SEARCH · Engineering Papers
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Technological requirements for Space Station design were discussed. The requirements are discussed in relation to the following areas: high voltage arrays; environmental interactions; energy management; power supplies; architecture; and modularity.
NASA is developing technologies to prepare for human exploration missions to Mars. Solar electric propulsion (SEP) systems are expected to enable a new cost effective means to deliver cargo to the Mars surface. Nearer term missions to Mars moons or near-Earth asteroids can be used to both develop and demonstrate the needed technology for these future Mars missions while demonstrating new capabilities in their own right. This presentation discusses recent technology development accomplishments for high power, high voltage solar arrays and power management that enable a new class of SEP missions.
As large airline companies compete to reduce emissions, fuel, noise, and maintenance costs, it is expected that more of their aircraft systems will shift from using turbofan propulsion, pneumatic bleed power, and hydraulic actuation, to instead using electrical motor propulsion, generator power, and electrical actuation. This requires new flight-weight and flight-efficient powertrain components, fault tolerant power management, and electromagnetic interference mitigation technologies. Moreover, initial studies indicate some combination of ambient and cryogenic thermal management and relatively high bus voltages when compared to state of practice will be required to achieve a net system benefit. Developing all these powertrain technologies within a realistic aircraft architectural geometry and under realistic operational conditions requires a unique electric aircraft testbed. This report will summarize existing testbed capabilities located in the U.S. and details the development of a unique complementary testbed that industry and government can utilize to further mature electric aircraft technologies.
In the commercial aviation world, hybrid/electric propulsion is a promising technology for fuel, emissions, and noise reduction in support of the challenging goals established by 2050 EU Flightpath/SRIA, NASA ARMD Strategic Implementation Plan, and the US Air Force ATTAM programs. Ongoing results indicate operational benefits are possible in those three technical areas. Considering military applications, hybrid/electric propulsion may yield further significant improvements by enabling new, unorthodox mission capabilities. Potential benefits are expected in the areas of vehicle signature reduction (lower noise, lower exhaust signature), usage in enhanced flight environments, minimized human-in-the-loop workload by offering a platform compatible with future goals of autonomous operations facilitation, maintenance cost reductions, and performance burst/dash energy. Additional synergies are likely when used in conjunction with energy weapons. Some potential areas of mutual interest could include, dusty operations capability, remote supply capability, extended surveillance, dispatch able power, fuel-flexible vehicles, and autonomous rescue equipment. Many of the key technologies that have been demonstrated in ground operation must now be qualified for altitude conditions. We expect to have many flight qualified powertrain systems over the next decade for military planners to choose from for new future battlefield capability. This requires new flight-weight and flight-efficient powertrain components, fault tolerant power management, and electromagnetic interference mitigation technologies. Moreover, initial studies indicate some combination of ambient and cryogenic thermal management and relatively high bus voltages when compared to state of practice will be required to achieve a net system benefit. Developing all these powertrain technologies within a realistic aircraft architectural geometry and under realistic operational conditions requires a unique electric aircraft test bed. The MC-12 surveillance aircraft is an ideal military aircraft for demonstrating some of the benefits of incorporating hybrid electric propulsion. This report details an approach for full-scale ground-based altitude testing the hybrid electric MC-12 powertrain through a full flight profile.
As power levels of spacecraft rise to the 50 to 100 kW range, it becomes apparent that low voltage (28 V) dc power distribution and management systems will not operate efficiently at these higher power levels. The concept of transforming a solar array voltage at 150 V dc into a 1000 V ac distribution system operating at 20 kHz is examined. The transformation is accomplished with series-resonant inverter by using a rotary transformer to isolate the solar array from the spacecraft. The power can then be distributed in any desired method such as three phase delta to delta. The distribution voltage can be easily transformed to any desired load voltage and operating frequency. The reasons for the voltage limitations on the solar array due to plasma interactions and the many advantages of a high voltage, high frequency at distribution system are discussed.
