Station (ISS) heritage hardware. The high-energy depots at L1 and Mars orbit are compatible with, but do not require, electric propulsion tug use for propellant and/or cargo delivery. New reusable in-space crew transportation vehicles include a Crew Transfer Vehicle (CTV) for crew transportation between the LEO Depot and the L1 Depot, a new reusable Lunar Lander for crew transportation between the L1 Depot and the lunar surface, and a Deep Space Habitat (DSH) to support crew missions from the L1 Depot to ESL2, Asteroid, and Mars destinations. A 6 meter diameter Mars lander concept is presented that can be launched without a fairing based on the Delta IV heavy Payload Planners Guide, which indicates feasibility of a 6.5 meter fairing. This lander would evolve to re-usable operations when propellant production is established on Mars. Figure 1 provides a summary of the possible missions this infrastructure can support. Summary mission profiles are presented for each primary mission capability. These profiles are the basis for propellant loads, numbers of vehicles/stages and launches for each mission capability. Data includes the number of launches required for each mission utilizing current expendable launch vehicle systems, and concluding remarks include ideas for reducing the number of launches through incorporation of heavy-lift launch vehicles, solar electric propulsion, and other transportation support concepts.

Smitherman, David↗

Space processing applications payload equipment study. Volume 2B: Payload interface analysis (power/thermal/electromagnetic compatibility)

As a part of the task of performing preliminary engineering analysis of modular payload subelement/host vehicle interfaces, a subsystem interface analysis was performed to establish the integrity of the modular approach to the equipment design and integration. Salient areas that were selected for analysis were power and power conditioning, heat rejection and electromagnetic capability (EMC). The equipment and load profiles for twelve representative experiments were identified. Two of the twelve experiments were chosen as being representative of the group and have been described in greater detail to illustrate the evaluations used in the analysis. The shuttle orbiter will provide electrical power from its three fuel cells in support of the orbiter and the Spacelab operations. One of the three shuttle orbiter fuel cells will be dedicated to the Spacelab electrical power requirements during normal shuttle operation. This power supplies the Spacelab subsystems and the excess will be available to the payload. The current Spacelab sybsystem requirements result in a payload allocation of 4.0 to 4.8 kW average (24 hour/day) and 9.0 kW peak for 15 minutes.

Hammel, R. L.↗

Mount Protects Thin-Walled Glass or Ceramic Tubes from Large Thermal and Vibration Loads

The design allows for the low-stress mounting of fragile objects, like thin walled glass, by using particular ways of compensating, isolating, or releasing the coefficient of thermal expansion (CTE) differences between the mounted object and the mount itself. This mount profile is lower than true full kinematic mounting. Also, this approach enables accurate positioning of the component for electrical and optical interfaces. It avoids the higher and unpredictable stress issues that often result from potting the object. The mount has been built and tested to space-flight specifications, and has been used for fiber-optic, optical, and electrical interfaces for a spaceflight mission. This mount design is often metal and is slightly larger than the object to be mounted. The objects are optical or optical/electrical, and optical and/or electrical interfaces are required from the top and bottom. This requires the mount to be open at both ends, and for the object s position to be controlled. Thin inside inserts at the top and bottom contact the housing at defined lips, or edges, and hold the fragile object in the mount. The inserts can be customized to mimic the outer surface of the object, which further reduces stress. The inserts have the opposite CTE of the housing material, partially compensating for the CTE difference that causes thermal stress. A spring washer is inserted at one end to compensate for more CTE difference and to hold the object against the location edge of the mount for any optical position requirements. The spring also ensures that any fiber-optic or optic interface, which often requires some pressure to ensure a good interface, does not overstress the fragile object. The insert thickness, material, and spring washer size can be traded against each other to optimize the mount and stresses for various thermal and vibration load ranges and other mounting requirements. The alternate design uses two separate, unique features to reduce stress and hold the object. A release agent is applied to the inside surface of the mount just before the binding potting material is injected in the mount. This prevents the potting material from bonding to the mount, and thus prevents stress from being applied, at very low temperatures, to the fragile object being mounted. The potting material mixing and curing is temperature- and humidity-controlled. The mount has radial grooves cut in it that the potting material fills, thus controlling the vertical position of the mounted object. The design can easily be used for long and thin objects, short and wide objects, and any shape in between. The design s advantages are amplified for long and thin fragile objects. The general testing range was 45 to +45 C, but multiple mounts were successfully tested down to 60 and up to 50 C and the design can be adjusted for larger ranges.

