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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.

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At least 847 records · Page 47

Thermal Analysis of Liquid and Air Cooling of High-Power-Density Integrated Motor Drives

Thermal management is a crucial aspect in the design of motor and drive systems. This paper introduces a coordinated cooling approach utilizing both liquid and air to enhance the integrated motor drive's power density. The proposed solution incorporates a shared water jacket to cool both the machine and power electronics, combined with forced air ventilation for the end windings and rotor. This approach is structurally simpler, less expensive, and more effective than conventional non-interacting cooling schemes. The paper addresses the modeling of key thermal features and nonlinearities including material anisotropy, contact thermal resistance, and uneven winding loss distributions. In addition, this study utilizes a more detailed model of the loss distribution among the winding turns in each slot that delivers a higher level of accuracy. Finite Element Analysis (FEA) results demonstrate the effectiveness of the integrated cooling system for efficiently cooling the designed integrated motor drive system.

42 ENGINEERING↗

Hardware design and testing of the generic rear transition module for the global trigger subsystem of ATLAS Phase-II Upgrade

Abstract In the framework of the ATLAS experiment’s Phase-II Upgrade at the High-Luminosity Large Hadron Collider (HL-LHC), new and improved trigger hardware and algorithms will be implemented onto a single-level, 10 μs-latency architecture. The Global Trigger is a new subsystem which will bring event-filter capabilities by performing offline-like algorithms on full-granularity calorimeter data. The implementation of the functionality is firmware-focused and composed of several processing nodes, which are hosted on identical hardware, made up of an Advanced Telecommunications Computing Architecture (ATCA) front board, called Global Common Module (GCM), and a rear transition module (RTM), called Generic RTM (GRM). The GRM, which was developed to mitigate the risks deriving from the complex design and power management of the GCM, features an advanced Xilinx Versal Prime system-on-chip and can handle communication with the GCM and Front-End Link eXchange (FELIX) subsystem and trigger processors through 124 25.8 Gb/s transceiver links, for readout and control. Additionally, the GRM mounts a Low-Power GigaBit Transceiver (lpGBT) chip which enables emulation of the detector front-ends for integration tests. This paper presents the GRM hardware design and its testing.

Instruments & Instrumentation↗

Optimization of the FRIB beam dump: a hybrid genetic algorithm and reinforcement learning approach

The operational envelope of high-power-density systems, such as particle accelerators and advanced nuclear energy systems, is critically constrained by the need to manage extreme thermal loads. To address this, we present a novel hybrid optimization framework combining a genetic algorithm (GA) with a soft actor-critic (SAC) deep reinforcement learning agent. This framework was applied to a practical high-heat-flux problem: redesigning the beam dump at the Facility for Rare Isotope Beams (FRIB) for a power upgrade from 20 kW to 50 kW. The resulting design, validated by three-dimensional conjugate heat transfer simulations, suppresses hazardous hot spots and yields a markedly more uniform temperature distribution. This provides a robust operating margin, increasing the average power-handling capability by 72% relative to the current design, demonstrating the framework’s potential to solve complex thermal management challenges in both accelerator technology and advanced nuclear systems.

Accelerator↗

Experimental and computational study of the microporous layer and hydrophobic treatment in the gas diffusion layer of a proton exchange membrane fuel cell

Enabling fuel cell operation at high current density is critical for developing competitive alternative power system to replace internal combustion engine. However, liquid water management continues to be a challenge for high humidity or high current density operation. Water condensation in the porous media hinders efficient oxygen transport to the catalyst layer, which in turns, reduces fuel cell performance. To improve water management capability, the gas diffusion layer is often impregnated with Polytetrafluoroethylene (PTFE) and coated with a thin microporous layer, which have shown to improve fuel cell performance, especially under wet conditions. However, the fundamental mechanism that drives the performance enhancement is still not well understood. In this work, the effects of PTFE impregnation and MPL were studied using both experimental and computational techniques. Both limiting current and polarization tests under dry and wet operating condition are conducted to study the oxygen transport resistance and fuel cell performance. In addition, a 2-D, two-phase, multi-physics PEMFC model is developed to simulate performance and gain a fundamental understanding of local water saturation and oxygen concentration. The combined results show that 5 wt% PTFE impregnation with MPL significantly enhances liquid water management, which enables higher current density operation of a fuel cell.

