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Modeling and Analysis of Stirling Power Convertors

Modeling and Analysis of Stirling Power Convertors Luis A. Rodriguez1 Steven M. Geng, Terry V. Reid, Scott D. Wilson NASA Glenn Research Center, Cleveland, OH, 44135, USA NASA Glenn’s Thermal Energy Conversion Branch is supporting the development of the next generation free-piston Stirling power convertors. American Superconductor (AMSC) and Sunpower Inc. are the two firms under contract to develop the Flexure Isotope Stirling Convertor (FISC) and the Sunpower Robust Stirling Convertor (SRSC), respectively. To comprehend and forecast convertor performance, Sage, ANSYS® Maxwell, and ANSYS® Fluent were used to model the Stirling thermodynamic cycle, alternator electromagnetics, and piston and displacer dynamics. I. Introduction Stirling convertors are being developed by NASA as a potential steady source of electrical power for NASA’s future scientific space missions. Currently, NASA Glenn Research Center has two corporations under contract, American Superconductor (AMSC) and Sunpower Inc., for the development of the next generation of free-piston Stirling convertors for dynamic radioisotope power systems. AMSC is developing the Flexure Isotope Stirling Convertor (FISC), which uses flexures to prevent side motion and rubbing of the piston. Similarly, Sunpower Inc, is developing the Sunpower Robust Stirling Convertor (SRSC). The SRSC uses gas bearings to prevent radial contact of the moving piston. As convertor development continues, it is increasingly important to understand and predict the interactions of components in the system, how they respond to one another, and how they perform as a response to changes in operating conditions. A suitable and enlightening way to demonstrate and foresee these interactions is with the use of accurate modeling software. Sage, ANSYS® Maxwell, and ANSYS® Fluent are the current modeling tools used by NASA to analytically determine convertor performance. Sage is a one-dimensional object-oriented commercial software package used for modeling and optimizing Stirling convertors for Dynamic Radioisotope Power Systems (DRPS) and it is one of the most accurate Stirling convertor codes in use by NASA. This code is the successor to GLIMPS (Globally-Implicit Stirling Cycle Simulation) and GLOP (GLIMPS Optimization) software created by Gedeon Associates [1]. Model input parameters are typically material/gas type, component physical dimensions, temperatures, frequency, charge pressure, and number of time/space nodes. Sage is used to model both the FISC’s and SRSC’s Stirling cycle thermodynamics and piston/displacer dynamics. Performance maps were created and analyzed for both power systems to better understand the relationship between the following conditions: cold-end temperature, hot-end temperature, piston/displacer amplitudes, pressure drop, and thermal input power. The synergy between these conditions will help determine parameter sensitivity. ANSYS® Maxwell was used to create a three-dimensional (3-D) axisymmetric model for both FISC and SRSC alternators. The significant physical components included in each model are the magnets, magnet carrier, outer/inner laminations, and the coil. Inputs to the model are piston amplitude, piston frequency, alternator load, coil resistance, tuning capacitance, and specific material properties. The alternator models calculate terminal voltage, current, piston/current phase, voltage/current phase, coil inductance, terminal power and efficiency. The RI2 losses, core (hysteresis and eddy) losses, and magnet/can eddy losses are also a part of the final results. ANSYS® Fluent is used to build 3-D computational fluid dynamic (CFD) models to examine the Stirling cycle thermodynamics for both the FISC and SRSC systems. Three-dimensional Computer Aided Design (CAD) models were used to create the physical components of each convertor. Steady-state simulations were conducted for hardware testing, prediction of environmental losses during testing, and generation of radiation look-up tables. The model inputs to the aforementioned analysis are the material properties and boundary thermal conditions. The steady-state model calculates temperature and heat flow distributions. Transient 3-D calculations were also part of the CFD analysis. In this study a physically reduced version of the FISC is used to obtain a prediction of available engine power. For the gas bearing SRSC, the transient effort is used to obtain a prediction of bearing pad performance and its sensitivity to micro-channel geometric variation. The model inputs to the transient simulations are the piston amplitude, displacer amplitude, frequency, displacer/piston phase angle, dynamic deforming CFD grid, temperature boundary conditions, and user defined files describing motion profile of piston/displacer. The results of the model are temperature distributions, heat distributions, and PV power produced at pre-determined conditions.

