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Volume and Mass Estimation of Three-Phase High Power Transformers for Space Applications

Spacecraft historically have had sub-1kW(sub e), electrical requirements for GN&C, science, and communications: Galileo at 600W(sub e), and Cassini at 900W(sub e), for example. Because most missions have had the same order of magnitude power requirements, the Power Distribution Systems (PDS) use existing, space-qualified technology and are DC. As science payload and mission duration requirements increase, however, the required electrical power increases. Subsequently, this requires a change from a passive energy conversion (solar arrays and batteries) to dynamic (alternator, solar dynamic, etc.), because dynamic conversion has higher thermal and conversion efficiencies, has higher power densities, and scales more readily to higher power levels. Furthermore, increased power requirements and physical distribution lengths are best served with high-voltage, multi-phase AC to maintain distribution efficiency and minimize voltage drops. The generated AC-voltage must be stepped-up (or down) to interface with various subsystems or electrical hardware. Part of the trade-space design for AC distribution systems is volume and mass estimation of high-power transformers. The volume and mass are functions of the power rating, operating frequency, the ambient and allowable temperature rise, the types and amount of heat transfer available, the core material and shape, the required flux density in a core, the maximum current density, etc. McLyman has tabulated the performance of a number of transformers cores and derived a "cookbook" methodology to determine the volume of transformers, whereas Schawrze had derived an empirical method to estimate the mass of single-phase transformers. Based on the work of McLyman and Schwarze, it is the intent herein to derive an empirical solution to the volume and mass estimation of three-phase, laminated EI-core power transformers, having radiated and conducted heat transfer mechanisms available. Estimation of the mounting hardware, connectors, etc. is not included.

Kimnach, Greg L.↗

Intermodal microwave-to-optical transduction using silicon-on-sapphire optomechanical ring resonator

Optomechanical and electro-optomechanical systems have emerged as one of the most promising approaches for quantum microwave-to-optical transduction to interconnect distributed quantum modalities for scaling the quantum systems. These systems use suspended structures to increase mode overlap and mitigate loss to achieve high efficiency. However, the suspended design’s poor heat dissipation under strong drive limits the ultimate efficiency. Here, we demonstrate an unsuspended optomechanical ring resonator (OMR) based on the silicon-on-sapphire (SOS) platform for microwave-to-optical frequency conversion. The OMR achieves a triply resonant optical-to-optical conversion with an enhanced coupling rateG b = 3.6 gigahertz per square-root milliwatt at a peak conversion efficiency of 1.2% with 3.6-milliwatt microwave drive power and a microwave-to-optical conversion efficiency of 1.5 × 10 −5 at 10-milliwatt optical drive power. Our results show that the unsuspended SOS platform, which mitigates the thermal effect and is compatible with superconducting qubits, is a promising platform for optomechanical circuitry and quantum transduction.

Science & Technology - Other Topics↗

NASA Radioisotope Power Conversion Technology NRA Overview

The focus of the National Aeronautics and Space Administration's (NASA) Radioisotope Power Systems (RPS) Development program is aimed at developing nuclear power and technologies that would improve the effectiveness of space science missions. The Radioisotope Power Conversion Technology (RPCT) NASA Research Announcement (NRA) is an important mechanism through which research and technology activities are supported in the Advanced Power Conversion Research and Technology project of the Advanced Radioisotope Power Systems Development program. The purpose of the RPCT NRA is to advance the development of radioisotope power conversion technologies to provide higher efficiencies and specific powers than existing systems. These advances would enable a factor of two to four decrease in the amount of fuel and a reduction of waste heat required to generate electrical power, and thus could result in more cost effective science missions for NASA. The RPCT NRA selected advanced RPS power conversion technology research and development proposals in the following three areas: innovative RPS power conversion research, RPS power conversion technology development in a nominal 100 W(sub e) scale; and, milliwatt/multi-watt RPS (mWRPS) power conversion research. Ten RPCT NRA contracts were awarded in 2003 in the areas of Brayton, Stirling, thermoelectric (TE), and thermophotovoltaic (TPV) power conversion technologies. This paper will provide an overview of the RPCT NRA, a summary of the power conversion technologies approaches being pursued, and a brief digest of first year accomplishments.