Amato, Michael↗

Reconditioning of Batteries on the International Space Station

Primary source of electric power for the International Space Station (ISS) is the photovoltaic module (PVM). At assembly complete stage, the ISS will be served by 4 PVMs. Each PVM contains two independent power channels such that one failure will result in loss of only one power channel. During early stages of assembly, the ISS is served by only one PVM designated as P6. Solar arrays are used to convert solar flux into electrical power. Nickel hydrogen batteries are used to store electrical power for use during periods when the solar input is not adequate to support channel loads. Batteries are operated per established procedures that ensure that they are maintained within specified temperature limits, charge current is controlled to conform to a specified charge profile, and battery voltages are maintained within specified limits. Both power channels on the PVM P6 have been operating flawlessly since December 2000 with 100 percent power availability. All components, including batteries, are monitored regularly to ensure that they are operating within specified limits and to trend their wear out and age effects. The paper briefly describes the battery trend data. Batteries have started to show some effects of aging and a battery reconditioning procedure is being evaluated at this time. Reconditioning is expected to reduce cell voltage divergence and provide data that can be used to update the state of charge (SOC) computation in the software to account for battery age. During reconditioning, each battery, one at a time, will be discharged per a specified procedure and then returned to a full state of charge. The paper describes the reconditioning procedure and the expected benefits. The reconditioning procedures have been thoroughly coordinated by all affected technical teams and approved by all required boards. The reconditioning is tentatively scheduled for September 2004.

Hajela, Gyan↗

Evaluation Studies of a 800W Solid Oxide-Based Fuel Cells Stack for Electrical Power in Aviation

As both NASA and the aeronautics industry recognize the need for higher fuel efficiency and lower carbon emissions in both commercial airline and private aviation applications, development of all-electric or hybrid electric aircraft have garnered renewed interest in the aviation community. For the particular example of the hybrid-electric option, the solid oxide fuel cell (SOFC) is an attractive option for the power source, due to its potential to utilize aviation fuels thereby having minimal impact to aviation infrastructure. SOFC stack performance depends upon many factors, one of the most important is the way the oxidant and fuel gases are delivered to the fuel cells. System modeling of various aircraft configurations for FUELEAP (Fostering Ultra-Efficient, Low-Emitting Aviation Power) point to the need to operate SOFC stacks at high current densities. This creates challenges in the thermal profile of the stacks with potential to create large thermal gradients and hot spots. This study investigates two types of commercial solid oxide fuel cell stacks, the cross flow and co-flow gas designs, both convectively cooled with cathode air. High fuel utilization factors were also employed under varying electrical loads expected from the demands of flight. In addition, performance, range of operation and endurance were investigated under conditions of high current loads and thermal cycling. Evaluations include the study of gas kinetic using electrochemical spectroscopy. Testing took place at the facilities of NASA Glenn using a commercial test system (FuelCon AG, Magdeburg Germany). These studies are crucial to the Glenn Research Center's ability to conduct research, evaluation and development of the next-generation SOFC based stacks for cutting-edge energy technologies for aerospace applications. This study supports NASA's Convergent Aeronautics Solutions' (CAS) FUELEAP project.

Goldsby, Jon C.↗

System Design Techniques for Reducing the Power Requirements of Advanced life Support Systems

The high power requirement associated with overall operation of regenerative life support systems is a critical Z:p technological challenge. Optimization of individual processors alone will not be sufficient to produce an optimized system. System studies must be used in order to improve the overall efficiency of life support systems. Current research efforts at NASA Ames Research Center are aimed at developing approaches for reducing system power and energy usage in advanced life support systems. System energy integration and energy reuse techniques are being applied to advanced life support, in addition to advanced control methods for efficient distribution of power and thermal resources. An overview of current results of this work will be presented. The development of integrated system designs that reuse waste heat from sources such as crop lighting and solid waste processing systems will reduce overall power and cooling requirements. Using an energy integration technique known as Pinch analysis, system heat exchange designs are being developed that match hot and cold streams according to specific design principles. For various designs, the potential savings for power, heating and cooling are being identified and quantified. The use of state-of-the-art control methods for distribution of resources, such as system cooling water or electrical power, will also reduce overall power and cooling requirements. Control algorithms are being developed which dynamically adjust the use of system resources by the various subsystems and components in order to achieve an overall goal, such as smoothing of power usage and/or heat rejection profiles, while maintaining adequate reserves of food, water, oxygen, and other consumables, and preventing excessive build-up of waste materials. Reductions in the peak loading of the power and thermal systems will lead to lower overall requirements. Computer simulation models are being used to test various control system designs.