25 ENERGY STORAGE↗

Demonstration of thermal fracture limits of gas-cooled Nd:APG-1 and Tm:YLF slabs

High-energy short-pulse laser systems demonstrated to date have been limited to low repetition rates due to significant thermal management challenges associated with scaling these systems to high average power, including the need to understand the thermal fracture limits of laser gain media. In this paper, we demonstrate the thermal fracture limits of two high-average-power gain media in a realistic diode-pumped amplifier geometry: a 5 mm thick Nd:APG-1 slab and a 2 mm thick Tm:YLF slab, both cooled by room-temperature helium gas. Finite element analysis revealed maximum tensile stress at fracture of 25 ± 3 MPa for Nd:APG-1 and 30 ± 3 MPa for Tm:YLF. These stress levels correspond to average volumetric heat loads of 13 ± 1 W/cm 3 in Nd:APG-1 and 247 ± 12 W/cm 3 in Tm:YLF. Additional simulations show geometric scaling: thinner slabs tolerate higher heat loads before fracture, while larger pump spots reach the fracture stress at lower heat loads.

Lasers↗

Free-flying teleoperator requirements and conceptual design.

A teleoperator, as defined by NASA, is a remotely controlled cybernetic man-machine system designed to augment and extend man's sensory, manipulative, and cognitive capabilities. Teleoperator systems can fulfill an important function in the Space Shuttle program. They can retrieve automated satellites for refurbishment and reuse. Cargo can be transferred over short or large distances and orbital operations can be supported. A requirements analysis is discussed, giving attention to the teleoperator spacecraft, docking and stowage systems, display and controls, propulsion, guidance, navigation, control, the manipulators, the video system, the electrical power, and aspects of communication and data management. Questions of concept definition and evaluation are also examined.

Onega, G. T.↗

Adaption of Space Station technology for lunar operations

The possible use of Space Station technology in a lunar base program is discussed, focusing on the lunar lander/ascent vehicles and surface modules. The application of the Space Station data management system, software, and communications, tracking, guidance, navigation, control, and power technologies is examined. The benefits of utilizing this technology for lunar operations are considered.

Garvey, J. M.↗

U.S. Laboratory Module - Its capabilities and accommodations to support user payloads

The U.S. Laboratory Module of the Space Station is discussed, focusing on user accommodations. The configuration and subsystems capabilities of the module are described, including the power, thermal, environmental control, and data management subsystems, the vacuum system, process materials management, and laboratory support equipment. The experimental facilities included in the laboratory are listed. The experiment operations planned for the laboratory are examined and compared with the experimental activities in other manned space laboratories.

Powell, Luther E.↗

Power management and distribution considerations for a lunar base

Design philosophies and technology needs for the power management and distribution (PMAD) portion of a lunar base power system are discussed. A process is described whereby mission planners may proceed from a knowledge of the PMAD functions and mission performance requirements to a definition of design options and technology needs. Current research efforts at the NASA LRC to meet the PMAD system needs for a Lunar base are described. Based on the requirements, the lunar base PMAD is seen as best being accomplished by a utility like system, although with some additional demands including autonomous operation and scheduling and accurate, predictive modeling during the design process.

Kenny, Barbara H.↗

Development of a Power Electronics Unit for the Space Station Plasma Contactor

A hollow cathode plasma contactor has been baselined as a charge control device for the Space Station (SS) to prevent deleterious interactions of coated structural components with the ambient plasma. NASA LeRC Work Package 4 initiated the development of a plasma contactor system comprised of a Power Electronics Unit (PEU), an Expellant Management Unit (EMU), a command and data interface, and a Plasma Contactor Unit (PCU). A breadboard PEU was designed and fabricated. The breadboard PEU contains a cathode heater and discharge power supply, which were required to operate the PCU, a control and auxiliary power converter, an EMU interface, a command and telemetry interface, and a controller. The cathode heater and discharge supplies utilized a push-pull topology with a switching frequency of 20 kHz and pulse-width-modulated (PWM) control. A pulse ignition circuit derived from that used in arcjet power processors was incorporated in the discharge supply for discharge ignition. An 8088 based microcontroller was utilized in the breadboard model to provide a flexible platform for controller development with a simple command/data interface incorporating a direct connection to SS Mulitplexer/Demultiplexer (MDM) analog and digital I/O cards. Incorporating this in the flight model would eliminate the hardware and software overhead associated with a 1553 serial interface. The PEU autonomously operated the plasma contactor based on command inputs and was successfully integrated with a prototype plasma contactor unit demonstrating reliable ignition of the discharge and steady-state operation.