Anderson, David J.↗

NASA Radioisotope Power Conversion Technology NRA Overview

The focus of the National Aeronautics and Space Administration s (NASA) Radioisotope Power Systems (RPS) Development program is aimed at developing nuclear power and technologies that would improve the effectiveness of space science missions. The Radioisotope Power Conversion Technology (RPCT) NASA Research Announcement (NRA) is an important mechanism through which research and technology activities are supported in the Advanced Power Conversion Research and Technology project of the Advanced Radioisotope Power Systems Development program. The purpose of the RPCT NRA is to advance the development of radioisotope power conversion technologies to provide higher efficiencies and specific powers than existing systems. These advances would enable a factor of 2 to 4 decrease in the amount of fuel and a reduction of waste heat required to generate electrical power, and thus could result in more cost effective science missions for NASA. The RPCT NRA selected advanced RPS power conversion technology research and development proposals in the following three areas: innovative RPS power conversion research, RPS power conversion technology development in a nominal 100We scale; and, milliwatt/multi-watt RPS (mWRPS) power conversion research. Ten RPCT NRA contracts were awarded in 2003 in the areas of Brayton, Stirling, thermoelectric (TE), and thermophotovoltaic (TPV) power conversion technologies. This paper will provide an overview of the RPCT NRA, a summary of the power conversion technologies approaches being pursued, and a brief digest of first year accomplishments.

Anderson, David J.↗

Modular Stirling Radioisotope Generator

High efficiency radioisotope power generators will play an important role in future NASA space exploration missions. Stirling Radioisotope Generators (SRG) have been identified as a candidate generator technology capable of providing mission designers with an efficient, high specific power electrical generator. SRGs high conversion efficiency has the potential to extend the limited Pu-238 supply when compared with current Radioisotope Thermoelectric Generators (RTG). Due to budgetary constraints, the Advanced Stirling Radioisotope Generator (ASRG) was canceled in the fall of 2013. Over the past year a joint study by NASA and DOE called the Nuclear Power Assessment Study (NPAS) recommended that Stirling technologies continue to be explored. During the mission studies of the NPAS, spare SRGs were sometimes required to meet mission power system reliability requirements. This led to an additional mass penalty and increased isotope consumption levied on certain SRG-based missions. In an attempt to remove the spare power system, a new generator architecture is considered which could increase the reliability of a Stirling generator and provide a more fault-tolerant power system. This new generator called the Modular Stirling Radioisotope Generator (MSRG) employs multiple parallel Stirling convertor/controller strings, all of which share the heat from the General Purpose Heat Source (GPHS) modules. For this design, generators utilizing one to eight GPHS modules were analyzed, which provide about 50 to 450 watts DC to the spacecraft, respectively. Four Stirling convertors are arranged around each GPHS module resulting in from 4 to 32 Stirling/controller strings. The convertors are balanced either individually or in pairs, and are radiatively coupled to the GPHS modules. Heat is rejected through the housing/radiator which is similar in construction to the ASRG. Mass and power analysis for these systems indicate that specific power may be slightly lower than the ASRG and similar to the MMRTG. However, the reliability should be significantly increased compared to ASRG.

Stirling Cycle↗

High-Power Microwave Oscillator of Twistron Type with Efficiency of 55% for Electron Energy of 180 keV

Highly effective mode of generation of a relativistic microwave oscillator of twistron type is calculated by numerical simulation using an axisymmetric version of completely electromagnetic PiC-code KARAT. With accelerating voltage of 180 kV, electron beam current of 1.2 kA, and 1.9 T guiding magnetic field strength, the simulated stationary generation power is 120 MW at an operating frequency of 10.7 GHz. The efficiency of electron beam power conversion to electromagnetic radiation is 55%, and the electronic efficiency of the oscillator calculated from the change of the initial electron energy is 64%.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Theoretical studies of solar pumped lasers

One concept for collecting solar energy is to use large solar collectors and then use lasers as energy converters whose output beams act as transmission lines to deliver the energy to a destination. The efficiency of the process would be improved if the conversion could be done directly using solar pumped lasers, and the possibility of making such lasers is studied. There are many applications for such lasers, and these are examined. By including the applications first, the requirements for the lasers will be more evident. They are especially applicable to the Space program, and include cases where no other methods of delivering power seem possible. Using the lasers for conveying information and surveillance is also discussed. Many difficulties confront the designer of an efficient system for power conversion. These involve the nature of the solar spectrum, the method of absorbing the energy, the transfer of power into laser beams, and finally, the far field patterns of the beams. The requirements of the lasers are discussed. Specific laser configurations are discussed. The thrust is into gas laser systems, because for space applications, the laser could be large, and also the medium would be uniform and not subject to thermal stresses. Dye and solid lasers are treated briefly. For gas lasers, a chart of the various possibilities is shown, and the various families of gas lasers divided according to the mechanisms of absorbing solar radiation and of lasing. Several specific models are analyzed and evaluated. Overall conclusions for the program are summarized, and the performances of the lasers related to the requirements of various applications.