The Second Workshop on Voltage Breakdown in Electronic Equipment at Low Air Pressure was sponsored by the Jet Propulsion Laboratory, Pasadena, California. It has been three and one-half years since the convening of the first workshop on voltage breakdown. In this interval, gains are evidenced in the progress and sophistication in solving voltage breakdown problems affecting electronic equipment operating at high altitudes or other low air pressure environments. Although space applications predominate the area of concern, other projects such as the SST are becoming increasingly involved with voltage breakdown. High-voltage breakdown in spacecraft continues; however, the incidences of occurrence appear to have decreased in spite of an increase in the number of missions flown. This, it is felt, is due to many project managers now requiring all equipment with voltage in excess of 270-V peak to be designed to operate in the critical pressure region without damage, even though its normal functional environment is sea level pressure and the hard vacuum of space. In addition, designers are becoming more aware of the principle of good high-voltage design by selecting void-free components, proper spacing of conductors, isolating high-voltage circuitry from lower voltage areas, etc. The consensus seems to be that the slight increase in cost to achieve a provable corona-free design is more than offset by the increase in confidence that the equipment will survive accidental loss of vacuum during high-vacuum tests, inadvertent turn on while passing through the critical air-pressure region of earth after launch or outgassing in flight pressurizing the enclosure into the critical pressure region.
The Modular, Reconfigurable High-Energy (MRHE) Technology Demonstrator project was to have been a series of ground-based demonstrations to mature critical technologies needed for in-space assembly of a highpower high-voltage modular spacecraft in low Earth orbit, enabling the development of future modular solar-powered exploration cargo-transport vehicles and infrastructure. MRHE was a project in the High Energy Space Systems (HESS) Program, within NASA's Exploration Systems Research and Technology (ESR&T) Program. NASA participants included Marshall Space Flight Center (MSFC), the Jet Propulsion Laboratory (JPL), and Glenn Research Center (GRC). Contractor participants were the Boeing Phantom Works in Huntsville, AL, Lockheed Martin Advanced Technology Center in Palo Alto, CA, ENTECH, Inc. in Keller, TX, and the University of AL Huntsville (UAH). MRHE's technical objectives were to mature: (a) lightweight, efficient, high-voltage, radiation-resistant solar power generation (SPG) technologies; (b) innovative, lightweight, efficient thermal management systems; (c) efficient, 100kW-class, high-voltage power delivery systems from an SPG to an electric thruster system; (d) autonomous rendezvous and docking technology for in-space assembly of modular, reconfigurable spacecraft; (e) robotic assembly of modular space systems; and (f) modular, reconfigurable distributed avionics technologies. Maturation of these technologies was to be implemented through a series of increasingly-inclusive laboratory demonstrations that would have integrated and demonstrated two systems-of-systems: (a) the autonomous rendezvous and docking of modular spacecraft with deployable structures, robotic assembly, reconfiguration both during assembly and (b) the development and integration of an advanced thermal heat pipe and a high-voltage power delivery system with a representative lightweight high-voltage SPG array. In addition, an integrated simulation testbed would have been developed containing software models representing the technologies being matured in the laboratory demos. The testbed would have also included models for non-MRHE developed subsystems such as electric propulsion, so that end-to-end performance could have been assessed. This paper presents an overview of the MRHE Phase I activities at MSFC and its contractor partners. One of the major Phase I accomplishments is the assembly demonstration in the Lockheed Martin Advanced Technology Center (LMATC) Robot-Satellite facility, in which three robot-satellites successfully demonstrated rendezvous & docking, self-assembly, reconfiguration, adaptable GN&C, deployment, and interfaces between modules. Phase I technology maturation results from ENTECH include material recommendations for radiation hardened Stretched Lens Array (SLA) concentrator lenses, and a design concept and test results for a hi-voltage PV receiver. UAH's accomplishments include Supertube heatpipe test results, which support estimates of thermal conductivities at 30,000 times that of an equivalent silver rod. MSFC performed systems trades and developed a preliminary concept design for a 100kW-class modular reconfigurable solar electric propulsion transport vehicle, and Boeing Phantom Works in Huntsville performed assembly and rendezvous and docking trades. A concept animation video was produced by SAIC, wllich showed rendezvous and docking and SLA-square-rigger deployment in LEO.
Power distribution subsystems are required for three elements of the SPS program: (1) orbiting satellite, (2) ground rectenna, and (3) Electric Orbiting Transfer Vehicle (EOTV). Power distribution subsystems receive electrical power from the energy conversion subsystem and provide the power busses rotary power transfer devices, switchgear, power processing, energy storage, and power management required to deliver control, high voltage plasma interactions, electric thruster interactions, and spacecraft charging of the SPS and the EOTV are also included as part of the power distribution subsystem design.
