High Efficiency Stirling Power Conversion for Robotic Space Exploration
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Realistic Specific Power Expectations for Advanced Radioisotope Power Systems
Radioisotope Power Systems (RPS) are being considered for a wide range of future NASA space science and exploration missions. Generally, RPS offer the advantages of high reliability, long life, and predictable power production regardless of operating environment. Previous RPS, in the form of Radioisotope Thermoelectric Generators (RTG), have been used successfully on many NASA missions including Apollo, Viking, Voyager, and Galileo. NASA is currently evaluating design options for the next generation of RPS. Of particular interest is the use of advanced, higher efficiency power conversion to replace the previous thermoelectric devices. Higher efficiency reduces the quantity of radioisotope fuel and potentially improves the RPS specific power (watts per kilogram). Power conversion options include Segmented Thermoelectric (STE), Stirling, Brayton, and Thermophotovoltaic (TPV). This paper offers an analysis of the advanced 100 watt-class RPS options and provides credible projections for specific power. Based on the analysis presented, RPS specific power values greater than 10 W/kg appear unlikely.
Mason, Lee S.↗
Electronic amplifier with power supply switching Patent
Increasing power conversion efficiency of electronic amplifiers by power supply switching
Kramer, M.↗
Cathode & Electromagnet Qualification Status and Power Processing Unit Development Update for the Ascendant Sub-kW Transcelestial Electric Propulsion System
A review of the component-level flight qualification efforts and power processing unit development status of the Ascendant Sub-kW Transcelestial Electric Propulsion System (ASTRAEUS) program is presented. Component-level qualification efforts were undertaken for the system’s ultra-compact heaterless LaB6 hollow cathode and electromagnets, both of which employ designs bespoke to ASTRAEUS, as they represent the highest failure risks for the thruster. Through parallel long-duration wear and ignition tests, the ASTRAEUS cathode demonstrated invariant discharge performance over more than 5000 h of operation at its maximum operating current of 4 A and demonstrated more than 25,000 ignition cycles. The ASTRAEUS electromagnets completed their environmental qualification through a demonstration of more than 1200 deep thermal cycles with no indication of coil degradation (the test articles previously completed qualification-level vibration and shock testing). ASTRAEUS’s prototype power processing unit has demonstrated more than 92% total power conversion efficiency and class-leading power density & specific power density of 4.5 W/cm3 & 1670 W/kg, respectively. The various power converters found in the ASTRAEUS power processing unit are reviewed with a focus on the methods by which such high performance was achieved.
Conversano, Ryan W.↗
Development of optical coatings for cds thin film solar cells first quarterly report, dec. 2, 1964 - mar. 1, 1965
Developing and applying optical coatings to solar cells to increase power conversion efficiency
POWER CONVERSION↗
Carbon Nanotubes for Space Photovoltaic Applications
Carbon nanotubes (CNTs) can be envisioned as an individual graphene sheet rolled into a seamless cylinder (single-walled, SWNT), or concentric sheets as in the case of a multi-walled carbon nanotube (MWNT) (1). The role-up vector will determine the hexagonal arrangement and "chirality" of the graphene sheet, which will establish the nanotube to be metallic or semiconducting. The optoelectronic properties will depend directly on this chiral angle and the diameter of the SWNT, with semiconductor types exhibiting a band gap energy (2). Characteristic of MWNTs are the concentric graphene layers spaced 0.34 nm apart, with diameters from 10-200 nm and lengths up to hundreds of microns (2). In the case of SWNTs, the diameters range from 0.4 - 2 nm and lengths have been reported up to 1.5 cm (3). SWNTs have the distinguishable property of "bundling" together due to van der Waal's attractions to form "ropes." A comparison of these different structural types is shown in Figure 1. The use of SWNTS in space photovoltaic (PV) applications is attractive for a variety of reasons. Carbon nanotubes as a class of materials exhibit unprecedented optical, electrical, mechanical properties, with the added benefit of being nanoscale in size which fosters ideal interaction in nanomaterial-based devices like polymeric solar cells. The optical bandgap of semiconducting SWNTs can be varied from approx. 0.4 - 1.5 eV, with this property being inversely proportional to the nanotube diameter. Recent work at GE Global Research has shown where a single nanotube device can behave as an "ideal" pn diode (5). The SWNT was bridged over a SiO2 channel between Mo contacts and exhibited an ideality factor of 1, based on a fit of the current-voltage data using the diode equation. The measured PV efficiency under a 0.8 eV monochromatic illumination showed a power conversion efficiency of 0.2 %. However, the projected efficiency of these junctions is estimated to be > 5 %, especially when one considers the enhanced absorption (from nanotubes whose bandgap is tailored to illumination) and electromagnetic coupling in a network of nanotubes.