Harries, Wynford L.↗

Gallium nitride based power switches for next generation of power conversion

Power conversion impacts all areas of electricity consumption, including motion control, lighting, air conditioning, and information technology. Si, the workhorse of the industry, has served well so far but reached its material limits. To keep up with the advancement of technologies enabling new conveniences, power conversion techniques need to go through significant transformation that calls for the next generation semiconductor for power switching. SiC and GaN, which have the potential to push the envelope beyond Si providing solutions for the entire range of power conversion at higher efficiencies and reduced form factors. GaN HEMTs have an added advantage over SiC MOSFETs owing to the high-mobility electron channel formed at the AlGaN/GaN interface, which has been the basis of radio frequency amplifiers. GaN has enabled systems that can run with lesser cooling at frequencies at least ten times higher than current Si-based systems, significantly reducing the form factor both electrically (passive components) and mechanically (heat sinks). The high current and voltage required for high power conversion application make the chip area in a lateral topology uneconomical and difficult to manufacture. Vertical GaN devices on bulk GaN substrates complete the portfolio of power switches required to address the power conversion market.

Chowdhury, S↗

Crystal Lattice Controlled SiGe Thermoelectric Materials with High Figure of Merit

Direct energy conversion between thermal and electrical energy, based on thermoelectric (TE) effect, has the potential to recover waste heat and convert it to provide clean electric power. The energy conversion efficiency is related to the thermoelectric figure of merit ZT expressed as ZT=S(exp 2)(sigma)T/Kappa, T is temperature, S is the Seebeck coefficient, sigma is conductance and Kappa is thermal conductivity. For a lower thermal conductivity Kappa and high power factor (S(exp 2)(sigma)), our current strategy is the development of rhombohedrally strained single crystalline SiGe materials that are highly [111]-oriented twinned. The development of a SiGe "twin lattice structure (TLS)" plays a key role in phonon scattering. The TLS increases the electrical conductivity and decreases thermal conductivity due to phonon scattering at stacking faults generated from the 60 X rotated primary twin structure. To develop high performance materials, the substrate temperature, chamber working pressure, and DC sputtering power are controlled for the aligned growth production of SiGe layer and TLS on a c-plane sapphire. Additionally, a new elevated temperature thermoelectric characterization system, that measures the thermal diffusivity and Seebeck effect nondestructively, was developed. The material properties were characterized at various temperatures and optimized process conditions were experimentally determined. The present paper encompasses the technical discussions toward the development of thermoelectric materials and the measurement techniques.

Kim, Hyun-Jung↗

Milestone Report: Effect of High Temperature CO 2 on Haynes 230 Alloy

The supercritical carbon dioxide (sCO 2 ) Brayton cycle is a promising candidate for future nuclear reactors due to its ability to improve power cycle energy conversion efficiency. The sCO 2 Brayton cycle can operate with an efficiency of 45-50% at operating temperatures of 550-700 C. One of the greatest hurdles currently faced by sCO 2 Brayton cycles is the extreme corrosivity of sCO 2 . This affects the longevity of the power cycle and thus the levelized cost of electricity. Past studies have shown that sCO 2 corrosion occurs through the formation of metal carbonates, oxide layers, and carburization, and alloys with Cr, Mo and Ni generally exhibit less corrosion. While stainless steels may offer sufficient corrosion resistance at the lower range of temperatures seen by the sCO 2 Brayton cycles, more expensive alloys such as Inconel and Haynes are typically needed for the higher temperature regions. This study investigates the effects of corrosion on the Haynes 230 alloy, focusing on changes in the mechanical properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

High efficiency fluorescent excimer lamps: An alternative to mercury based UVC lamps

A high efficiency xenon excimer lamp radiating at 172 nm, with an internal phosphor coating shifting to UVC has been demonstrated, showing the feasibility of a cost effective alternative to UVC mercury lamps. Fluorescent lamps so designed can be fabricated in various geometries with high efficiency. Unlike other xenon excimer lamps based on dielectric barrier discharges this new system is highly compatible with existing and proposed phosphors as it operates in an inert gas environment at modest temperature and is subject only to 172 nm primary radiation. Using a lamp coated with a UVC phosphor we have demonstrated the feasibility of germicidal and curing lamps with 40% energy conversion efficiency and high power density. These lamps are rapidly switchable, have long projected lifetimes and are compatible with dimmers.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Solid-State Power Generating Microdevices for Distributed Space System Architectures

