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NASA NTRS2004

Oil-Free Rotor Support Technologies for Long Life, Closed Cycle Brayton Turbines

The goal of this study is to provide technological support to ensure successful life and operation of a 50-300 kW dynamic power conversion system specifically with response to the rotor support system. By utilizing technical expertise in tribology, bearings, rotordynamic, solid lubricant coatings and extensive test facilities, valuable input for mission success is provided. A discussion of the history of closed cycle Brayton turboalternators (TA) will be included. This includes the 2 kW Mini-Brayton Rotating Unit (Mini-BRU), the 10kW Brayton Rotating Unit (BRU) and the 125 kW turboalternator-compressor (TAC) designed in mid 1970's. Also included is the development of air-cycle machines and terrestrial oil-free gas turbine power systems in the form of microturbines, specifically Capstone microturbines. A short discussion of the self-acting compliant surface hydrodynamic fluid film bearings, or foil bearings, will follow, including a short history of the load capacity advances, the NASA coatings advancements as well as design model advances. Successes in terrestrial based machines will be noted and NASA tribology and bearing research test facilities will be described. Finally, implementation of a four step integration process will be included in the discussion.

Lucero, John M.↗

NASA NTRS1993

A Demonstration Plan For Lalser-Beamed Power

In a constrained budgetary era under pressure to develop faster, better, and less expensive space projects, efforts to develop laser-beamed power for lunar and propulsion applications must first focus on defining near-term, commercially attractive deliverables that will demonstrate progress toward, and engender support for development of an operational laser-beamed earth-orbital propulsion/lunar power system.

Laser-Beamed Power↗

NASA NTRS2012

Miniature EVA Software Defined Radio

As NASA embarks upon developing the Next-Generation Extra Vehicular Activity (EVA) Radio for deep space exploration, the demands on EVA battery life will substantially increase. The number of modes and frequency bands required will continue to grow in order to enable efficient and complex multi-mode operations including communications, navigation, and tracking applications. Whether conducting astronaut excursions, communicating to soldiers, or first responders responding to emergency hazards, NASA has developed an innovative, affordable, miniaturized, power-efficient software defined radio that offers unprecedented power-efficient flexibility. This lightweight, programmable, S-band, multi-service, frequency- agile EVA software defined radio (SDR) supports data, telemetry, voice, and both standard and high-definition video. Features include a modular design, an easily scalable architecture, and the EVA SDR allows for both stationary and mobile battery powered handheld operations. Currently, the radio is equipped with an S-band RF section. However, its scalable architecture can accommodate multiple RF sections simultaneously to cover multiple frequency bands. The EVA SDR also supports multiple network protocols. It currently implements a Hybrid Mesh Network based on the 802.11s open standard protocol. The radio targets RF channel data rates up to 20 Mbps and can be equipped with a real-time operating system (RTOS) that can be switched off for power-aware applications. The EVA SDR's modular design permits implementation of the same hardware at all Network Nodes concept. This approach assures the portability of the same software into any radio in the system. It also brings several benefits to the entire system including reducing system maintenance, system complexity, and development cost.

Pozhidaev, Aleksey↗

NASA NTRS2012

Transforming Community Access to Space Science Models

Researching and forecasting the ever changing space environment (often referred to as space weather) and its influence on humans and their activities are model-intensive disciplines. This is true because the physical processes involved are complex, but, in contrast to terrestrial weather, the supporting observations are typically sparse. Models play a vital role in establishing a physically meaningful context for interpreting limited observations, testing theory, and producing both nowcasts and forecasts. For example, with accurate forecasting of hazardous space weather conditions, spacecraft operators can place sensitive systems in safe modes, and power utilities can protect critical network components from damage caused by large currents induced in transmission lines by geomagnetic storms.