Efstathiadis, Harry↗
P/N In(Al) GaAs Multijunction Laser Power Converters
Eight In(Al)GaAs P/N junctions grown epitaxially on a semi-insulating wafer were monolithically integrated in series to boost the approx. 0.4 V photovoltage per typical In(Al)GaAs junction to over 3 volts for the 1 sq cm laser power converter (LPC) chip. This is the first report of a multijunction LPC for the 1.3 to 1.5 microns wavelength range. This wavelength range is optimum for laser power transmission over low- loss single-mode silica optical fiber, and is also useful with high efficiency 1.315 microns iodine lasers in free-space power transmission. Advantages of multijunction LPC designs include the need for less circuitry for power reconditioning and the potential for lower I(exp 2)R power loss. As an example, these LPCs have a responsivity of approx.1 amp/watt. With a single junction LPC, 100 watts/sq cm incident power would lead to about 100 A/sq cM short-circuit current at approx. 0.4 V open-circuit voltage. One disadvantage is the large current would lead to a large 1(exp 2)R loss which would lower the fill factor so that 40 wattS/sq cm output would not be obtained. Another is that few circuits are designed to work at 0.4 volts, so DC-DC power conversion circuitry would be necessary to raise the voltage to a reasonable level. The multijunction LPC being developed in this program is a step toward solving these problems. In the above example, an eight-junction LPC would have eight times the voltage, approx. 3 V, so that DC-DC power conversion may not be needed in many instances. In addition, the multijunction LPC would have 1/8 the current of a single-junction LPC, for only 1/64 the 1(exp 2)R loss if the series resistance is the same. Working monolithic multijunction laser power converters (LPCs) were made in two different compositions of the ln(x)Al(y)Ga(l-x-y)As semiconductor alloy, In(0.53)Ga(0.47)As (0.74 eV) and In(0.5)Al(0.1)Ga(0.4)As (0.87 eV). The final 0.8 sq cm LPCs had output voltages of about 3 volts and output currents up to about one-half amp. Maximum 1.3 microns power conversion efficiencies were approx. 22%. One key advantage of multijunction LPCs is that they have higher output voltages, so that less DC-DC power conversion circuitry is needed in applications.
Wojtczuk, Steven↗
Performance and load data from Mod-0A and Mod-1 wind turbine generators
Experimental data, together with supporting analysis, are presented on the power conversion performance and blade loading of large, horizontal-axis wind turbines tested at electric utility sites in the U.S. Four turbine rotor configurations, from 28 to 61 meters in diameter, and data from five test sites are included. Performance data are presented in the form of graphs of power and system efficiency versus free-stream wind speed. Deviations from theoretical performance are analyzed statistically. Power conversion efficiency averaged 0.34 for all tests combined, compared with 0.31 predicted. Round blade tips appeared to improve performance significantly. Cyclic blade loads were normalized to develop load factors which can be used in the design of rotors with rigid hubs.