Deep space missions have a strong need for compact, high power density, reliable and long life electrical power generation and storage under extreme temperature conditions. Conventional power generating devices become inefficient at very low temperatures (temperatures lower than 200 K encountered during Mars missions for example) and rechargeable energy storage devices cannot be operated thereby limiting mission duration. At elevated temperatures (for example for planned solar probe or Venus lander missions), thin film interdiffusion destroys electronic devices used for generating and storing power. Solar power generation strongly depends upon the light intensity, which falls rapidly in deep interplanetary missions (beyond 5 AU), and in planetary missions in the sun shadow or in dusty environments (Mars, for example). Radioisotope thermoelectric generators (RTGs) have been successfully used for a number of deep space missions RTGs. However, their energy conversion efficiency and specific power characteristics are quite low, and this technology has been limited to relatively large systems (more than 100 W). The National Aeronautics and Space Administration (NASA) and the Jet Propulsion Laboratory (JPL) have been planning the use of much smaller spacecrafts that will incorporate a variety of microdevices and miniature vehicles such as microdetectors, microsensors, and microrovers. Except for electrochemical batteries and solar cells, there are currently no available miniaturized power sources. Novel technologies that will function reliably over a long duration mission (ten years and over), in harsh environments (temperature, pressure, and atmosphere) must be developed to enable the success of future space missions. It is also expected that such micropower sources could have a wide range of terrestrial applications, in particular when the limited lifetime and environmental limitations of batteries are key factors. Additional information is contained in the original extended abstract.

Fleurial, J.-P.↗

Special Pyrheliometer Shroud Development

To insure that the insolation values accurately represent the input power to a power conversion unit the field of view (FOV) of the concentrator aperture and the insolation radiometer must be the same. The calculations, implementation, and results of this approach are covered. Three instruments were used to measure the insolation: an Eppley Normal Incidence Radiometer (NIP) and two versions of the kendall cavity radiometer. The shrouds used to limit the FOV of the radiometers were designed to simulate the FOV of the PDC-1 concentrater with the cold water cavity calorimeter. This technique of matching the FOV of an insolation radiometer to the FOV of a specific concentrater and receiver aperture appears to be both practical and effective. The efficiency of a power conversion unit will be too low if the insolation is measured with a radiometer which has a FOV which is larger than the FOV of the concentrator.

Dennison, E. W.↗

Electrodeposited Nanolaminated CoNiFe Cores for Ultracompact DC-DC Power Conversion

Laminated metallic alloy cores (i.e., alternating layers of thin film metallic alloy and insulating material) of appropriate lamination thickness enable suppression of eddy current losses at high frequencies. Magnetic cores comprised of many such laminations yield substantial overall magnetic volume, thereby enabling high-power operation. Previously, we reported nanolaminated permalloy (Ni-80 Fe-20) cores based on a sequential electrodeposition technique, demonstrating negligible eddy current losses at peak flux densities up to 0.5 T and operating at megahertz frequencies. This paper demonstrates improved performance of nanolaminated cores comprising tens to hundreds of layers of 300-500-nm-thick CoNiFe films that exhibit superior magnetic properties (e.g., higher saturation flux density and lower coercivity) than permalloy. Nanolaminated CoNiFe cores can be operated up to a peak flux density of 0.9 T, demonstrating improved power handling capacity and exhibiting 30% reduced volumetric core loss, attributed to lowered hysteresis losses compared to the nanolaminated permalloy core of the same geometry. Operating these cores in a buck dc-dc power converter at a switching frequency of 1 MHz, the nanolaminated CoNiFe cores achieved a conversion efficiency exceeding 90% at output power levels up to 7 W, compared to an achieved permalloy core conversion efficiency below 86% at 6 W.