MacNeice, Peter↗

NASA NTRS1971

SNAP-8 electrical generating system development program

The SNAP-8 program has developed the technology base for one class of multikilowatt dynamic space power systems. Electrical power is generated by a turbine-alternator in a mercury Rankine-cycle loop to which heat is transferred and removed by means of sodium-potassium eutectic alloy subsystems. Final system overall criteria include a five-year operating life, restartability, man rating, and deliverable power in the 90 kWe range. The basic technology was demonstrated by more than 400,000 hours of major component endurance testing and numerous startup and shutdown cycles. A test system, comprised of developed components, delivered up to 35 kWe for a period exceeding 12,000 hours. The SNAP-8 system baseline is considered to have achieved a level of technology suitable for final application development for long-term multikilowatt space missions.

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NASA NTRS1988

A reliable data collection/control system

The Cal Poly Space Project requires a data collection/control system which must be able to reliably record temperature, pressure and vibration data. It must also schedule the 16 electroplating and 2 immiscible alloy experiments so as to optimize use of the batteries, maintain a safe package temperature profile, and run the experiment during conditions of microgravity (and minimum vibration). This system must operate unattended in the harsh environment of space and consume very little power due to limited battery supply. The design of a system which meets these requirements is addressed.

Maughan, Thom↗

NASA NTRS1991

SEI power source alternatives for rovers and other multi-kWe distributed surface applications

Results of the study performed to support the Space Exploration Initiative (SEI) which investigated power system alternatives for the rover vehicles and servicers that would be used for construction and operation of a lunar base is described. Using the mission requirements and power profiles that were subsequently generated for each of these rovers and servicers, candidate power sources incorporating various power generation and energy storage technologies were identified. The technologies were those believed most appropriate to the SEI missions, and included solar, electrochemical, and isotope systems. The candidates were characterized with respect to system mass, deployed area and volume. For each of the missions a preliminary selection was made. Results of this study depict the available power sources in light of the mission requirements as they are currently defined.

Bents, D. J.↗

NASA NTRS1983

Optimal design of gas adsorption refrigerators for cryogenic cooling

The design of gas adsorption refrigerators used for cryogenic cooling in the temperature range of 4K to 120K was examined. The functional relationships among the power requirement for the refrigerator, the system mass, the cycle time and the operating conditions were derived. It was found that the precool temperature, the temperature dependent heat capacities and thermal conductivities, and pressure and temperature variations in the compressors have important impacts on the cooling performance. Optimal designs based on a minimum power criterion were performed for four different gas adsorption refrigerators and a multistage system. It is concluded that the estimates of the power required and the system mass are within manageable limits in various spacecraft environments.

Chan, C. K.↗

NASA NTRS1971

SNAP-8 electrical generating system development program

The SNAP-8 program has developed the technology base for one class of multikilowatt dynamic space power systems. Electrical power is generated by a turbine-alternator in a mercury Rankine-cycle loop to which heat is transferred and removed by means of sodium-potassium eutectic alloy subsystems. Final system overall criteria include a five-year operating life, restartability, man rating, and deliverable power in the 90 kWe range. The basic technology has been demonstrated by more than 400,000 hours of major component endurance testing and numerous startup and shutdown cycles. A test system, comprised of developed components, delivered up to 35 kWe for a period exceeding 12,000 hours. The SNAP-8 system baseline is considered to have achieved a level of technology suitable for final application development for long-term multikilowatt space missions.

