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At least 361 records · Page 20

Design Evolution of the Wide Field Infrared Survey Telescope Using Astrophysics Focused Telescope Assets (WFIRST-AFTA) and Lessons Learned

The design of the Wide Field Infrared Survey Telescope using Astrophysics Focused Telescope Assets (WFIRST-AFTA) continues to evolve as each design cycle is analyzed. In 2012, two Hubble sized (2.4 m diameter) telescopes were donated to NASA from elsewhere in the Federal Government. NASA began investigating potential uses for these telescopes and identified WFIRST as a mission to benefit from these assets. With an updated, deeper, and sharper field of view than previous design iterations with a smaller telescope, the optical designs of the WFIRST instruments were updated and the mechanical and thermal designs evolved around the new optical layout. Beginning with Design Cycle 3, significant analysis efforts yielded a design and model that could be evaluated for Structural-Thermal-Optical-Performance (STOP) purposes for the Wide Field Imager (WFI) and provided the basis for evaluating the high level observatory requirements. Development of the Cycle 3 thermal model provided some valuable analysis lessons learned and established best practices for future design cycles. However, the Cycle 3 design did include some major liens and evolving requirements which were addressed in the Cycle 4 Design. Some of the design changes are driven by requirements changes, while others are optimizations or solutions to liens from previous cycles. Again in Cycle 4, STOP analysis was performed and further insights into the overall design were gained leading to the Cycle 5 design effort currently underway. This paper seeks to capture the thermal design evolution, with focus on major design drivers, key decisions and their rationale, and lessons learned as the design evolved.

WFIRST↗

Thermal Protection Design for Uranus Orbiter Flagship Mission: Probes and Aerocapture

Introduction: The Decadal Strategy for Plane-tary Science and Astrobiology prioritized a Uranus Orbiter and Probe (UOP) as the highest-priority new Flagship mission for the 2023 – 2032 decade. Missions to the outer solar system require significant interplanetary cruise durations on the order of 12 – 15 years while carrying propellant to reduce velocity by several km/s to achieve a desired orbit. Parasitic mass and travel time can be traded where faster arrival velocities require more mass expensive capture burns. Recent advancements in Thermal Protection Systems (TPS) for planetary entry enable mass-efficient designs for atmospheric probes and missions that apply aerocapture for orbit insertion.

Uranus TPS Aerocapture Probe↗

Multiscale Electrothermal Design of a Modular Multilevel Converter for Grid-Tied Applications

As a key feature of modular multilevel converters (MMCs), a large number of semiconductor devices are employed in the converter and distributed over a stack of submodules. Each submodule has a strict temperature limit that imposes constraints on the operating range of the converter. Different loading conditions/losses in the submodules lead to unavoidable temperature variations inside the MMC, which consequently affect the system-level performance and reliability. This paper is focused on the electrothermal analysis and design of a medium-voltage silicon carbide (SiC)-based MMC system, from submodule power semiconductors to the overall MMC system integration of multiple submodules. Loss calculations are performed to estimate the cooling requirements and aid thermal design at different levels. The performance of forced-air cooling approach is analyzed within a numerical modeling framework. Maximum temperature of the SiC power modules is predicted using numerical tools. Thermal design of the MMC cabinet with various arrangement of air inlet(s) and outlet(s) is investigated and compared from a cooling performance perspective.

CFD↗

Optimization of thermal systems with sensitive optics, electronics, and structures

A strategy was investigated by which thermal designers for spacecraft could devise an optimal thermal control system to maintain the required temperatures, temperature differences, changes in temperature, and changes in temperature differences for specified equipment and elements of the spacecraft's structure. Thermal control is to be maintained by the coating pattern chosen for the external surfaces and heaters chosen to supplement the coatings. The approach is to minimize the thermal control power, thereby minimizing the weight of the thermal control system. Because there are so many complex computations involved in determining the optimal coating design a computerized approach was contemplated. An optimization strategy including all the elements considered by the thermal designer for use in the early stages of design, where impact on the mission is greatest, and a plan for implementing the strategy were successfully developed. How the optimization process may be used to optimize the design of the Space Telescope as a test case is demonstrated.