Luis A Rodriguez↗

NASA NTRS2006

Automated design of spacecraft systems power subsystems

This paper discusses the application of evolutionary computing to a dynamic space vehicle power subsystem resource and performance simulation in a parallel processing environment. Our objective is to demonstrate the feasibility, application and advantage of using evolutionary computation techniques for the early design search and optimization of space systems.

optimzation space designs↗

NASA NTRS2007

SRG110 Stirling Generator Dynamic Simulator Vibration Test Results and Analysis Correlation

The U.S. Department of Energy (DOE), Lockheed Martin (LM), and NASA Glenn Research Center (GRC) have been developing the Stirling Radioisotope Generator (SRG110) for use as a power system for space science missions. The launch environment enveloping potential missions results in a random input spectrum that is significantly higher than historical radioisotope power system (RPS) launch levels and is a challenge for designers. Analysis presented in prior work predicted that tailoring the compliance at the generator-spacecraft interface reduced the dynamic response of the system thereby allowing higher launch load input levels and expanding the range of potential generator missions. To confirm analytical predictions, a dynamic simulator representing the generator structure, Stirling convertors and heat sources were designed and built for testing with and without a compliant interface. Finite element analysis was performed to guide the generator simulator and compliant interface design so that test modes and frequencies were representative of the SRG110 generator. This paper presents the dynamic simulator design, the test setup and methodology, test article modes and frequencies and dynamic responses, and post-test analysis results. With the compliant interface, component responses to an input environment exceeding the SRG110 qualification level spectrum were all within design allowables. Post-test analysis included finite element model tuning to match test frequencies and random response analysis using the test input spectrum. Analytical results were in good overall agreement with the test results and confirmed previous predictions that the SRG110 power system may be considered for a broad range of potential missions, including those with demanding launch environments.

Lewandowski, Edward J.↗

NASA NTRS2014

Propulsion Electric Grid Simulator (PEGS) for Future Turboelectric Distributed Propulsion Aircraft

NASA Glenn Research Center, in collaboration with the aerospace industry and academia, has begun the development of technology for a future hybrid-wing body electric airplane with a turboelectric distributed propulsion (TeDP) system. It is essential to design a subscale system to emulate the TeDP power grid, which would enable rapid analysis and demonstration of the proof-of-concept of the TeDP electrical system. This paper describes how small electrical machines with their controllers can emulate all the components in a TeDP power train. The whole system model in Matlab/Simulink was first developed and tested in simulation, and the simulation results showed that system dynamic characteristics could be implemented by using the closed-loop control of the electric motor drive systems. Then we designed a subscale experimental system to emulate the entire power system from the turbine engine to the propulsive fans. Firstly, we built a system to emulate a gas turbine engine driving a generator, consisting of two permanent magnet (PM) motors with brushless motor drives, coupled by a shaft. We programmed the first motor and its drive to mimic the speed-torque characteristic of the gas turbine engine, while the second motor and drive act as a generator and produce a torque load on the first motor. Secondly, we built another system of two PM motors and drives to emulate a motor driving a propulsive fan. We programmed the first motor and drive to emulate a wound-rotor synchronous motor. The propulsive fan was emulated by implementing fan maps and flight conditions into the fourth motor and drive, which produce a torque load on the driving motor. The stator of each PM motor is designed to travel axially to change the coupling between rotor and stator. This feature allows the PM motor to more closely emulate a wound-rotor synchronous machine. These techniques can convert the plain motor system into a unique TeDP power grid emulator that enables real-time simulation performance using hardware-in-the-loop (HIL).

electric power grid emulator↗

NASA NTRS1974

Time response simulation of the 1975 Viking Orbiter digital tape recorder

The objective of the present study was to verify and understand in depth the performance of the speed control (frequency loop) servo of the 1975 Viking Orbiter (VO75) digital tape recorder (DTR). The time response method employed is written in the continuous system simulation language (CSSL) for the Univac 1108 computer system. In order to demonstrate the power and flexibility of the graphic interactive simulation program, four aspects of system dynamics are interactively adjusted to arrive at a number of stable system configurations that have significantly different tape transport and/or summing amplifier gain, larger static/dynamic Coulomb friction, and different system lag than envisioned in the nominal design by linear methods. Work is currently underway to derive a new higher-order DST transfer function and to simulate the servo using state-space variable techniques.