Source record↗

NASA NTRS2003

Miniature Gas-Turbine Power Generator

A proposed microelectromechanical system (MEMS) containing a closed- Brayton-cycle turbine would serve as a prototype of electric-power generators for special applications in which high energy densities are required and in which, heretofore, batteries have been used. The system would have a volume of about 6 cm3 and would operate with a thermal efficiency >30 percent, generating up to 50 W of electrical power. The energy density of the proposed system would be about 10 times that of the best battery-based systems now available, and, as such, would be comparable to that of a fuel cell. The working gas for the turbine would be Xe containing small quantities of CO2, O2, and H2O as gaseous lubricants. The gas would be contained in an enclosed circulation system, within which the pressure would typically range between 5 and 50 atm (between 0.5 and 5 MPa). The heat for the Brayton cycle could be supplied by any of a number of sources, including a solar concentrator or a combustor burning a hydrocarbon or other fuel. The system would include novel heat-transfer and heat-management components. The turbine would be connected to an electric power generator/starter motor. The system would include a main rotor shaft with gas bearings; the bearing surfaces would be made of a ceramic material coated with nanocrystalline diamond. The shaft could withstand speed of 400,000 rpm or perhaps more, with bearing-wear rates less than 10(exp -)4 those of silicon bearings and 0.05 to 0.1 those of SiC bearings, and with a coefficient of friction about 0.1 that of Si or SiC bearings. The components of the system would be fabricated by a combination of (1) three-dimensional xray lithography and (2) highly precise injection molding of diamond-compatible metals and ceramic materials. The materials and fabrication techniques would be suitable for mass production. The disadvantages of the proposed system are that unlike a battery-based system, it could generate a perceptible amount of sound, and, if it were to burn fuel, then it would also generate exhaust, similarly to other combustion-based power sources.

Wiberg, Dean↗

NASA NTRS1986

Technology for Bayton-cycle powerplants using solar and nuclear energy

Brayton cycle gas turbines have the potential to use either solar heat or nuclear reactors for generating from tens of kilowatts to tens of megawatts of power in space, all this from a single technology for the power generating system. Their development for solar energy dynamic power generation for the space station could be the first step in an evolution of such powerplants for a very wide range of applications. At the low power level of only 10 kWe, a power generating system has already demonstrated overall efficiency of 0.29 and operated 38 000 hr. Tests of improved components show that these components would raise that efficiency to 0.32, a value twice that demonstrated by any alternate concept. Because of this high efficiency, solar Brayton cycle power generators offer the potential to increase power per unit of solar collector area to levels exceeding four times that from photovoltaic powerplants using present technology for silicon solar cells. The technologies for solar mirrors and heat receivers are reviewed and assessed. This Brayton technology for solar powerplants is equally suitable for use with the nuclear reactors. The available long time creep data on the tantalum alloy ASTAR-811C show that such Brayton cycles can evolve to cycle peak temperatures of 1500 K (2240 F). And this same technology can be extended to generate 10 to 100 MW in space by exploiting existing technology for terrestrial gas turbines in the fields of both aircraft propulsion and stationary power generation.

English, R. E.↗

NASA NTRS2012

Analysis of Roll Steering for Solar Electric Propulsion Missions

Nothing is more vital to a spacecraft than power. Solar Electric Propulsion (SEP) uses that power to provide a safe, reliable, and, most importantly, fuel efficient means to propel a spacecraft to its destination. The power performance of an SEP vehicle s solar arrays and electrical power system (EPS) is largely influenced by the environment in which the spacecraft is operating. One of the most important factors that determines solar array power performance is how directly the arrays are pointed to the sun. To get the most power from the solar arrays, the obvious solution is to point them directly at the sun at all times. Doing so is not a problem in deep space, as the environment and pointing conditions that a spacecraft faces are fairly constant and are easy to accommodate, if necessary. However, large and sometimes rapid variations in environmental and pointing conditions are experienced by Earth orbiting spacecraft. SEP spacecraft also have the additional constraint of needing to keep the thrust vector aligned with the velocity vector. Thus, it is important to analyze solar array power performance for any vehicle that spends an extended amount of time orbiting the Earth, and to determine how much off-pointing can be tolerated to produce the required power for a given spacecraft. This paper documents the benefits and drawbacks of perfectly pointing the solar arrays of an SEP spacecraft spiraling from Earth orbit, and how this might be accomplished. Benefits and drawbacks are defined in terms of vehicle mass, power, volume, complexity, and cost. This paper will also look at the application of various solar array pointing methods to future missions. One such pointing method of interest is called roll steering . Roll steering involves rolling the entire vehicle twice each orbit. Roll steering, combined with solar array gimbal tracking, is used to point the solar arrays perfectly towards the sun at all points in the orbit, while keeping the vehicle thrusters aligned in the velocity direction. Roll steering is particularly attractive for a recently proposed mission that involves a spiral trajectory from low Earth orbit (LEO) to the Earth-Moon Lagrange Point 1 (E-M L1). During the spiral, the spacecraft will spend over 300 days experiencing the full spectrum of near-earth environments and solar array pointing conditions. An extensive study of the application of SEP (and roll steering) to this spiral mission is included, highlighting the ultimate goal of reduced vehicle cost and mass. Tools used for this analysis include the Systems Power Analysis for Capability Evaluation (Refs. 1 and 2) (SPACE) electrical power systems code, and SEP trajectory simulation tools developed at NASA Glenn Research Center.