Miniaturized thermoelectric devices integrated into thermal management packages and low power, high voltage, electrical power source systems are of interest for a variety of space and terrestrial applications.
This presentation reviews: (1) the goals and objectives, (2) the NASA and Airforce requirements, (3) the potential near term missions, (4) management approach, (5) the technical approach and (6) the program road map. The objectives of the program include: (1) develop high specific energy and long life lithium ion cells and smart batteries for aerospace and defense applications, (2) establish domestic production sources, and to demonstrate technological readiness for various missions. The management approach is to encourage the teaming of universities, R&D organizations, and battery manufacturing companies, to build on existing commercial and government technology, and to develop two sources for manufacturing cells and batteries. The technological approach includes: (1) develop advanced electrode materials and electrolytes to achieve improved low temperature performance and long cycle life, (2) optimize cell design to improve specific energy, cycle life and safety, (3) establish manufacturing processes to ensure predictable performance, (4) establish manufacturing processes to ensure predictable performance, (5) develop aerospace lithium ion cells in various AH sizes and voltages, (6) develop electronics for smart battery management, (7) develop a performance database required for various applications, and (8) demonstrate technology readiness for the various missions. Charts which review the requirements for the Li-ion battery development program are presented.
The bipolar battery concept, developed in cooperation with NASA, is described in the context of the advantages afforded by near-term IPV and CVP cell technology. The projected performance, development requirements, and a possible approach to bipolar battery design are outlined. Consideration is given to packaging electrodes within a common hydrophobic plastic frame, electrode technology that involves a photochemically etched 0.1 mm thick nickel substrate coated with a 10 mg/sq cm mixture of platinum powder and TFE30, and an electrode design that eliminates the screen and doubles the electrode thickness (from the currently used 0.8 mm) while retaining the active material loading of 1.6-1.8 gm/cu cm. Also covered are thermal management, and electrolyte and oxygen management. It is concluded that a high voltage, high capacity, bipolar NiH2 cell can be configured with proper development for use in large power systems, and that it can provide considerable weight savings.
In this article, we present the datasets collected from nine different Li-ion batteries. These datasets contain voltage, current and time measurements during a full charge-discharge cycle of a battery at very low current (that is nearly at �/30 rate). Such low current rate data is suitable for open circuit voltage characterization. The collection of this data was done through the use of an Arbin battery cycler and a thermal chamber was used to control the test temperature. Data were collected over a wide range of temperatures from −25∘C to 50∘C.
Reflectivity control devices (RCDs), thin film optical devices that are actuated (by application of a voltage across the device) to control the reflection of sunlight on their surfaces, can effectively enable roll momentum management (MM) of a solar sail operating in deep space, outside any magnetic field. This enables solar sails to maintain adequate attitude control in these challenging environments without sacrificing mission life by using expendables. They were planned and developed for use on Solar Cruiser, operating sunward of the Sun-Earth Lagrange Point 1 (sub-L1) in a propulsion-intensive artificial halo orbit. Located in pairs of panels near the distal end of each of four booms, each articulated at a slight angle out of the sail plane to produce a force tangent to the sail at a large moment arm, the RCDs provide roll torque capabilities by using simple switching logic to determine which panels should be activated (voltage applied) to produce torque in the desired direction. The performance capabilities and constraints of these devices across a range of operating conditions, namely sun-relative attitude, is well characterized, granting designers insight on how to properly size the system and optimize the system and component designs to maximize roll torque per unit area. With an informed design, RCDs can be very effective actuators for managing roll momentum with minimal detrimental system impacts (mass, power, complexity, etc.) on Solar Cruiser and other future deep space solar sail missions.
CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload,1 providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cm cu and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high delta v maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Recently, work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) 2 that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. Iodine stores as a dense solid at very low pressures, making it acceptable as a propellant on a secondary payload. It has exceptionally high ρIsp (density times specific impulse), making it an enabling technology for small satellite near-term applications and providing the potential for systems-level advantages over mid-term high power electric propulsion options. Iodine flow can also be thermally regulated, subliming at relatively low temperature ( less than100 C) to yield I2 vapor at or below 50 torr. At low power, the measured performance of an iodine-fed HET is very similar to that of a state-of-the-art xenon-fed thruster. Just as importantly, the current-voltage discharge characteristics of low power iodine-fed and xenon-fed thrusters are remarkably similar, potentially reducing development and qualifications costs by making it possible to use an already-qualified xenon-HET PPU in an iodine-fed system. Finally, a cold surface can be installed in a vacuum test chamber on which expended iodine propellant can deposit. In addition, the temperature doesn't have to be extremely cold to maintain a low vapor pressure in the vacuum chamber (it is under 10(exp -6) torr at -75 C), making it possible to 'cryopump' the propellant with lower-cost recirculating refrigerant-based systems as opposed to using liquid nitrogen or low temperature gaseous helium cryopanels. In the present paper, we describe testing performed using an iodine-fed 200 W Hall thruster mounted to a thrust stand and operated in conjunction with MSFCs Small Projects Rapid Integration and Test Environment (SPRITE) Portable Hardware In the Loop (PHIL) hardware. This work is performed in support of the iodine satellite (iSAT) project, which aims to fly a 200-W iodine-fed thruster on a 12-U CubeSat. The SPRITE PHIL hardware allows a given vehicle to do a checkout of its avionics algorithm by allowing it to monitor and feed data to simulated sensors and effectors in a digital environment. These data are then used to determine the attitude of the vehicle and a separate computer is used to interpret the data set and visualize it using a 3D graphical interface. The PHIL hardware allows the testing of the vehicles bus by providing 'real' hardware interfaces (in the case of this test a real RS422 bus) and specific components can be modeled to show their interactions with the avionics algorithm (e.g. a thruster model). For the iSAT project the PHIL is used to visualize the operating cycle of the thruster and the subsequent effect this thrusting has on the attitude of the satellite over a given period of time. The test is controlled using software running on an Andrews Space Cortex 160 flight computer. This computer is the current baseline for a full iSAT mission. While the test could be conducted with a lab computer and software, the team chose to exercise the propulsion system with a representative CubeSat-class computer. For purposes of this test, the "flight" software monitored the propulsion and PPU systems, controlled operation of the thruster, and provided thruster state data to the PHIL simulation. Commands to operate the thruster were initiated from an operator's workstation outside the vacuum chamber and passed through the Cortex 160 to exercise portions of the flight avionics. Two custom-designed pieces of electronics hardware have been designed to operate the propellant feed system. One piece of hardware is an auxiliary board that controls a latch valve, proportional flow control valves (PFCVs) and valve heaters as well as measuring pressures, temperatures and PFCV feedback voltage. An onboard FPGA provides a serial link for issuing commands and manages all lower level input-output functions. The other piece of hardware is a power distribution board, which accepts a standard bus voltage input and converts this voltage into all the different current-voltage types required to operate the auxiliary board. These electronics boards are located in the vacuum chamber near the thruster, exposing this hardware to both the vacuum and plasma environments they would encounter during a mission, with these components communicating to the flight computer through an RS-422 interface. The auxiliary board FPGA provides a 28V MOSFET switch circuit with a 20ms pulse to open or close the iodine propellant feed system latch valve. The FPGA provides a pulse width modulation (PWM) signal to a DC/DC boost converter to produce the 12-120V needed for control of the proportional flow control valve. There are eight MOSFET-switched heating circuits in the system. Heaters are 28V and located in the latch valve, PFCV, propellant tank and propellant feed lines. Both the latch valve and PFCV have thermistors built into them for temperature monitoring. There are also seven resistance temperature device (RTD) circuits on the auxiliary board that can be used to measure the propellant tank and feedline temperatures. The signals are conditioned and sent to an analog to digital converter (ADC), which is directly commanded and controlled by the FPGA.
The salient feature of a gravitationally-stabilized satellite solar power system (SSPS) for a photovoltaic system is that the large solar array is separated into smaller segments or subunits, joined together in a linear array oriented along the local vertical. Applicability of gravitational stabilization to the design of photovoltaic SSPS is demonstrated. Both actively controlled systems using multiple solar panels oriented to the sun and passively controlled systems requiring no sun orientation are considered and determined to be feasible. Expressions for gravity-gradient induced tension and restoring torques about the local vertical are assessed. Particular attention is directed to the applicability of solid-state approaches to the design of SSPS. It is shown that an all solid-state SSPS utilizing the LITOMIC (light-to-microwave conversion) concept is feasible but that a hybrid system employing a combination of both solid-state and cryogenic cooled low-voltage techniques to the design of the power management and distribution subsystem may also provide a solution.