Spera, D. A.↗
Inverted Three-Junction Tandem Thermophotovoltaic Modules
An InGaAs-based three-junction (3J) tandem thermophotovoltaic (TPV) cell has been investigated to utilize more of the blackbody spectrum (from a 1,100 C general purpose heat source GPHS) efficiently. The tandem consists of three vertically stacked subcells, a 0.74-eV InGaAs cell, a 0.6- eV InGaAs cell, and a 0.55-eV InGaAs cell, as well as two interconnecting tunnel junctions. A greater than 20% TPV system efficiency was achieved by another group with a 1,040 C blackbody using a single-bandgap 0.6- eV InGaAs cell MIM (monolithic interconnected module) (30 lateral junctions) that delivered about 12 V/30 or 0.4 V/junction. It is expected that a three-bandgap tandem MIM will eventually have about 3 this voltage (1.15 V) and about half the current. A 4 A/cm2 would be generated by a single-bandgap 0.6-V InGaAs MIM, as opposed to the 2 A/cm2 available from the same spectrum when split among the three series-connected junctions in the tandem stack. This would then be about a 50% increase (3xVoc, 0.5xIsc) in output power if the proposed tandem replaced the single- bandgap MIM. The advantage of the innovation, if successful, would be a 50% increase in power conversion efficiency from radioisotope heat sources using existing thermophotovoltaics. Up to 50% more power would be generated for radioisotope GPHS deep space missions. This type of InGaAs multijunction stack could be used with terrestrial concentrator solar cells to increase efficiency from 41 to 45% or more.
Wojtczuk, Steven↗
ARCJET ENGINE PERFORMANCE- EXPERIMENT AND THEORY
Performance of a hydrogen radiation-cooled arc jet engine, with emphasis on power conversion efficiency and the energy addition and loss mechanism
POWER CONVERSION↗
Heat engine development for solar thermal power systems
The technical status of three heat engines (Stirling, high-temperature Brayton, and Combined cycle) for use in solar thermal power systems is presented. Performance goals necessary to develop a system competitive with conventional power requirements include an external heated engine output less than 40 kW, and efficiency power conversion subsystem at least 40% at rated output, and a half-power efficiency of at least 37%. Results show that the Stirling engine can offer a 39% efficiency with 100 hours of life, and a 20% efficiency with 10,000 hours of life, but problems with seals and heater heads exist. With a demonstrated efficiency near 31% at 1500 F and a minimum lifetime of 100,000 hours, the Brayton engine does not offer sufficient engine lifetime, efficiency, and maintenance for solar thermal power systems. Examination of the Rankine bottoming cycle of the Combined cycle engine reveals a 30 year lifetime, but a low efficiency. Additional development of engines for solar use is primarily in the areas of components to provide a long lifetime, high reliability, and low maintenance (no more than $0.001/kW-hr).
Pham, H. Q.↗
High power diode lasers for solid-state laser pumps
The development and commercial application of high power diode laser arrays for use as solid-state laser pumps is described. Such solid-state laser pumps are significantly more efficient and reliable than conventional flash-lamps. This paper describes the design and fabrication of diode lasers emitting in the 780 - 900 nm spectral region, and discusses their performance and reliability. Typical measured performance parameters include electrical-to-optical power conversion efficiencies of 50 percent, narrow-band spectral emission of 2 to 3 nm FWHM, pulsed output power levels of 50 watts/bar with reliability values of over 2 billion shots to date (tests to be terminated after 10 billion shots), and reliable operation to pulse lengths of 1 ms. Pulse lengths up to 5 ms have been demonstrated at derated power levels, and CW performance at various power levels has been evaluated in a 'bar-in-groove' laser package. These high-power 1-cm stacked-bar arrays are now being manufactured for OEM use. Individual diode laser bars, ready for package-mounting by OEM customers, are being sold as commodity items. Commercial and medical applications of these laser arrays include solid-state laser pumping for metal-working, cutting, industrial measurement and control, ranging, wind-shear/atmospheric turbulence detection, X-ray generation, materials surface cleaning, microsurgery, ophthalmology, dermatology, and dental procedures.
