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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↗

Developing Information Power Grid Based Algorithms and Software

This was an exploratory study to enhance our understanding of problems involved in developing large scale applications in a heterogeneous distributed environment. It is likely that the large scale applications of the future will be built by coupling specialized computational modules together. For example, efforts now exist to couple ocean and atmospheric prediction codes to simulate a more complete climate system. These two applications differ in many respects. They have different grids, the data is in different unit systems and the algorithms for inte,-rating in time are different. In addition the code for each application is likely to have been developed on different architectures and tend to have poor performance when run on an architecture for which the code was not designed, if it runs at all. Architectural differences may also induce differences in data representation which effect precision and convergence criteria as well as data transfer issues. In order to couple such dissimilar codes some form of translation must be present. This translation should be able to handle interpolation from one grid to another as well as construction of the correct data field in the correct units from available data. Even if a code is to be developed from scratch, a modular approach will likely be followed in that standard scientific packages will be used to do the more mundane tasks such as linear algebra or Fourier transform operations. This approach allows the developers to concentrate on their science rather than becoming experts in linear algebra or signal processing. Problems associated with this development approach include difficulties associated with data extraction and translation from one module to another, module performance on different nodal architectures, and others. In addition to these data and software issues there exists operational issues such as platform stability and resource management.

Dongarra, Jack↗

Titanium Optics for Ion Thrusters

Ion thruster total impulse capability is limited, in part, by accelerator grid sputter erosion. A development effort was initiated to identify a material with a lower accelerator grid volumetric sputter erosion rate than molybdenum, but that could utilize the present NSTAR thruster grid design and fabrication techniques to keep development costs low, and perform as well as molybdenum optics. After comparing the sputter erosion rates of several atomic materials to that of molybdenum at accelerator voltages, titanium was found to offer a 45% reduction in volumetric erosion rates. To ensure that screen grid sputter erosion rates are not higher at discharge chamber potentials, titanium and molybdenum sputter erosion rates were measured at these potentials. Preliminary results showed only a slightly higher volumetric erosion rate for titanium, so that screen grid erosion is insignificant. A number of material, thermal, and mechanical properties were also examined to identify any fabrication, launch environment, and thruster operation issues. Several titanium grid sets were successfully fabricated. A titanium grid set was mounted onto an NSTAR 30 cm engineering model ion thruster and tested to determine optics performance. The titanium optics operated successfully over the entire NSTAR power range of 0.5 to 2.3 kW. Differences in impingement-limited perveances and electron backstreaming limits were found to be due to a larger cold gap for the titanium optics. Discharge losses for titanium grids were lower than those for molybdenum, likely due to a slightly larger titanium screen grid open area fraction. Radial distributions of beam current density with titanium optics were very similar to those with molybdenum optics at all power levels. Temporal electron backstreaming limit measurements showed that titanium optics achieved thermal equilibrium faster than molybdenum optics.

Soulas, George C.↗

Stability, Transient Response, Control, and Safety of a High-Power Electric Grid for Turboelectric Propulsion of Aircraft

This document contains the deliverables for the NASA Research and Technology for Aerospace Propulsion Systems (RTAPS) regarding the stability, transient response, control, and safety study for a high power cryogenic turboelectric distributed propulsion (TeDP) system. The objective of this research effort is to enumerate, characterize, and evaluate the critical issues facing the development of the N3-X concept aircraft. This includes the proposal of electrical grid architecture concepts and an evaluation of any needs for energy storage.

Armstrong, Michael↗

Latency Hiding in Dynamic Partitioning and Load Balancing of Grid Computing Applications

The Information Power Grid (IPG) concept developed by NASA is aimed to provide a metacomputing platform for large-scale distributed computations, by hiding the intricacies of highly heterogeneous environment and yet maintaining adequate security. In this paper, we propose a latency-tolerant partitioning scheme that dynamically balances processor workloads on the.IPG, and minimizes data movement and runtime communication. By simulating an unsteady adaptive mesh application on a wide area network, we study the performance of our load balancer under the Globus environment. The number of IPG nodes, the number of processors per node, and the interconnected speeds are parameterized to derive conditions under which the IPG would be suitable for parallel distributed processing of such applications. Experimental results demonstrate that effective solution are achieved when the IPG nodes are connected by a high-speed asynchronous interconnection network.