Finn, Cory↗

Results of electric-vehicle propulsion system performance on three lead-acid battery systems

Three types of state of the art 6 V lead acid batteries were tested. The cycle life of lead acid batteries as a function of the electric vehicle propulsion system design was determined. Cycle life, degradation rate and failure modes with different battery types (baseline versus state of the art tubular and thin plate batteries were compared. The effects of testing strings of three versus six series connected batteries on overall performance were investigated. All three types do not seem to have an economically feasible battery system for the propulsion systems. The tubular plate batteries on the load leveled profile attained 235 cycles with no signs of degradation and minimal capacity loss.

Ewashinka, J. G.↗

Results of electric-vehicle propulsion system performance on three lead-acid battery systems

Three types of state of the art 6 V lead acid batteries were tested. The cycle life of lead acid batteries as a function of the electric vehicle propulsion system design was determined. Cycle life, degradation rate and failure modes with different battery types (baseline versus state of the art tubular and thin plate batteries) were compared. The effects of testing strings of three versus six series connected batteries on overall performance were investigated. All three types do not seem to have an economically feasible battery system for the propulsion systems. The tubular plate batteries on the load leveled profile attained 235 cycles with no signs of degradation and minimal capacity loss.

Ewashinka, J. G.↗

Wind turbine generator interaction with diesel generators on an isolated power system

The results of a dynamic interaction investigation to characterize any disturbances caused by interfacing the Mod 0A wind turbine (150 kW configuration) with the Block Island utility diesel generator grid are reported. The tests were run when only two diesel generators were on line, and attention was given to power, frequency, and voltage time profiles. The interconnected system was examined in the start-up and synchronization phase, normal shutdown and cut-out of the wind turbine, during fixed pitch generation, and during variable pitch operation. Governors were installed on the diesel generators to accommodate the presence of wind-derived electricity. The blade pitch control was set to maintain power at 150 kW or below. Power and voltage transients were insignificant during start-up and shutdown, and frequency aberrations were within the range caused by load fluctuations. It is concluded that wind turbine generation can be successfully implemented by an isolated utility, even with a significant penetration to the total grid output.

Scott, G. W.↗

Hubble Space Telescope six-battery nickel-cadmium mission simulation test

A simulation test of the six-battery nickel-cadmium mission to determine battery life and electrical power system (EPS) performance characteristics for the Hubble Space Telescope (HST) program, is described. The basic HST power system requirements are to provide power generation, energy storage, and EPS control and distribution for 2.5 years with the nickel-cadmium (NiCd) batteries at an end of life solar array of 2 years. Mission simulation life testing begain in April of 1986, and the batteries have completed their 2.5 year mission requirement. Conditions as close as practical to the actual predicted mission profiles were used. These included solar array degradation, load variations, beta angle changes, temperature changes (with excursions to 10 C), battery reconditioning, safemode simulations, and off-normal roll activities. Discounting system cycling interruptions caused by hardware, software, human error, and periodic updates and revisions, the HST EPS breadboard hardware operated continuously for 30 months and demonstrated the power system's ability to meet the HST requirement.

Jackson, Lorna G.↗

Autonomous power expert system

The Autonomous Power Expert (APEX) system was designed to monitor and diagnose fault conditions that occur within the Space Station Freedom Electrical Power System (SSF/EPS) Testbed. APEX is designed to interface with SSF/EPS testbed power management controllers to provide enhanced autonomous operation and control capability. The APEX architecture consists of three components: (1) a rule-based expert system, (2) a testbed data acquisition interface, and (3) a power scheduler interface. Fault detection, fault isolation, justification of probable causes, recommended actions, and incipient fault analysis are the main functions of the expert system component. The data acquisition component requests and receives pertinent parametric values from the EPS testbed and asserts the values into a knowledge base. Power load profile information is obtained from a remote scheduler through the power scheduler interface component. The current APEX design and development work is discussed. Operation and use of APEX by way of the user interface screens is also covered.