Linden, Kurt J.↗
P/N In(Al) GaAs multijunction laser power converters
Eight In(AI)GaAs PN junctions grown epitaxially on the semi-insulating wafer were monolithically integrated in series to boost the approximately 0.4V photovoltage per typical In(Al)GaAs junction to over 3 volts for the 1 sq cm laser power converted (LPC) chip. Advantages of multijunction LCP designs include the need for less circuitry for power reconditioning and the potential for lower I(sup 2)R power loss. As an example, these LPC's have a responsivity of approximately 1 amp/watt. With a single junction LPC, 100 watts/sq cm incident power would lead to about 100 A/sq cm short-circuit current at approximately 0.4V open-cicuit voltage. One disadvantage is the large current would lead to a large I(sup 2)R loss which would lower the fill factor so that 40 watts/sq cm output would not be obtained. Another is that few circuits are designed to work at 0.4 volts, so DC-DC power conversion circuitry would be necessary to raise the voltage to a reasonable level. The multijunction LPC being developed in this program is a step toward solving these problems. In the above example, an eight-junction LPC would have eight times the voltage, approximately 3V, so that DC-DC power conversion may not be needed in many instances. In addition, the multijunction LPC would have 1/8 the current of a single-junction LPC, for only 1/64 the I(sup 2)R loss if the series resistance is the same. Working monolithic multijunction laser power converters (LPC's) were made in two different compositions of the In(x)Al(y)Ga(1-x-y)As semiconductor alloy, In(0.53)Ga(0.47)As (0.74 eV) and In(0.5)Al(0.1)Ga(0.4)As (0.87 eV). The final 0.8 sq cm LPC's had output voltages of about 3 volts and output currents up to about one-half amp. Maximum 1.3 micron power conversion efficiencies were approximately 22 percent. One key advantage of multijunction LPC's is that they have higher output voltages, so that less DC-DC power conversion circuitry is needed in applications.
Wojtczuk, Steven↗
High Performance Power Module for Hall Effect Thrusters
Previous efforts to develop power electronics for Hall thruster systems have targeted the 1 to 5 kW power range and an output voltage of approximately 300 V. New Hall thrusters are being developed for higher power, higher specific impulse, and multi-mode operation. These thrusters require up to 50 kW of power and a discharge voltage in excess of 600 V. Modular power supplies can process more power with higher efficiency at the expense of complexity. A 1 kW discharge power module was designed, built and integrated with a Hall thruster. The breadboard module has a power conversion efficiency in excess of 96 percent and weighs only 0.765 kg. This module will be used to develop a kW, multi-kW, and high voltage power processors.
Pinero, Luis R.↗
Sub mm laser local oscillators: Design criteria and results
Diagnostic results are given of the spectral features and the power conversion efficiency of submillimeter (SMM) laser local oscillators. Several criteria are obtained for the design of frequency stable and efficient smm lasers for local oscillator applications. Finally, a design is described and results on the power output and power and frequency stability are given. The mode pattern is very close to a Gaussian profile so that efficient coupling to a quasioptical mixer is possible. The laser provides sufficient output power at a large number of lines to drive the mixer into the low conversion loss regime. Radiometric integration times of several minutes with a spectral resolution of 1 MHz will be possible. With present state-of-the-art Schottky mixers and low noise preamplifiers a radiometric temperature resolution of a few K can be expected over a spectral range from 500to 900 GHz.