Das, Sajal K.↗

Optimization of electrostatic dual-grid beam-deflection system

Tests were performed to minimize accelerator grid erosion of a 5-cm diameter Kaufman ion thruster due to direct beam impingement. Several different screen hole diameters, pillow-shape-square screen holes, and dished screen grids were tried. The optimization was accomplished by copper plating the accelerator grid before testing each grid configuration on a thruster for a 2-hour run. The thruster beam sputtered copper and molybdenum from the accelerator grid where the beam impinged. The observed erosion patterns and measured accelerator currents were used to determine how to modify the accelerator system. The lowest erosion was obtained for a 50-percent open area pillow-shape-square-aperture screen grid, dished 0.043 centimeter convex toward the accelerator grid, which was positioned with the center of the screen grid 0.084 centimeter from the accelerator grid. During this investigation the accelerator current was reduced from 120 to 55 microamperes and was also more uniformly distributed over the area of the accelerator grid.

Hudson, W. R.↗

Web-Based Distributed Simulation of Aeronautical Propulsion System

An application was developed to allow users to run and view the Numerical Propulsion System Simulation (NPSS) engine simulations from web browsers. Simulations were performed on multiple INFORMATION POWER GRID (IPG) test beds. The Common Object Request Broker Architecture (CORBA) was used for brokering data exchange among machines and IPG/Globus for job scheduling and remote process invocation. Web server scripting was performed by JavaServer Pages (JSP). This application has proven to be an effective and efficient way to couple heterogeneous distributed components.

Zheng, Desheng↗

Distributed Accounting on the Grid

By the late 1990s, the Internet was adequately equipped to move vast amounts of data between HPC (High Performance Computing) systems, and efforts were initiated to link together the national infrastructure of high performance computational and data storage resources together into a general computational utility 'grid', analogous to the national electrical power grid infrastructure. The purpose of the Computational grid is to provide dependable, consistent, pervasive, and inexpensive access to computational resources for the computing community in the form of a computing utility. This paper presents a fully distributed view of Grid usage accounting and a methodology for allocating Grid computational resources for use on a Grid computing system.

Thigpen, William↗

NASA Exhibits

A series of NASA presentations for the Supercomputing 2001 conference are summarized. The topics include: (1) Mars Surveyor Landing Sites "Collaboratory"; (2) Parallel and Distributed CFD for Unsteady Flows with Moving Overset Grids; (3) IP Multicast for Seamless Support of Remote Science; (4) Consolidated Supercomputing Management Office; (5) Growler: A Component-Based Framework for Distributed/Collaborative Scientific Visualization and Computational Steering; (6) Data Mining on the Information Power Grid (IPG); (7) Debugging on the IPG; (8) Debakey Heart Assist Device: (9) Unsteady Turbopump for Reusable Launch Vehicle; (10) Exploratory Computing Environments Component Framework; (11) OVERSET Computational Fluid Dynamics Tools; (12) Control and Observation in Distributed Environments; (13) Multi-Level Parallelism Scaling on NASA's Origin 1024 CPU System; (14) Computing, Information, & Communications Technology; (15) NAS Grid Benchmarks; (16) IPG: A Large-Scale Distributed Computing and Data Management System; and (17) ILab: Parameter Study Creation and Submission on the IPG.

Deardorff, Glenn↗

Decay of isotropic turbulence generated by a mechanically agitated grid.

Experimental study of weak isotropic turbulence, created by a mechanically agitated grid, has indicated that in the absence of large linear-momentum wakes the energy of turbulence relaxes very quickly into a stable self-preserving structure, which, depending on the initial Reynolds number of turbulence, decays at different constant inverse powers of time. Both the longitudinal correlation coefficients and the corresponding spectral distributions, except for the difference in the parametric constants, are of the same functional type as those found previously for a passive grid.