Pederson, Dylan, M.↗

NASA NTRS2010

Optical Structural Health Monitoring Device

This non-destructive, optical fatigue detection and monitoring system relies on a small and unobtrusive light-scattering sensor that is installed on a component at the beginning of its life in order to periodically scan the component in situ. The method involves using a laser beam to scan the surface of the monitored component. The device scans a laser spot over a metal surface to which it is attached. As the laser beam scans the surface, disruptions in the surface cause increases in scattered light intensity. As the disruptions in the surface grow, they will cause the light to scatter more. Over time, the scattering intensities over the scanned line can be compared to detect changes in the metal surface to find cracks, crack precursors, or corrosion. This periodic monitoring of the surface can be used to indicate the degree of fatigue damage on a component and allow one to predict the remaining life and/or incipient mechanical failure of the monitored component. This wireless, compact device can operate for long periods under its own battery power and could one day use harvested power. The prototype device uses the popular open-source TinyOS operating system on an off-the-shelf Mica2 sensor mote, which allows wireless command and control through dynamically reconfigurable multi-node sensor networks. The small size and long life of this device could make it possible for the nodes to be installed and left in place over the course of years, and with wireless communication, data can be extracted from the nodes by operators without physical access to the devices. While a prototype has been demonstrated at the time of this reporting, further work is required in the system s development to take this technology into the field, especially to improve its power management and ruggedness. It should be possible to reduce the size and sensitivity as well. Establishment of better prognostic methods based on these data is also needed. The increase of surface roughness with fatigue is closely connected to the microstructure of the metal, and ongoing research is seeking to connect this observed evidence of the fatigue state with microstructural theories of fatigue evolution to allow more accurate prognosis of remaining component life. Plans are also being discussed for flight testing, perhaps on NASA s SOFIA platform.