Koepf, G. A.↗
Power and Efficiency Optimized in Traveling-Wave Tubes Over a Broad Frequency Bandwidth
A traveling-wave tube (TWT) is an electron beam device that is used to amplify electromagnetic communication waves at radio and microwave frequencies. TWT's are critical components in deep space probes, communication satellites, and high-power radar systems. Power conversion efficiency is of paramount importance for TWT's employed in deep space probes and communication satellites. A previous effort was very successful in increasing efficiency and power at a single frequency (ref. 1). Such an algorithm is sufficient for narrow bandwidth designs, but for optimal designs in applications that require high radiofrequency power over a wide bandwidth, such as high-density communications or high-resolution radar, the variation of the circuit response with respect to frequency must be considered. This work at the NASA Glenn Research Center is the first to develop techniques for optimizing TWT efficiency and output power over a broad frequency bandwidth (ref. 2). The techniques are based on simulated annealing, which has the advantage over conventional optimization techniques in that it enables the best possible solution to be obtained (ref. 3). Two new broadband simulated annealing algorithms were developed that optimize (1) minimum saturated power efficiency over a frequency bandwidth and (2) simultaneous bandwidth and minimum power efficiency over the frequency band with constant input power. The algorithms were incorporated into the NASA coupled-cavity TWT computer model (ref. 4) and used to design optimal phase velocity tapers using the 59- to 64-GHz Hughes 961HA coupled-cavity TWT as a baseline model. In comparison to the baseline design, the computational results of the first broad-band design algorithm show an improvement of 73.9 percent in minimum saturated efficiency (see the top graph). The second broadband design algorithm (see the bottom graph) improves minimum radiofrequency efficiency with constant input power drive by a factor of 2.7 at the high band edge (64 GHz) and increases simultaneous bandwidth by 500 MHz.
Wilson, Jeffrey D.↗
A ten-stage electrostatic depressed collector for improving klystron efficiency.
A ten-stage electrostatic depressed collector, designed with the aid of an analog computer, was tested on a 1-kW CW 750-MHz klystron. Excellent correlation was achieved between computed and measured performance under varying conditions of RF drive. At full RF power output approximately 60 per cent of the spent beam energy was recovered by use of the depressed collector. The net power conversion efficiency of the tube was raised from its undepressed value of 54.3 per cent to approximately 70.9 per cent. At one-half full power output, a collector efficiency of 70 per cent was measured. At zero RF power output collector efficiency was 80 per cent. To achieve these results it was necessary to install a small focusing coil between the final drift tube and the collector. No spurious oscillations or instabilities were detected when collector depression was employed, nor was electron backstreaming increased significantly. Intentional short circuiting of adjacent collector electrode pairs was shown to cause only minor degradation in collector performance.
Neugebauer, W.↗
A comparison of 8.415-, 32.0- and 565646-GHz deep space telemetry links
An economic and performance comparison is made of spacecraft telecommunication links at 8.415, 32.0, and 565646 GHz (0.53-micron wavelength) for the return of 3.43 x 10 to the 11th power bits from a Saturn Orbiter/Titan Probe mission in year 2000. Technical performance and costs for both ends of the links are included. Spacecraft antenna or telescope efficiencies, pointing losses, ground-based or Earth-orbiting relay terminals efficiencies, noise temperatures, recurring and nonrecurring engineering, and maintenance and operations costs are modeled. Weather effects, dc-to-RF or laser power conversion efficiencies, gravity and other environment distortions gain reductions, and the cost of pointing and tracking are analyzed. The effort is focused primarily on the microwave frequency links. There are large uncertainties in the cost results, but conclusions indicate that for a mid-1990's launch, the Ka-band system is as cost effective as X-band. The Ka-band system has a data rate advantage as compared to the X-band system for the same dc power input to the spacecraft. The magnitude of the advantage is a complex function of the weather at the DSN stations and the elevation angle of the ground antenna. A simple numerical comparison of the advantage is difficult and curves are provided. The optical frequency link is more costly based on the launch-to-orbit costs for the orbiting terminal. A more detailed study of the optical system is recommended to quantify astrometric tracking benefits and improve the accuracy of the cost estimate.
Dickinson, R. M.↗