Ling, S. C.↗

Optical beam forming techniques for phased array antennas

Conventional phased array antennas using waveguide or coax for signal distribution are impractical for large scale implementation on satellites or spacecraft because they exhibit prohibitively large system size, heavy weight, high attenuation loss, limited bandwidth, sensitivity to electromagnetic interference (EMI) temperature drifts and phase instability. However, optical beam forming systems are smaller, lighter, and more flexible. Three optical beam forming techniques are identified as applicable to large spaceborne phased array antennas. They are (1) the optical fiber replacement of conventional RF phased array distribution and control components, (2) spatial beam forming, and (3) optical beam splitting with integrated quasi-optical components. The optical fiber replacement and the spatial beam forming approaches were pursued by many organizations. Two new optical beam forming architectures are presented. Both architectures involve monolithic integration of the antenna radiating elements with quasi-optical grid detector arrays. The advantages of the grid detector array in the optical process are the higher power handling capability and the dynamic range. One architecture involves a modified version of the original spatial beam forming approach. The basic difference is the spatial light modulator (SLM) device for controlling the aperture field distribution. The original liquid crystal light valve SLM is replaced by an optical shuffling SLM, which was demonstrated for the 'smart pixel' technology. The advantages are the capability of generating the agile beams of a phased array antenna and to provide simultaneous transmit and receive functions. The second architecture considered is the optical beam splitting approach. This architecture involves an alternative amplitude control for each antenna element with an optical beam power divider comprised of mirrors and beam splitters. It also implements the quasi-optical grid phase shifter for phase control and grid amplifier for RF power. The advantages are no SLM is required for this approach, and the complete antenna system is capable of full monolithic integration.

Wu, Te-Kao↗

Analysis of the Electrical Grid for UAM

A wide range of challenges must be overcome to conduct Urban Air Mobility (UAM) operations at scale with electric vertical takeoff and landing aircraft as envisioned. This presentation is on an analysis of one potential infrastructure challenge for UAM: available electrical grid power capacity. The success of UAM depends on the availability of electricity, which will be increasingly impacted by the proliferation of ground electric vehicles over time. Under the best-case assumption that electricity can be transmitted and distributed as needed within each interconnection (i.e., electrical grid), it is estimated that the maximum number of UAM aircraft that can charge simultaneously in the continental United States will decrease by 20% from about 595 thousand in the year 2021 to about 475 thousand in the year 2050 due to the projected increase in ground electric vehicles.

electrical grid; urban air mobility; electric vehi↗

A Control Framework for Autonomous Smart Grids for Space Power Applications

With the National Aeronautics and Space Administration's (NASA) rising interest in lunar surface operations and deep space exploration, there is a growing need to move from traditional ground-based mission operations to more autonomous vehicle level operations. In lunar surface operations, there are periods of time where communications with ground-based mission control could not occur, forcing vehicles and a lunar base to completely operate independent of the ground. For deep space exploration missions, communication latency times increase to greater than 15 minutes making real-time control of critical systems difficult, if not near impossible. These challenges are driving the need for an autonomous power control system that has the capability to manage power and energy. This will ensure that critical loads have the necessary power to support life systems and carry out critical mission objectives. This paper presents a flexible, hierarchical, distributed control methodology that enables autonomous operation of smart grids and can integrate into a higher level autonomous architecture.

Csank, Jeffrey T.↗

A Control Framework for Autonomous Smart Grids for Space Power Applications

With the National Aeronautics and Space Administration's (NASA) rising interest in lunar surface operations and deep space exploration, there is a growing need to move from traditional ground-based mission operations to more autonomous vehicle level operations. In lunar surface operations, there are periods of time where communications with ground-based mission control could not occur, forcing vehicles and a lunar base to completely operate independent of the ground. For deep space exploration missions, communication latency times increase to greater than 15 minutes making real-time control of critical systems difficult, if not near impossible. These challenges are driving the need for an autonomous power control system that has the capability to manage power and energy. This will ensure that critical loads have the necessary power to support life systems and carry out critical mission objectives. This paper presents a flexible, hierarchical, distributed control methodology that enables autonomous operation of smart grids and can integrate into a higher level autonomous architecture.