Mukhopadhyay, A. K.↗

NASA NTRS2015

Integrated Vehicle and Trajectory Design of Small Spacecraft with Electric Propulsion for Earth and Interplanetary Missions

This paper investigates the feasibility of Earth-transfer and interplanetary mission architectures for miniaturized spacecraft using emerging small solar electric propulsion technologies. Emerging small SEP thrusters offer significant advantages relative to existing technologies and will enable U-class systems to perform trajectory maneuvers with significant Delta V requirements. The approach in this paper is unique because it integrates trajectory design with vehicle sizing and accounts for the system and operational constraints of small U-class missions. The modeling framework includes integrated propulsion, orbit, energy, and external environment dynamics and systems-level power, energy, mass, and volume constraints. The trajectory simulation environment models orbit boosts in Earth orbit and flyby and capture trajectories to interplanetary destinations. A family of small spacecraft mission architectures are studied, including altitude and inclination transfers in Earth orbit and trajectories that escape Earth orbit and travel to interplanetary destinations such as Mercury, Venus, and Mars. Results are presented visually to show the trade-offs between competing performance objectives such as maximizing available mass and volume for payloads and minimizing transfer time. The results demonstrate the feasibility of using small spacecraft to perform significant Earth and interplanetary orbit transfers in less than one year with reasonable U-class mass, power, volume, and mission durations.

Spangelo, Sara↗

NASA NTRS2006

SRG110 Stirling Generator Dynamic Simulator Vibration Test Results and Analysis Correlation

The U.S. Department of Energy (DOE), Lockheed Martin (LM), and NASA Glenn Research Center (GRC) have been developing the Stirling Radioisotope Generator (SRG110) for use as a power system for space science missions. The launch environment enveloping potential missions results in a random input spectrum that is significantly higher than historical RPS launch levels and is a challenge for designers. Analysis presented in prior work predicted that tailoring the compliance at the generator-spacecraft interface reduced the dynamic response of the system thereby allowing higher launch load input levels and expanding the range of potential generator missions. To confirm analytical predictions, a dynamic simulator representing the generator structure, Stirling convertors and heat sources was designed and built for testing with and without a compliant interface. Finite element analysis was performed to guide the generator simulator and compliant interface design so that test modes and frequencies were representative of the SRG110 generator. This paper presents the dynamic simulator design, the test setup and methodology, test article modes and frequencies and dynamic responses, and post-test analysis results. With the compliant interface, component responses to an input environment exceeding the SRG110 qualification level spectrum were all within design allowables. Post-test analysis included finite element model tuning to match test frequencies and random response analysis using the test input spectrum. Analytical results were in good overall agreement with the test results and confirmed previous predictions that the SRG110 power system may be considered for a broad range of potential missions, including those with demanding launch environments.

Suarez, Vicente J.↗

NASA NTRS1999

Hybrid Modeling for Testing Intelligent Software for Lunar-Mars Closed Life Support

Intelligent software is being developed for closed life support systems with biological components, for human exploration of the Moon and Mars. The intelligent software functions include planning/scheduling, reactive discrete control and sequencing, management of continuous control, and fault detection, diagnosis, and management of failures and errors. Four types of modeling information have been essential to system modeling and simulation to develop and test the software and to provide operational model-based what-if analyses: discrete component operational and failure modes; continuous dynamic performance within component modes, modeled qualitatively or quantitatively; configuration of flows and power among components in the system; and operations activities and scenarios. CONFIG, a multi-purpose discrete event simulation tool that integrates all four types of models for use throughout the engineering and operations life cycle, has been used to model components and systems involved in the production and transfer of oxygen and carbon dioxide in a plant-growth chamber and between that chamber and a habitation chamber with physicochemical systems for gas processing.