Hamley, John A.↗

A Reliability Model to Assess Reliability of Shuttle Derived Launch Vehicle and Next Generation Vehicles

One important thrust in NASA s space exploration vision is to improve the safety and reliability of future launch vehicles. A quantitative reliability model is an essential technical tool to evaluate launch vehicle reliability and to enhance launch vehicle configuration down selection and detailed designs. A quantitative reliability model that supports NASA's thrust has been developed and implemented in an MS Excel spreadsheet. The model addresses key reliability parameters, and provides for sensitivity analysis of various vehicle designs. This paper presents the specific elements of the model and examples of selected sensitivity analysis results. Reliability input parameters in the model include the following: 1. Main propulsion element failure probability; 2. Propulsion element catastrophic failure fraction (Cf). This is defined as the ratio of probability of uncontained failures over sum of probability of uncontained failures and contained failures); 3. Engine-out design vs. no-engine-out design; 4. Engine with redlines vs. no redlines; 5. Different levels of health management system implementation; 6. Launch Escape System (LES) reliability; and 7. Power level correlation with reliability. The sensitivity results will illustrate the impact of each of the above parameters on several reliability metrics: Loss of Mission (LOM), LOV (Loss of Vehicle) and Loss of Crew (LOC).

Huang, Zhao↗

Measurement of the Shear Lift Force on a Bubble in a Channel Flow

Two-phase flow systems play vital roles in the design of some current and anticipated space applications of two-phase systems which include: thermal management systems, transfer line flow in cryogenic storage, space nuclear power facilities, design and operation of thermal bus, life support systems, propulsion systems, In Situ Resource Utilization (ISRU), and space processes for pharmaceutical applications. The design of two-phase flow systems for space applications requires a clear knowledge of the behaviors of the dispersed phase (bubble), its interaction with the continuous phase (liquid) and its effect on heat and mass transfer processes, The need to understand the bubble generation process arises from the fact that for all space applications, the size and distribution of bubbles are extremely crucial for heat and mass transfer control. One important force in two-phase flow systems is the lift force on a bubble or particle in a liquid shear flow. The shear lift is usually overwhelmed by buoyancy in normal gravity, but it becomes an important force in reduced gravity. Since the liquid flow is usually sheared because of the confining wall, the trajectories of bubbles and particles injected into the liquid flow are affected by the shear lift in reduced gravity. A series of experiments are performed to investigate the lift force on a bubble in a liquid shear flow and its effect on the detachment of a bubble from a wall under low gravity conditions. Experiments are executed in a Poiseuille flow in a channel. An air-water system is used in these experiments that are performed in the 2.2 second drop tower. A bubble is injected into the shear flow from a small injector and the shear lift is measured while the bubble is held stationary relative to the fluid. The trajectory of the bubble prior, during and after its detachment from the injector is investigated. The measured shear lift force is calculated from the trajectory of the bubble at the detachment point. These values for the shear lift are then compared with the theoretical predictions from various published works on shear lift in the open literature, which include asymptotic solutions at low bubble Reynolds number, potential flow predictions and numerical studies that deal with intermediate bubble Reynolds numbers.

Nahra, Henry K.↗

Leveraging Existing Mission Tools in a Re-Usable, Component-Based Software Environment