Walters, Jerry L.↗

Radio Wave Propagation for Communication on and around Mars: Highlights: Propagation Through Mars Environment - Part 1

We recommend to use the dayside Martian ionosphere as a reflector for global communication, because the dayside ionosphere has stable density peak and usable critic frequency. This is very crucial for the future Mars ground to around communication. The dayside ionosphere has been well modeled as a Chapman layer. We suggest to perform the Martian nightside ionospheric modeling study. Because the nightside ionosphere has very little measurements available, we propose to drop a digital ionosond instrument into the Mars surface for data collection. Even though the Martian tropospheric radio refractivity has small value, it still can cause the ray bending and multipath effects. We recommend to perform an accurate calculation on excess phase and group delays (range and time delays). Other effects, such as range rate errors, appearance angle deviation, defocusing loss on Mars, etc. are also needed to be estimated. Ice depolarization effects due to Martian clouds on radio waves is unknown yet, which is expected to be small, because lower optical depth and thinner layer of cloud: Total Martian atmospheric gaseous attenuation is expected to be less than 1 dB on microwaves band, because the Martian atmosphere has very low concentration in uncondensed H2O and O2. An accurate calculation for zenith opacity requires the information about scale heights of H2O and O2 distribution. An accurate water vapor altitude profile at Mars is not available yet. Under the normal condition, CO2 and N2 gases do not have electric or magnetic dipoles and do not absorb electromagnetic energy from the waves. However, they may generate the dipoles through a collision and interact with waves under a high density condition and absorb electromagnetic waves in the infrared and visible band. Dust storm is most dominant factor to the radio wave attenuation. Large Martian dust storm can cause at least 3 dB or higher loss to Ka band wave. For a normal dust storm, the attenuation is about 1 dB. The attenuation much depends on dust mass loading, dust size distribution, etc. Most large dust storm occur in the southern hemisphere during later spring and early summer when the southern hemisphere become suddenly hot.

Ho, Christian↗

Highlights of Part I: Propagation Through Mars Environment: Propagation through Mars Environment - Part 1

We recommend using the dayside Martian ionosphere as a reflector for global communication, because it has a stable density peak and usable critical frequency. This is very crucial for the future Mars ground to ground communication. The dayside ionosphere has been well modeled as a Chapman layer. We suggest performing the Martian nightside ionosphere modeling study. Because the nightside ionosphere has very little measurements available, we propose to drop a digital ionosound instrument into the Mars surface for data collection. Even though the Martian tropospheric radio refractivity had a small value, it still can cause ray bending and multipath effects. We recommend performing an accurate calculation on excess phase and group delays (range and time delays). Other effects, such as range rate errors, appearance angle deviation, defocusing loss on Mars, etc. should be estimated. Ice depolarization effects due to Martian clouds on radio waves are unknown yet, but they are expected to be small, because of lower optical depth and the thinner layer of cloud. Total Martian atmospheric gaseous attenuation is expected to be less than 1 dB on microwaves and, because the Martian atmosphere had very low concentration in uncondensed H2O and O2. An accurate calculation for zenith opacity requires the information about scale heights of H2O and O2 distribution. An accurate water vapor altitude profile at Mars is not available et. Under the normal condition, CO2 and N2 gases ddo not have electric or magnetic dipoles and do not absorb electromagnetic energy from the waves. However, they may generate the dipoles through a collision and interact with waves under a high density condition and absorb electromagnetic waves in the infrared and visible band. Dust storm is the most dominant factor on the radio wave attenuation. Large Martian dust storms can cause at least 3 dB or higher loss to Ka band wave. For a normal dust storm, the attenuation is about 1 dB. The attenuation much depends on dust mass loading, dust size distribution, etc. Most large dust storms occur in the southern hemisphere during later spring and early summer when the southern hemisphere becomes suddenly hot.