Malin, Jane T.↗

NASA NTRS2012

Design and Test Plans for a Non-Nuclear Fission Power System Technology Demonstration Unit

A joint National Aeronautics and Space Administration (NASA) and Department of Energy (DOE) team is developing concepts and technologies for affordable nuclear Fission Power Systems (FPSs) to support future exploration missions. A key deliverable is the Technology Demonstration Unit (TDU). The TDU will assemble the major elements of a notional FPS with a non-nuclear reactor simulator (Rx Sim) and demonstrate system-level performance in thermal vacuum. The Rx Sim includes an electrical resistance heat source and a liquid metal heat transport loop that simulates the reactor thermal interface and expected dynamic response. A power conversion unit (PCU) generates electric power utilizing the liquid metal heat source and rejects waste heat to a heat rejection system (HRS). The HRS includes a pumped water heat removal loop coupled to radiator panels suspended in the thermal-vacuum facility. The basic test plan is to subject the system to realistic operating conditions and gather data to evaluate performance sensitivity, control stability, and response characteristics. Upon completion of the testing, the technology is expected to satisfy the requirements for Technology Readiness Level 6 (System Demonstration in an Operational and Relevant Environment) based on the use of high-fidelity hardware and prototypic software tested under realistic conditions and correlated with analytical predictions.

Mason, Lee↗

NASA NTRS2009

Design and Sizing of the Air Revitalization System for Altair Lunar Lander

Designing closed-loop Air Revitalization Systems (ARS) for human spaceflight applications requires a delicate balance between designing for system robustness while minimizing system power and mass requirements. This presentation will discuss the design of the ARS for the Altair Lunar Lander. The presentation will illustrate how dynamic simulations, using Aspen Custom Modeler, were used to develop a system configuration with the ability to control atmospheric conditions under a wide variety of circumstances while minimizing system mass/volume and the impact on overall power requirements for the Lander architecture.

Allada, Rama Kumar↗

NASA NTRS1995

elVis: An Interactive System For Visualization of Unsteady Fluid Flow

ElVis is a prototype system with allows for the interactive visualization of unsteady fluid flow. The increasing computational power applied to fluid dynamics simulations presents the enormous challenge to the visualization system designer to apply a wide range of technologies to the analysis process with ever increasing demands on performance. Visualization of the results of unsteady fluid flow simulations presents the challenge of exploring very large and complex data sets. Since exploration is a trial and error process, it is of utmost importance that the time required to execute a trial (i.e., create a visualization) be at a minimum in order to provide real time interaction.

Gerald-Yamasaki, Michael↗

NASA NTRS1997

Dynamics of Numerics & Spurious Behaviors in CFD Computations

The global nonlinear behavior of finite discretizations for constant time steps and fixed or adaptive grid spacings is studied using tools from dynamical systems theory. Detailed analysis of commonly used temporal and spatial discretizations for simple model problems is presented. The role of dynamics in the understanding of long time behavior of numerical integration and the nonlinear stability, convergence, and reliability of using time-marching approaches for obtaining steady-state numerical solutions in computational fluid dynamics (CFD) is explored. The study is complemented with examples of spurious behavior observed in steady and unsteady CFD computations. The CFD examples were chosen to illustrate non-apparent spurious behavior that was difficult to detect without extensive grid and temporal refinement studies and some knowledge from dynamical systems theory. Studies revealed the various possible dangers of misinterpreting numerical simulation of realistic complex flows that are constrained by available computing power. In large scale computations where the physics of the problem under study is not well understood and numerical simulations are the only viable means of solution, extreme care must be taken in both computation and interpretation of the numerical data. The goal of this paper is to explore the important role that dynamical systems theory can play in the understanding of the global nonlinear behavior of numerical algorithms and to aid the identification of the sources of numerical uncertainties in CFD.

Yee, Helen C.↗

NASA NTRS2010

Life Support with Failures and Variable Supply

The life support system for long duration missions will recycle oxygen and water to reduce the material resupply mass from Earth. The impact of life support failures was investigated by dynamic simulation of a lunar outpost habitat life support model. The model was modified to simulate resupply delays, power failures, recycling system failures, and storage failures. Many failures impact the lunar outpost water supply directly or indirectly, depending on the water balance and water storage. Failure effects on the water supply are reduced if Extra Vehicular Activity (EVA) water use is low and the water supply is ample. Additional oxygen can be supplied by scavenging unused propellant or by production from regolith, but the amounts obtained can vary significantly. The requirements for oxygen and water can also vary significantly, especially for EVA. Providing storage buffers can improve efficiency and reliability, and minimize the chance of supply failing to meet demand. Life support failures and supply variations can be survivable if effective solutions are provided by the system design