Emerging methods in component-based software development offer significant advantages but may seem incompatible with existing mission operations applications. In this paper we relate our positive experiences integrating existing mission applications into component-based tools we are delivering to three missions. In most operations environments, a number of software applications have been integrated together to form the mission operations software. In contrast, with component-based software development chunks of related functionality and data structures, referred to as components, can be individually delivered, integrated and re-used. With the advent of powerful tools for managing component-based development, complex software systems can potentially see significant benefits in ease of integration, testability and reusability from these techniques. These benefits motivate us to ask how component-based development techniques can be relevant in a mission operations environment, where there is significant investment in software tools that are not component-based and may not be written in languages for which component-based tools even exist. Trusted and complex software tools for sequencing, validation, navigation, and other vital functions cannot simply be re-written or abandoned in order to gain the advantages offered by emerging component-based software techniques. Thus some middle ground must be found. We have faced exactly this issue, and have found several solutions. Ensemble is an open platform for development, integration, and deployment of mission operations software that we are developing. Ensemble itself is an extension of an open source, component-based software development platform called Eclipse. Due to the advantages of component-based development, we have been able to vary rapidly develop mission operations tools for three surface missions by mixing and matching from a common set of mission operation components. We have also had to determine how to integrate existing mission applications for sequence development, sequence validation, and high level activity planning, and other functions into a component-based environment. For each of these, we used a somewhat different technique based upon the structure and usage of the existing application.

Greene, Kevin↗

System Engineering & Integration (SE&I) In-Situ Resource Utilization (ISRU) Modeling and Analysis (SIMA)

NASA developed a flexible system modeling framework of integrated ISRU and ISRU related subsystem models: MAIT (Mission Analysis & Integration Tool) that enables point solutions, optimization, and/or parametric studies at the system level to predict mission architecture mass, power, and volume and provides accessible consolidated database that categorizes specific ISRU and ISRU related subsystem variables common between NASA & industry. Directly and indirectly addresses multiple STMD shortfalls: - ISRU-581 - ‘ISRU System Modeling’: Establish a modular end-to-end ISRU system modeling & analysis capability by leveraging and evolving prior, on-going, and future investments - More than an ISRU system modeling tool, MAIT integrates power, excavation, Environmental Control & Life Support System (ECLSS), Cryogenic Fluid Management (CFM) liquification, & compares surface ops & environments, to assist in the closure of other related ISRU shortfalls Adheres to governing NASA procedures for Models & Simulations (NASA-HDBK-7009) & AIAA standards for Mass Properties Control for Space Systems.

Modeling↗

System performance predictions for Space Station Freedom's electric power system

Space Station Freedom Electric Power System (EPS) capability to effectively deliver power to housekeeping and user loads continues to strongly influence Freedom's design and planned approaches for assembly and operations. The EPS design consists of silicon photovoltaic (PV) arrays, nickel-hydrogen batteries, and direct current power management and distribution hardware and cabling. To properly characterize the inherent EPS design capability, detailed system performance analyses must be performed for early stages as well as for the fully assembled station up to 15 years after beginning of life. Such analyses were repeatedly performed using the FORTRAN code SPACE (Station Power Analysis for Capability Evaluation) developed at the NASA Lewis Research Center over a 10-year period. SPACE combines orbital mechanics routines, station orientation/pointing routines, PV array and battery performance models, and a distribution system load-flow analysis to predict EPS performance. Time-dependent, performance degradation, low earth orbit environmental interactions, and EPS architecture build-up are incorporated in SPACE. Results from two typical SPACE analytical cases are presented: (1) an electric load driven case and (2) a maximum EPS capability case.

Kerslake, Thomas W.↗

Frequency threshold determination for frequency-responsive load controllers

Systems, methods, and computer media for managing frequency response in a power grid are provided herein. Individual grid-connected electrical devices can be turned on and/or off by corresponding frequency-responsive load controllers when frequency deviations beyond a threshold are detected. Each controller selects, for the corresponding electrical device, a frequency threshold from available frequencies in a frequency range. If the selected frequency falls within a deadband frequency range, then the controller sets the frequency threshold to a frequency outside of the deadband (e.g., to a closest available frequency outside of the deadband). On a system-wide level, this approximates a uniform distribution of frequency thresholds over the entire frequency range, including the deadband, and achieves the proper power-to-frequency relationship for grid stability. A supervisory coordinator can determine the frequency range from which a frequency threshold is selected based on aggregated power information for devices and controllers throughout the grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Space systems engineering and risk management - joined at the hip

This paper explores the separate skills and capabilities practiced until now, and the powerful coupling to be achieved, practically and effectively, in implementing a space mission, from inception (pre-phase A) to the end of Operations (phase E). The use of risk assessment techniques in balancing cost risk against performance risk, and the application of the systems engineering team in these trades, is the key to achieving this new implementation paradigm.

systems engineering↗