Kim, J↗

164-GHz MMIC HEMT Frequency Doubler

A monolithic microwave integrated circuit (MMIC) that includes a high-electron-mobility transistor (HEMT) has been developed as a prototype of improved frequency doublers for generating signals at frequencies greater than 100 GHz. Signal sources that operate in this frequency range are needed for a variety of applications, notably including general radiometry and, more specifically, radiometric remote sensing of the atmosphere. Heretofore, it has been common practice to use passive (diode-based) frequency multipliers to obtain frequencies greater than 100 GHz. Unfortunately, diode-based frequency multipliers are plagued by high DC power consumption and low conversion efficiency. Moreover, multiplier diodes are not easily integrated with such other multiplier-circuit components as amplifiers and oscillators. The goals of developing the present MMIC HEMT frequency doubler were (1) to utilize the HEMT as an amplifier to increase conversion efficiency (more precisely, to reduce conversion loss), thereby increasing the output power for a given DC power consumption or, equivalently, reducing the DC power consumption for a given output power; and (2) to provide for the integration of amplifier and oscillator components on the same chip. The MMIC frequency doubler (see Figure 1) contains an AlInAs/GaInAs/InP HEMT biased at pinch-off to make it function as a class-B amplifier (meaning that it conducts in half-cycle pulses). Grounded coplanar waveguides (GCPWs) are used as impedance-matching transmission lines. Air bridges are placed at discontinuities to suppress undesired slot electromagnetic modes. Another combination of GCPWs also serves both as a low-pass filter to suppress undesired oscillations at frequencies below 60 GHz and as a DC blocker. Large decoupling capacitors and epitaxial resistors are added in the drain and gate lines to suppress bias oscillations. At the output terminal, the fundamental frequency is suppressed by a quarter-wave open stub, which presents a short circuit at the fundamental frequency and an open circuit at the second harmonic. At an input power of 7 mW, the output power and conversion loss at an output frequency of 164 GHz were found to be 5 dBm (approximately equal to 3.2 mW) and 2 dB, respectively, with a 3-dB output-power bandwidth of 14 GHz. This is the best performance reported to date for an MMIC HEMT frequency doubler above 100 GHz.

Samoska, Lorene↗

Hydrogen Fueling Station in Honolulu, Hawaii Feasibility Analysis

The Department of Energy Hydrogen & Fuel Cells Program Plan (September 2011) identifies the use of hydrogen for government and fleet electric vehicles as a key step for achieving “reduced greenhouse gas emissions; reduced oil consumption; expanded use of renewable power…; highly efficient energy conversion; fuel flexibility…; reduced air pollution; and highly reliable grid-support.” This report synthesizes several pieces of existing information that can inform a decision regarding the viability of deploying a hydrogen (H2) fueling station at the Fort Armstrong site in Honolulu, Hawaii.

08 HYDROGEN↗

Novel fractal-textured solar absorber surfaces for concentrated solar power

The solar absorptance of a thermal receiver surface significantly affects the photothermal conversion efficiency of concentrated solar power (CSP) plants. The development of low-cost Gen3 CSP systems calls for increasing the solar absorptance of the thermal receivers at operating temperatures above 750 °C. This study presents an innovative approach to the fractal, multiscale texturing of absorber surfaces to significantly enhance solar energy absorption for Gen3 CSP applications. The absorber surface is described in terms of its fractal parameters that are uniquely determined from surface profile measurements. The interaction of solar radiation with the fractal surface is numerically simulated by solving the governing Maxwell’s equations for electromagnetic wave propagation to investigate the effect of texturing on the absorptance of the surfaces. It is shown that absorption of the solar spectrum increases with an increase in the fractal dimension and the multiscale asperity height of the surface texturing. Here, the theoretical model is demonstrated to be in close agreement with experimental measurements of spectral absorptance of electrodeposited copper (Cu), copper mono-oxide (CuO), and copper-manganese oxide (CuMnO) surfaces that are textured to produce a range of fractal parameters by tailoring the deposition parameters. Fractal surface texturing is shown to reduce reflectance by over one order of magnitude, yielding an absorptance of greater than 0.985 for CuMnO. For the first time, the study presents a significant effective means of increasing solar absorptance and a fundamental theoretical description of the underlying physics.

14 SOLAR ENERGY↗

High-Temperature Air Stability of Electrodeposited Copper Cobalt Oxide and Copper Manganese Oxide Absorber Coatings for Concentrating Solar Power

The solar absorptance of a thermal receiver surface significantly affects the photothermal conversion efficiency of concentrating solar power (CSP) plants. The stability of solar receivers and coatings applied to improve solar absorptance at high temperatures is critical for efficient and long-term operation. This study analyzes the high-temperature air stability of multiscale fractal textured electrodeposited copper manganese oxide and copper cobalt oxide solar receiver coatings over a range of temperatures. The study also investigates the effect of high temperature on phase stability, chemical and morphological evolution, and the optical properties of the two solar absorber materials. A computational model is developed to determine the absorptance of the textured absorbers and is shown to match the experimental measurements closely over a range of heat treatment temperatures from 450 °C to 850 °C and durations up to 100 h. Degradation curves and coating stability maps are developed from the study. Copper manganese oxide and copper cobalt oxide coatings exhibit good thermal stability up to ~815 °C and 630 °C, respectively, with minimal changes in their optical and structural properties with thermal efficiency greater than 90%. Furthermore, the study offers valuable insights into the high-temperature annealing effects on the optical and structural properties of multiscale copper alloyed coatings fabricated by electrodeposition and presents a means of designing the optimal temperature range for maximizing absorber efficiency in practical applications.

14 SOLAR ENERGY↗