Buckner, Benjamin D.↗

NASA NTRS2000

Power Systems Evaluated for Solar Electric Propulsion Vehicles

Solar electric propulsion (SEP) mission architectures are applicable to a wide range NASA missions including the robotic exploration of the outer planets in the next decade and the human exploration of Mars within the next 2 decades. SEP enables architectures that are very mass efficient with reasonable power levels (1-MW class) aerobrake and cryogenic upper-stage transportation technologies are utilized. In this architecture, the efficient SEP stage transfers the payload from low Earth orbit (LEO) High Energy Elliptical Parking Orbit (HEEPO) within a period of 6 to 12 months. highthrust, cryogenic upper stage and payload then separate from the SEP vehicle for injection to the planetary target, allowing for fast heliocentric trip times. This mission architecture offers a potential reduction in mass to LEO in comparison to alternative all-chemical nuclear propulsion schemes. Mass reductions may allow launch vehicle downsizing enable missions that would have been grounded because of cost constraints. The preceding figure illustrates a conceptual SEP stage design for a human Mars mission. Researchers at the NASA Glenn Research Center at Lewis Field designed conceptual SEP vehicle, conceived the mission architecture to use this vehicle, and analyzed the vehicle s performance. This SEP stage has a dry mass of 35 metric tons (MT), 40 MT of xenon propellant, and a photovoltaic array that spans 110 m, providing power to a cluster of eight 100-kW Hall thrusters. The stage can transfer an 80-MT payload and upper stage to the desired HEEPO. Preliminary packaging studies show this space-station-class SEP vehicle meets the proposed "Magnum" launch vehicle and volume requirements with considerable margin. An SEP vehicle for outer planetary missions, such as the Europa Mapper Mission, would be dramatically smaller than human Mars mission SEP stage. In this mission architecture, the SEP power system with the payload to provide spacecraft power throughout the mission. Several photovoltaic array design concepts were considered for the SEP vehicle power system for the human mission to Mars. These include a space station derivative, a SCARLET (Solar Concentrator Arrays with Refractive Linear Element Technology) derivative, and a hybrid inflatable-deployable thin polymer membrane array with thin-film solar cells (as shown in the concept illustration). This concept is based on a design developed for the Next Generation Space Telescope Sun shield. The array is divided into 16 independent electrical sections with 500-V, negative-grounded solar cell strings. The power system employs a channelized, 500-Vdc power management and distribution (PMAD) architecture with lithium ion batteries for energy storage for vehicle and payload secondary loads (the high-power Hall thrusters do not operate in eclipse periods). The 500-V PMAD voltage permits "direct-drive" thruster operation, greatly reducing the power processing unit size, complexity, and power loss. Similar power system architecture, designs, and technology are assumed for the Europa Mapper Mission SEP vehicle. The primary exceptions are that the photovoltaic array is assumed to consist of two rectangular wings and that the power system rating is 15 kW in Earth orbit and 200 W at Europa. To size the SEP vehicle power system, a dedicated Fortran code was developed to predict detailed power system performance, mass, and thermal control requirements. This code also modeled all the relevant Earth orbit environments; that is, the particulate radiation, plasma, meteoroids and debris, ultraviolet radiation, contamination, and thermal conditions. Analysis results for the Human Mars Mission SEP vehicle show a power system mass of 9-MT and photovoltaic array area of 5800-square meters for the thin-membrane design concept with CuInS2 thin-film cells. Power processing unit input power for a thin-membrane array design with three-junction, amorphous SiGe solar cells is shown in the graph. Power falls off rapidly inhe first weeks of the mission because of light-induced (Staebler-Wronksi) solar cell losses. During the next 200 days, power decreases steadily as the SEP stage spirals through the proton belts and sustains the bulk of the mission radiation damage. Once the vehicle apogee is above approximately four Earth radii, little additional degradation is incurred. From 400 to 800 days, a 1100-km "parking" orbit is maintained to await the next payload transfer opportunity. This orbit is below the main proton belt, and thus, little radiation dose is accumulated during this time period. During the second LEO-to-HEEPO transfer, power degrades somewhat further, but power requirements are still met. In comparison, the Europa Mapper SEP vehicle power system had a mass of 150 kg and a thin membrane array area of 100 square meters.

Kerslake, Thomas W.↗

NASA NTRS1976

Pulsed thermionic converter study

A nuclear electric propulsion concept using a thermionic reactor inductively coupled to a magnetoplasmadynamic accelerator (MPD arc jet) is described, and the results of preliminary analyses are presented. In this system, the MPD thruster operates intermittently at higher voltages and power levels than the thermionic generating unit. A typical thrust pulse from the MPD arc jet is characterized by power levels of 1 to 4 MWe, a duration of 1 msec, and a duty cycle of approximately 20%. The thermionic generating unit operates continuously but with a lower power level of approximately 0.4 MWe. Energy storage between thrust pulses is provided by building up a large current in an inductor using the output of the thermionic converter array. Periodically, the charging current is interrupted, and the energy stored in the magnetic field of the inductor is utilized for a short duration thrust pulse. The results of the preliminary analysis show that a coupling effectiveness of approximately 85 to 90% is feasible for a nominal 400 KWe system with an inductive unit suitable for a flight vehicle.