Jones, Harry↗

NASA NTRS1990

An expert system for simulating electric loads aboard Space Station Freedom

Space Station Freedom will provide an infrastructure for space experimentation. This environment will feature regulated access to any resources required by an experiment. Automated systems are being developed to manage the electric power so that researchers can have the flexibility to modify their experiment plan for contingencies or for new opportunities. To define these flexible power management characteristics for Space Station Freedom, a simulation is required that captures the dynamic nature of space experimentation; namely, an investigator is allowed to restructure his experiment and to modify its execution. This changes the energy demands for the investigator's range of options. An expert system competent in the domain of cryogenic fluid management experimentation was developed. It will be used to help design and test automated power scheduling software for Freedom's electric power system. The expert system allows experiment planning and experiment simulation. The former evaluates experimental alternatives and offers advice on the details of the experiment's design. The latter provides a real-time simulation of the experiment replete with appropriate resource consumption.

Kukich, George↗

NASA NTRS1990

An expert system for simulating electric loads aboard Space Station Freedom

Space Station Freedom will provide an infrastructure for space experimentation. This environment will feature regulated access to any resources required by an experiment. Automated systems are being developed to manage the electric power so that researchers can have the flexibility to modify their experiment plan for contingencies or for new opportunities. To define these flexible power management characteristics for Space Station Freedom, a simulation is required that captures the dynamic nature of space experimentation; namely, an investigator is allowed to restructure his experiment and to modify its execution. This changes the energy demands for the investigator's range of options. An expert system competent in the domain of cryogenic fluid management experimentation, was developed. It will be used to help design and test automated power scheduling software for Freedom's electric power system. The expert system allows experiment planning and experiment simulation. The former evaluates experimental alternatives and offers advice on the details of the experiment's design. The latter provides a real-time simulation of the experiment replete with appropriate resource consumption.

Kukich, George↗

NASA NTRS2010

General Pressurization Model in Simscape

System integration is an essential part of the engineering design process. The Ares I Upper Stage (US) is a complex system which is made up of thousands of components assembled into subsystems including a J2-X engine, liquid hydrogen (LH2) and liquid oxygen (LO2) tanks, avionics, thrust vector control, motors, etc. System integration is the task of connecting together all of the subsystems into one large system. To ensure that all the components will "fit together" as well as safety and, quality, integration analysis is required. Integration analysis verifies that, as an integrated system, the system will behave as designed. Models that represent the actual subsystems are built for more comprehensive analysis. Matlab has been an instrument widely use by engineers to construct mathematical models of systems. Simulink, one of the tools offered by Matlab, provides multi-domain graphical environment to simulate and design time-varying systems. Simulink is a powerful tool to analyze the dynamic behavior of systems over time. Furthermore, Simscape, a tool provided by Simulink, allows users to model physical (such as mechanical, thermal and hydraulic) systems using physical networks. Using Simscape, a model representing an inflow of gas to a pressurized tank was created where the temperature and pressure of the tank are measured over time to show the behavior of the gas. By further incorporation of Simscape into model building, the full potential of this software can be discovered and it hopefully can become a more utilized tool.

Servin, Mario↗

NASA NTRS1999

800 Hours of Operational Experience from a 2 kW(sub e) Solar Dynamic System

From December 1994 to September 1998, testing with a 2 kW(sub e) Solar Dynamic power system resulted in 33 individual tests, 886 hours of solar heating, and 783 hours of power generation. Power generation ranged from 400 watts to over 2 kW(sub e), and SD system efficiencies have been measured up to 17 per cent, during simulated low-Earth orbit operation. Further, the turbo-alternator-compressors successfully completed 100 start/stops on foil bearings. Operation was conducted in a large thermal/vacuum facility with a simulated Sun at the NASA Lewis Research Center. The Solar Dynamic system featured a closed Brayton conversion unit integrated with a solar heat receiver, which included thermal energy storage for continuous power output through a typical low-Earth orbit. Two power conversion units and three alternator configurations were used during testing. This paper will review the test program, provide operational and performance data, and review a number of technology issues.

Shaltens, Richard K.↗

NASA NTRS1988

A simulation model for reliability evaluation of Space Station power systems

A detailed simulation model for the hybrid Space Station power system is presented which allows photovoltaic and solar dynamic power sources to be mixed in varying proportions. The model considers the dependence of reliability and storage characteristics during the sun and eclipse periods, and makes it possible to model the charging and discharging of the energy storage modules in a relatively accurate manner on a continuous basis.

Singh, C.↗