Bettini, R. G.↗

Cooling Design and Thermal Analysis for Thermal Shields of a Cryocooler-Cooled Superconducting ECR Ion Source MARS-D Magnet

Here, a demonstrative NbTi based Mixed Axial and Radial field System (MARS-D) is being developed for a next-Generation Electron Cyclotron Resonance Ion Source (ECRIS) at Lawrence Berkeley National Laboratory (LBL), which employs a novel closed-loop coil design scheme that more efficiently utilizes conductor fields and extend the application of NbTi for high frequency (up to 45 GHz) ECR operation. The NbTi MARS-D magnet consists of a single hexagonally shaped closed-loop coil and a set of auxiliary solenoids. A cryostat for cooling the MARS-D magnet is under design at LBL. The MARS-D magnet working around 4.2 K will be bath-cooled in liquid helium using multiple two-stage cryocoolers. An intermediate temperature thermal radiation shield is adopted to reduce the heat leakage imposed on 4.2 K coil cold mass from room temperature. The thermal shield is conduction-cooled by the first-stage cold heads of four two-stage cryocoolers and the cold head of a single-stage cryocooler shared with nine binary leads. The temperature in the area of the shield that warm ends of HTS leads are mounted on is expected no higher than 60 K, which is limited by maximum allowable working temperature of HTS leads. The paper presents thermal analysis on the thermal radiation shield including heat loads and effects of eddy current induced during quench on its material selection.

ECRIS↗

Spacecraft heat transfer analysis

Two somewhat related but yet distinct topics are presented below. First, some of our thoughts, at the Jet Propulsion Laboratory, on the position of computing as a tool for developing the thermal design of a spacecraft are given. The purpose in doing, this is to stimulate discussion on the subject of the computer by presenting one approach to how computing might fit into thermal design. Second, a new general type heat transfer program that was recently acquired from Arthur D. Little, Inc. is briefly described. The program, is called, "The Method of Zones for the Calculation of Temperature Distribution".

SPACECRAFT DESIGN↗

SIM PlanetQuest: Mili-Kelvin Analysis of the Collector Sub-system Thermal Model

Space Interferometry Mission (SIM) PlanetQuest is part of the NASA Astronomical Search for Origins (ASO) program. It will use a Michelson Interferometer to locate extrasolar planets, among other objectives. The spacecraft's subsystems, temperature requirements, and thermal control approach are discussed. The current SIM thermal design is analyzed using a Milli-Kelvin approach and appears to meet temperature stability requirements on the OOPCC optic. SIM absolute temperature requirements are met through the robustness of the thermal design (i.e., PIC control).

PlanetQuest↗

Multiscale Electrothermal Design of a Modular Multilevel Converter for Medium-Voltage Grid-Tied Applications

As a key feature of modular multilevel converters (MMCs), a large number of semiconductor devices are employed in the converter and distributed over a stack of submodules. Each submodule has a strict temperature limit that imposes constraints on the operating range of the converter. Different loading conditions/losses in the submodules lead to unavoidable temperature variations inside the MMC, which consequently affect the system-level performance and reliability. This paper is focused on the electrothermal analysis and design of a medium-voltage silicon carbide (SiC)-based MMC system, from submodule power semiconductors to the overall MMC system integration of multiple submodules, for grid-connected applications. Loss calculations are performed to estimate the cooling requirements and aid thermal design at different levels. The performance of a forced-air cooling approach is analyzed within a numerical modeling framework. Maximum temperature of the SiC power modules is predicted using numerical tools. Thermal design of the MMC cabinet with various arrangements of air inlet(s) and outlet(s) is investigated and compared from a cooling performance perspective. A fully resolved model of the arrangement that yields optimal results is developed to accurately predict the temperature profile of the essential components in the submodules.

computational fluid dynamics↗

Thermal-structural Design Study of an Airframe-integrated Scramjet

Design concepts for the cooled structures assembly for the Langley Scramjet engine, for engine subsystems, and for the aircraft/engine interface were developed and evaluated. Results show that the objectives for the Scramjet engine can be met. A thermal protection system was defined that makes it possible to attain a life of 100 hours and 1000 cycles, which is the specified goal. With stoichiometric combustion, the fuel provides an adequate heat sink for cooling the engine at Mach numbers up to 9 at the minimum fuel flow condition. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six-module engine, the mass per unit capture area is 1328 kg/sq m (259 lb/sq ft). The total mass of a six-module engine assembly including the fuel system is 1577 kg (3477 lb).