Carbone, Marc A.↗

Analysis of Electrical Grid Capacity by Interconnection for Urban Air Mobility

A wide range of challenges must be overcome to conduct Urban Air Mobility (UAM)operations at scale with electric vertical take-off and landing aircraft as envisioned. This paper documents an analysis of one potential infrastructure challenge for UAM: available electrical grid power capacity. The success of UAM depends on the availability of electricity, which will be increasingly impacted by the proliferation of ground electric vehicles(EVs) over time. Under the best-case assumption that electricity can be transmitted and distributed as needed within each interconnection (i.e., electrical grid), it is estimated that the maximum number of UAM aircraft that can charge simultaneously in the continental United States will decrease by 20% from about 595 thousand in the year 2021 to about 475 thousand in the year 2050due to the projected increase in ground EVs.

electrical grid↗

Analysis of Electrical Grid Capacity by Interconnection for Urban Air Mobility

A wide range of challenges must be overcome to conduct Urban Air Mobility (UAM)operations at scale with electric vertical take-off and landing aircraft as envisioned. This paper documents an analysis of one potential infrastructure challenge for UAM: available electrical grid power capacity. The success of UAM depends on the availability of electricity, which will be increasingly impacted by the proliferation of ground electric vehicles(EVs) over time. Under the best-case assumption that electricity can be transmitted and distributed as needed within each interconnection (i.e., electrical grid), it is estimated that the maximum number of UAM aircraft that can charge simultaneously in the continental United States will decrease by 20% from about 595 thousand in the year 2021 to about 475 thousand in the year 2050due to the projected increase in ground EVs.

electrical grid↗

A Simple XML Producer-Consumer Protocol

There are many different projects from government, academia, and industry that provide services for delivering events in distributed environments. The problem with these event services is that they are not general enough to support all uses and they speak different protocols so that they cannot interoperate. We require such interoperability when we, for example, wish to analyze the performance of an application in a distributed environment. Such an analysis might require performance information from the application, computer systems, networks, and scientific instruments. In this work we propose and evaluate a standard XML-based protocol for the transmission of events in distributed systems. One recent trend in government and academic research is the development and deployment of computational grids. Computational grids are large-scale distributed systems that typically consist of high-performance compute, storage, and networking resources. Examples of such computational grids are the DOE Science Grid, the NASA Information Power Grid (IPG), and the NSF Partnerships for Advanced Computing Infrastructure (PACIs). The major effort to deploy these grids is in the area of developing the software services to allow users to execute applications on these large and diverse sets of resources. These services include security, execution of remote applications, managing remote data, access to information about resources and services, and so on. There are several toolkits for providing these services such as Globus, Legion, and Condor. As part of these efforts to develop computational grids, the Global Grid Forum is working to standardize the protocols and APIs used by various grid services. This standardization will allow interoperability between the client and server software of the toolkits that are providing the grid services. The goal of the Performance Working Group of the Grid Forum is to standardize protocols and representations related to the storage and distribution of performance data. These standard protocols and representations must support tasks such as profiling parallel applications, monitoring the status of computers and networks, and monitoring the performance of services provided by a computational grid. This paper describes a proposed protocol and data representation for the exchange of events in a distributed system. The protocol exchanges messages formatted in XML and it can be layered atop any low-level communication protocol such as TCP or UDP Further, we describe Java and C++ implementations of this protocol and discuss their performance. The next section will provide some further background information. Section 3 describes the main communication patterns of our protocol. Section 4 describes how we represent events and related information using XML. Section 5 describes our protocol and Section 6 discusses the performance of two implementations of the protocol. Finally, an appendix provides the XML Schema definition of our protocol and event information.

Smith, Warren↗

Automated CFD Parameter Studies on Distributed Parallel Computers

The objective of the current work is to build a prototype software system which will automated the process of running CFD jobs on Information Power Grid (IPG) resources. This system should remove the need for user monitoring and intervention of every single CFD job. It should enable the use of many different computers to populate a massive run matrix in the shortest time possible. Such a software system has been developed, and is known as the AeroDB script system. The approach taken for the development of AeroDB was to build several discrete modules. These include a database, a job-launcher module, a run-manager module to monitor each individual job, and a web-based user portal for monitoring of the progress of the parameter study. The details of the design of AeroDB are presented in the following section. The following section provides the results of a parameter study which was performed using AeroDB for the analysis of a reusable launch vehicle (RLV). The paper concludes with a section on the lessons learned in this effort, and ideas for future work in this area.

Rogers, Stuart E.↗