As a critical part of the NEXT test validation process, a multiple-string integration test was performed on the NEXT propellant management system and ion thrusters. The objectives of this test were to verify that the PMS is capable of providing stable flow control to multiple thrusters operating over the NEXT system throttling range and to demonstrate to potential users that the NEXT PMS is ready for transition to flight. A test plan was developed for the sub-system integration test for verification of PMS and thruster system performance and functionality requirements. Propellant management system calibrations were checked during the single and multi-thruster testing. The low pressure assembly total flow rates to the thruster(s) were within 1.4 percent of the calibrated support equipment flow rates. The inlet pressures to the main, cathode, and neutralizer ports of Thruster PM1R were measured as the PMS operated in 1-thruster, 2-thruster, and 3-thruster configurations. It was found that the inlet pressures to Thruster PM1R for 2-thruster and 3-thruster operation as well as single thruster operation with the PMS compare very favorably indicating that flow rates to Thruster PM1R were similar in all cases. Characterizations of discharge losses, accelerator grid current, and neutralizer performance were performed as more operating thrusters were added to the PMS. There were no variations in these parameters as thrusters were throttled and single and multiple thruster operations were conducted. The propellant management system power consumption was at a fixed voltage to the DCIU and a fixed thermal throttle temperature of 75 C. The total power consumed by the PMS was 10.0, 17.9, and 25.2 W, respectively, for single, 2-thruster, and 3-thruster operation with the PMS. These sub-system integration tests of the PMS, the DCIU Simulator, and multiple thrusters addressed, in part, the NEXT PMS and propulsion system performance and functionality requirements.
Free-Piston Stirling Engines (FPSE) have the potential to provide high reliability, long life, and efficient operation. Therefore, they are excellent candidates for the dynamic power conversion module of a space-based, power-generating system. FPSE can be coupled with many potential heat sources (radioisotope, solar, or nuclear reactor), various heat input systems (pumped loop, heat pipe), heat rejection (pumped loop or heat pipe), and various power management and distribution systems (ac, dc, high or low voltage, and fixed or variable load). This paper reviews potential space missions that can be met using free-piston Stirling engines and discusses options of various system integration approaches. This paper briefly outlines the program and recent progress.
Customizable Digital Receivers for Radar Two-Camera Acquisition and Tracking of a Flying Target Visual Data Analysis for Satellites A Data Type for Efficient Representation of Other Data Types Hand-Held Ultrasonic Instrument for Reading Matrix Symbols Broadband Microstrip-to-Coplanar Strip Double-Y Balun A Topographical Lidar System for Terrain-Relative Navigation Programmable Low-Voltage Circuit Breaker and Tester Electronic Switch Arrays for Managing Microbattery Arrays Topics covered include: Lower-Dark-Current, Higher-Blue-Response CMOS Imagers; Fabricating Large-Area Sheets of Single-Layer Graphene by CVD; Support for Diagnosis of Custom Computer Hardware; Providing Goal-Based Autonomy for Commanding a Spacecraft; Dynamic Method for Identifying Collected Sample Mass; Optimal Planning and Problem-Solving; Attitude-Control Algorithm for Minimizing Maneuver Execution Errors; Grants Document-Generation System; Heat-Storage Modules Containing LiNO3 3H2O and Graphite Foam; Precipitation-Strengthened, High-Temperature, High-Force Shape Memory Alloys; Improved Relief Valve Would Be Less Susceptible to Failure; Safety Modification of Cam-and-Groove Hose Coupling; Using Composite Materials in a Cryogenic Pump; Using Electronic Noses to Detect Tumors During Neurosurgery; Producing Newborn Synchronous Mammalian Cells; Smaller, Lower-Power Fast-Neutron Scintillation Detectors; Rotationally Vibrating Electric-Field Mill; Estimating Hardness from the USDC Tool-Bit Temperature Rise; Particle-Charge Spectrometer; Automated Production of Movies on a Cluster of Computers; FIDO-Class Development Rover; and Tone-Based Command of Deep Space Probes Using Ground Antennas.