Buchmann, O. A.↗

Parametric Study of Variable Emissivity Radiator Surfaces

The goal of spacecraft thermal design is to accommodate a high function satellite in a low weight and real estate package. The extreme environments that the satellite is exposed during its orbit are handled using passive and active control techniques. Heritage passive heat rejection designs are sized for the hot conditions and augmented for the cold end with heaters. The active heat rejection designs to date are heavy, expensive and/or complex. Incorporating an active radiator into the design that is lighter, cheaper and more simplistic will allow designers to meet the previously stated goal of thermal spacecraft design Varying the radiator's surface properties without changing the radiating area (as with VCHP), or changing the radiators' views (traditional louvers) is the objective of the variable emissivity (vary-e) radiator technologies. A parametric evaluation of the thermal performance of three such technologies is documented in this paper. Comparisons of the Micro-Electromechanical Systems (MEMS), Electrochromics, and Electrophoretics radiators to conventional radiators, both passive and active are quantified herein. With some noted limitations, the vary-e radiator surfaces provide significant advantages over traditional radiators and a promising alternative design technique for future spacecraft thermal systems.

Grob, Lisa M.↗

Fuel Heating System Design and Thermal Modeling for Aviation Combustion Research

Aviation fuels offer substantial heat-sink capability that can be applied to aircraft thermal-management strategies and advanced propulsion-system concepts. Accurate control of fuel temperature is critical for understanding combustion behavior and supporting high temperature fuel experimental studies. This work describes the modeling and experimental validation of a portable, high temperature fuel-conditioning system designed for multiple NASA Glenn Research Center’s combustion facilities. The system utilizes a circulating-oil heating unit and modular tube-in-tube heat exchangers capable of conditioning Jet-A to temperatures approaching 600 K. A Thermal Desktop model was created to analyze heat exchanger configurations and predict performance across a range of operating conditions. Model predictions were compared with measurements collected in the CE-13C test facility, showing good agreement across the tested flow range except at low fuel flow rate around 2 kg/hr. Results provide guidance for sizing future fuel heating system for combustion research applications.

Jet fuel heating system↗

Design of thermal protection system for 8 foot HTST combustor

The combustor in the 8-foot high temperature structures tunnel at the NASA-Langley Research Center has encountered cracking over a period of 50-250 tunnel tests within a limited range of the required operating envelope. A program was conducted which analyzed the failed combustor liner hardware and determined that the mechanism of failure was vibratory fatigue. A vibration damper system using wave springs located axially between the liner T-bar and the liner support was designed as an intermediate solution to extend the life of the current two-pass regenerative air-cooled liner. The effects of liner wall thickness, cooling air passage height, stiffener ring geometry, reflective coatings, and liner material selection were investigated for these designs. Preliminary layout design arrangements including the external water-cooling system requirements, weight estimates, installation requirements and preliminary estimates of manufacturing costs were prepared for the most promissing configurations. A state-of-the-art review of thermal barrier coatings and an evaluation of reflective coatings for the gasside surface of air-cooled liners are included.