Ho, Christian↗

Fabrication and Modification of Nanoporous Silicon Particles

Silicon-based nanoporous particles as biodegradable drug carriers are advantageous in permeation, controlled release, and targeting. The use of biodegradable nanoporous silicon and silicon dioxide, with proper surface treatments, allows sustained drug release within the target site over a period of days, or even weeks, due to selective surface coating. A variety of surface treatment protocols are available for silicon-based particles to be stabilized, functionalized, or modified as required. Coated polyethylene glycol (PEG) chains showed the effective depression of both plasma protein adsorption and cell attachment to the modified surfaces, as well as the advantage of long circulating. Porous silicon particles are micromachined by lithography. Compared to the synthesis route of the nanomaterials, the advantages include: (1) the capability to make different shapes, not only spherical particles but also square, rectangular, or ellipse cross sections, etc.; (2) the capability for very precise dimension control; (3) the capacity for porosity and pore profile control; and (4) allowance of complex surface modification. The particle patterns as small as 60 nm can be fabricated using the state-of-the-art photolithography. The pores in silicon can be fabricated by exposing the silicon in an HF/ethanol solution and then subjecting the pores to an electrical current. The size and shape of the pores inside silicon can be adjusted by the doping of the silicon, electrical current application, the composition of the electrolyte solution, and etching time. The surface of the silicon particles can be modified by many means to provide targeted delivery and on-site permanence for extended release. Multiple active agents can be co-loaded into the particles. Because the surface modification of particles can be done on wafers before the mechanical release, asymmetrical surface modification is feasible. Starting from silicon wafers, a treatment, such as KOH dipping or reactive ion etching (RIE), may be applied to make the surface rough. This helps remove the nucleation layer. A protective layer is then deposited on the wafer. The protective layer, such as silicon nitride film or photoresist film, protects the wafer from electrochemical etching in an HF-based solution. A lithography technique is applied to pattern the particles onto the protective film. The undesired area of the protective film is removed, and the protective film on the back side of the wafer is also removed. Then the pattern is exposed to HF/surfactant solution, and a larger DC electrical current is applied to the wafers for a selected time. This step removes the nucleation layer. Then a DC current is applied to generate the nanopores. Next, a large electrical current is applied to generate a release layer. The particles are mechanically suspended in the solvent and collected by filtration or centrifuge.

Ferrari, Mauro↗

Effect of Reactant Purity on Proton Exchange Membrane Fuel Cell Performance

NASA has set a goal to return to the Moon and to establish a sustained lunar presence. Many applicable lander and upperstage vehicle concepts utilize cryogenic H2 and O2 propellants. This propellant selection enables appealing potential mission concepts wherein electricity is generated by operating a fuel cell on residual H2 and O2 propellants. This concept depends on the capability of the fuel cell to utilize dry, propellant-grade reactants with concentrations of up to 30 percent He present. This study consists of the evaluation of a 12-cell non-flow-through proton exchange membrane fuel cell stack of 50 sq. cm active area with passive water removal. This stack was supplied with three levels of reactant purity: >99.999, 99.1, and 70 mol%, with the remainder made up of He. The reactant humidity and flow-through rate were also assessed as performance factors, and the fuel stack repeatedly supported a load profile with current densities up to 500 mA/sq. cm (25 A). The fuel cell performed consistently over the course of testing, with cell voltages decreasing approximately 50 mV at the maximum current density when supplied with reactants with 30 percent He present.

electrochemistry↗

Development and Experimental Evaluation of Passive Fuel Cell Thermal Control

To provide uniform cooling for a fuel cell stack, a cooling plate concept was evaluated. This concept utilized thin cooling plates to extract heat from the interior of a fuel cell stack and move this heat to a cooling manifold where it can be transferred to an external cooling fluid. The advantages of this cooling approach include a reduced number of ancillary components and the ability to directly utilize an external cooling fluid loop for cooling the fuel cell stack. A number of different types of cooling plates and manifolds were developed. The cooling plates consisted of two main types; a plate based on thermopyrolytic graphite (TPG) and a planar (or flat plate) heat pipe. The plates, along with solid metal control samples, were tested for both thermal and electrical conductivity. To transfer heat from the cooling plates to the cooling fluid, a number of manifold designs utilizing various materials were devised, constructed, and tested. A key aspect of the manifold was that it had to be electrically nonconductive so it would not short out the fuel cell stack during operation. Different manifold and cooling plate configurations were tested in a vacuum chamber to minimize convective heat losses. Cooling plates were placed in the grooves within the manifolds and heated with surface-mounted electric pad heaters. The plate temperature and its thermal distribution were recorded for all tested combinations of manifold cooling flow rates and heater power loads. This testing simulated the performance of the cooling plates and manifold within an operational fuel cell stack. Different types of control valves and control schemes were tested and evaluated based on their ability to maintain a constant temperature of the cooling plates. The control valves regulated the cooling fluid flow through the manifold, thereby controlling the heat flow to the cooling fluid. Through this work, a cooling plate and manifold system was developed that could maintain the cooling plates within a minimal temperature band with negligible thermal gradients over power profiles that would be experienced within an operating fuel cell stack.

Fuel Cells↗