Source record↗

NASA NTRS2002

Power System for Venus Surface Exploration

A radioisotope power and cooling system is designed to provide electrical power for a probe operating on the surface of Venus. Most foreseeable electronics devices and sensors cannot operate at the 450 C ambient surface temperature of Venus. Because the mission duration is substantially long and the use of thermal mass to maintain an operable temperature range is likely impractical, some type of active refrigeration may be required to keep electronic components at a temperature below ambient. The fundamental cooling parameters are the cold sink temperature, the hot sink temperature, and the amount of heat to be removed. In this instance, it is anticipated that electronics would have a nominal operating temperature of 300 C. Due to the highly thermal convective nature of the high-density (90 bar CO2) atmosphere, the hot sink temperature was assumed to be 50 C, which provided a 500 C temperature of the cooler's heat rejecter to the ambient atmosphere. The majority of the heat load on the cooler is from the high temperature ambient surface environment on Venus, with a small contribution of heat generation from electronics and sensors. Both thermoelectric (RTG) and dynamic power conversion systems were analyzed, based on use of a standard isotope (General-purpose heat source, or GPHS) brick. For the radioisotope Stirling power converter configuration designed, the Sage model predicts a thermodynamic power output capacity of 478.1 watts, which slightly exceeds the required 469.1 watts. The hot sink temperature is 1200 C, and the cold sink temperature is 500 C. The required heat input is 1740 watts. This gives a thermodynamic efficiency of 27.48 %. It is estimated that the mechanical efficiency of the power converter design is on the order of 85 %, based on experimental measurements taken from 500-watt power class, laboratory-tested Stirling engines. The overall efficiency is calculated to be 23.36 %. The mass of the power converter is estimated at approximately 21.6 kg. Additional information is included in the original extended abstract.

Landis, Geoffrey A.↗

NASA NTRS1994

Mars power system concept definition study. Volume 1: Study results

A preliminary top level study was completed to define power system concepts applicable to Mars surface applications. This effort included definition of power system requirements and selection of power systems with the potential for high commonality. These power systems included dynamic isotope, Proton Exchange Membrane (PEM) regenerative fuel cell, sodium sulfur battery, photovoltaic, and reactor concepts. Design influencing factors were identified. Characterization studies were then done for each concept to determine system performance, size/volume, and mass. Operations studies were done to determine emplacement/deployment maintenance/servicing, and startup/shutdown requirements. Technology development roadmaps were written for each candidate power system (included in Volume 2). Example power system architectures were defined and compared on a mass basis. The dynamic isotope power system and nuclear reactor power system architectures had significantly lower total masses than the photovoltaic system architectures. Integrated development and deployment time phasing plans were completed for an example DIPS and reactor architecture option to determine the development strategies required to meet the mission scenario requirements.

Littman, Franklin D.↗

NASA NTRS2008

Design and Fabrication of a 5-kWe Free-Piston Stirling Power Conversion System

Progress in the design and fabrication of a 5-kWe free-piston Stirling power conversion system is described. A scaled-down version of the successful 12.5-kWe Component Test Power Converter (CTPC) developed under NAS3-25463, this single cylinder prototype incorporates cost effective and readily available materials (steel versus beryllium) and components (a commercial linear alternator). The design consists of a displacer suspended on internally pumped gas bearings and a power piston/alternator supported on flexures. Non-contacting clearance seals are used between internal volumes. Heat to and from the prototype is supplied via pumped liquid loops passing through shell and tube heat exchangers. The control system incorporates several novel ideas such as a pulse start capability and a piston stroke set point control strategy that provides the ability to throttle the engine to match the required output power. It also ensures stable response to various disturbances such as electrical load variations while providing useful data regarding the position of both power piston and displacer. All design and analysis activities are complete and fabrication is underway. Prototype test is planned for summer 2008 at Foster-Miller to characterize the dynamics and steady-state operation of the prototype and determine maximum power output and system efficiency. Further tests will then be performed at Auburn University to determine start-up and shutdown characteristics and assess transient response to temperature and load variations.

Chapman, Peter A.↗