Moskowitz, S.↗

Studying the effect of the upper internal structure design on thermal stratification in sodium fast reactors

Thermal stratification and mixing in large reactor pools can pose significant issues with regard to operation and safety of nuclear plants. While significant work has been done in this area on light water reactors it is more critical for sodium reactors and there is far less data with regard to low Prandtl number fluids. Here this paper focuses on the effect of the upper internal structure on the formation of thermal stratification in a scaled sodium fast reactor upper plenum. Six different upper internal structure configurations were tested to observe the effect on thermal stratification. The degree of stratification was quantified using the stratification number. Each configuration was tested from low to high flow rates at a temperature difference of 50 and 100 °C. Over this broad array of testing, it was observed that higher flow rates, more porosity in the upper internal structure design, and a smaller temperature difference yielded a lower degree of stratification. This information can be used to aid in the design of the upper internal structure in a sodium fast reactor. Furthermore, this high resolved temperature data can be used to verify models under prototypic low Prandtl numbers.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Select Variables Affecting Thermal System Design of a Liquid-Cooled Stator

NASA Glenn Researchers have endeavored to create a high-power-density, efficient electric motor called the High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power. These aggressive goals were set because increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing electrified aircraft (EA) to commercial realization. Resistive losses in the stator windings are by far the largest (34%) contributor to this design’s total energy losses. Previous testing of a HEMM-like stator test article (statorette) showed good agreement between measured performance and model predictions. Therefore, a foundation was provided to test other engineering parameters that are encountered when designing an electric machine. Of particular interest are the effects of changes to the thickness of the epoxy from the potting process, changes in the fluid volume/flow path around the end windings, and changes in the viscosity of the cooling fluid on the overall thermal performance of the unit. The impact of those parameters as revealed through a third-generation build, test, and finite element model analysis of a statorette test section is the focus of this paper.

EAP↗

Lessons Learned from the Wide Field Camera 3 TV1 and TV2 Thermal Vacuum Test Campaigns

The Wide Field Camera 3 (WFC3) instrument has undergone two complete thermal vacuum tests (TV1 and TV2), during which valuable lessons were learned regarding test configuration, test execution, model capabilities, and modeling practices. The very complex thermal design of WFC3 produced a number of challenging aspects to ground testing with numerous ThermoElectric Coolers and heat pipes, not all of which were functional. Lessons learned during TV1 resulted in significant upgrades to the model capabilities and a change in the test environment approach for TV2. These upgrades proved invaluable during TV2 when pretest modeling assumptions proved to be false. Each of the lessons learned relate to one of two following broad statements: 1. Ensure the design can be tested and that the effect of non-flight like conditions is well understood, particularly with respect to non passive devices (TECs, Heat Pipes, etc) 2. Ensure that the model is sufficiently detailed and is capable of predicting off-nominal behavior and the power dissipation of any thermal devices, especially TECs This paper outlines a number of the lessons learned over these two test campaigns with respect to the thermal design, model, and test configuration and presents recommendations for future tests.

Peabody, Hume↗

How Engineers Negotiate Domain Boundaries in a Complex, Interdisciplinary Engineering Project

Engineering educators have an essential role in preparing engineers to work in a complex, interdisciplinary workforce. While much engineering education focuses on teaching students to develop disciplinary expertise in specific engineering domains, there is a strong need to teach engineers about the knowledge that they develop or use in their work (Bucciarelli 1994, Allenby Sarewitz, 2011; Frodeman, 2013). The purpose of this research is to gain a better understanding of the knowledge systems of practicing engineers through observations of their practices such that the insights learned can guide future education efforts. Using an example from a complex and interdisciplinary engineering project, this paper presents a case study overviewing the types of epistemological (or knowledge-acquiring or using) complexities that engineers navigate. Specifically, we looked at a discussion of the thermal design of a CubeSat that occurred during an engineering review at NASA. We analyzed the review using a framework that we call 'peak events', or pointed discussions between reviewers, project engineers, and managers. We examined the dialog within peak events to identify the ways that knowledge was brought to bear, highlighting discussions of uncertainty and the boundaries of knowledge claims. We focus on one example discussion surrounding the thermal design of the CubeSat, which provides a particularly thorough example of a knowledge system since the engineers present explained, justified, negotiated, and defended knowledge within a social setting. Engineering students do not get much practice or instruction in explicitly negotiating knowledge systems and epistemic standards in this way. We highlight issues that should matter to engineering educators, such as the need to discuss what level of uncertainty is sufficient and the need to negotiate boundaries of system responsibility. Although this analysis is limited to a single discussion or 'peak event', our case shows that this type of discussion can occur in engineering and suggests that it could be important for future engineering education research.

ethnography↗

Heat transfer computer programs

On May 7, 1964, at the invitation of Dr. Raymond L. Bisplinghoff, Associate Administrator for Advanced Research and Technology, a confer­ence was held in NASA Headquarters, on the subject "Heat Transfer Computer Programs." The conference was one of several held in Headquarters during the first half of 1964 for review and planning of NASA's research program on space vehicle thermal radiation and temperature control. The conference brought about a useful interchange of information between the NASA Centers, including JPL, on computer programs which had been developed for the thermal design of spacecraft. The conferees concluded that in addition to our annual conference in this area, a useful con­tinuing exchange of information could be through the establishment of a quarterly newsletter issued from Headquarters describing, current efforts. Such a newsletter, on heat transfer. computer programs, has been established and it is hope that the publication of the present proceedings will be a further milestone in advancing the technology of using electronic computers as a tool in the thermal design of space vehicles. The present volume includes all of the formal presentations made by staff members of the various NASA Centers. Their cooperation, which led to a highly successful conference, is greatly appreciated.

SATELLITE↗

Sodium Ion Expansion Power Block for Distributed CSP

The Sodium Ion Expansion Power Block for Distributed CSP was a three-plus-one-year effort under the Concentrating Solar Power: Advanced Projects Offering Low LCOE Opportunities (CSP: APOLLO) funding program within the U.S. Department of Energy Solar Energy Technologies Office. The primary objective of this project is to develop a dual-stage modular sodium thermal electrochemical converter (Na-TEC) heat engine power block, which can be potentially integrated with either a small-scale dish solar or large-scale heliostats and parabolic trough CSP. Na-TEC is a heat engine that generates electricity through the isothermal expansion of sodium ions. The Na-TEC is a closed system that can theoretically achieve conversion efficiencies above 45% when operating between thermal reservoirs at 1150 K and 550 K. However, thermal designs have confined previous single-stage devices to thermal efficiencies below 20%. To mitigate some of these limitations, we consider dividing the isothermal expansion into two stages; one at the evaporator temperature (1150 K) and another at an intermediate temperature (650 K –1050 K). This dual-stage Na-TEC takes advantage of regeneration and reheating, and could be amenable to better thermal management. In light of this, we first designed and developed a thermo-electrochemical model, and thermodynamically demonstrated how the dual-stage device can improve the efficiency by up to 8% points over the best performing single-stage device. We also established an application regime map for the single- and dual-stage Na-TEC in terms of the power density and the total thermal parasitic loss. Moreover, a thermal design of an axisymmetric dual-stage Na-TEC is developed to guide the scale-up and fabrication of sub-components of prototype module. A reduced-order finite-element model is used in conjunction with a Na-TEC thermodynamic model that was developed to determine the total parasitic heat loss of this dual-stage design. A number of simplifications are applied in the reduced-order model to decrease the computational time while maintaining acceptable accuracy. According to this analysis, a maximum efficiency of 29% and a maximum power output of 125 W can be achieved. Ultimately, we were able to demonstrate thermal efficiency improvements of the Na-TEC heat engine from 19% up to 40.3%, in a dual-stage (non-optimized) prototype module that we designed, fabricated, and tested with high temperature stage at 923 K. Furthermore, a cost-performance analysis for this improved dual-stage design was carried out for distributed-CSP systems. A high-level techno-economic analysis (TEA) explores four scenarios where a Na-TEC is used as the heat engine for a distributed-CSP system. Overnight capital cost and levelized cost of electricity (LCOE) are estimated for a system lifetime of 30 years, revealing that overnight capital costs in a range from $3.57 to $17.71 per We are feasible, which equate to LCOEs from 6.9 to 17.2 cents/kWh e -1 . This analysis makes a significant contribution by concurrently quantifying the efficiency and unit costs for a range of multistage configurations, and demonstrating that a Na-TEC may be a promising alternative to Stirling engines for distributed-CSP systems at residential scale of 1–5 kW e .

14 SOLAR ENERGY↗