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Power-processing unit (PPU) designs for resistojet and arcjet propulsion systems were developed. Various PPU power converter and power circuit technologies were considered. Arcjet, resistojet and chemical propulsion system performance were compared. Significant propellant mass reductions are enabled with electric propulsion.
Static power processing efficiency illustrated by application to DC to DC converters
An advanced breadboard Power Processing Unit (PPU) for a low power ion propulsion system incorporating mass reduction techniques was designed and fabricated. As a result of similar output current requirements, the discharge supply was also used to provide the neutralizer heater and discharge heater functions by using three relays to switch the output connections. This multi-function supply reduces to four the number of power converters needed to produce the required six electrical outputs. Switching frequencies of 20 and 50 kHz were chosen as a compromise between the size of the magnetic components and switching losses. The advanced breadboard PPU is capable of a maximum total output power of 0.47 kW. Its component mass is 0.65 kg and its total mass 1.9 kg. The total efficiency at full power is 0.89.
Silicon carbide (SiC) power devices have demonstrated many performance advantages over their silicon (Si) counterparts. As the inherent material limitations of Si devices are being swiftly realized, wide-band-gap (WBG) materials such as SiC have become increasingly attractive for high power applications. In particular, SiC power metal oxide semiconductor field effect transistors' (MOSFETs) high breakdown field tolerance, superior thermal conductivity and low-resistivity drift regions make these devices an excellent candidate for power dense, low loss, high frequency switching applications in extreme environment conditions. In this paper, a novel power processing unit (PPU) architecture is proposed utilizing commercially available 4H-SiC power MOSFETs from CREE Inc. A multiphase straight boost converter topology is implemented to supply up to 10 kilowatts full-scale. High Temperature Gate Bias (HTGB) and High Temperature Reverse Bias (HTRB) characterization is performed to evaluate the long-term reliability of both the gate oxide and the body diode of the SiC components. Finally, susceptibility of the CREE SiC MOSFETs to damaging effects from heavy-ion radiation representative of the on-orbit galactic cosmic ray environment are explored. The results provide the baseline performance metrics of operation as well as demonstrate the feasibility of a hard-switched PPU in harsh environments.
An evaluation of high-power processing units (PPUs) for multimegawatt solar electric propulsion (SEP) vehicles using advanced ion thrusters is presented. Significant savings of scale are possible for PPUs used to supply power to ion thrusters operating at 0.1 to 1.5 MWe per thruster. The PPU specific mass is found to be strongly sensitive to variations in the ion thruster's power per thruster and moderately sensitive to variations in the thruster's screen voltage due to varying the I(sp) of the thruster. Each PPU consists of a dc-to-dc converter to increase the voltage from the 500 V dc of the photovoltaic power system to the 5 to 13 kV dc required by the ion thrusters.
The power of various multimegawatt (MMW) vehicles required for deep space missions such asthe Mars Missions in the stipulated time frame of years 2000-2015 ranges from 5 to 100 MWe. Thispaper summarizes an evaluation of high-power processing units (PPUs) for MMW solar electricpropulsion (SEP) vehicles using advanced magnetoplasma- dynamic (MPD) thrusters. Each PPUprovides DC-DC conversion and voltage matching between the phovoltaic power system and the MPDthrusters. The power system consists of DC-DC converter using MCTs. The PPUs are thencombined with contractors to provide PPU input and output isolation, and to allow switching betweenoperating and spare (redundant) PPUs and thrusters as needed. Based on analyses, it is found thatsignificant economies of scale are possible for PPUs that supply power to MPD thrusters operating at0.1 to 5 MWe per thruster.
This paper summarizes an evaluation of power processing units for nuclear electric propulsion vehicles using advanced magnetoplasmadynamic thruster.
A power processing system (PPS) is designed for a space-type high power (200W RF) multi-collector traveling-wave tube (TWT). The basic power circuit is presented along with the simplified block diagram and the input, output, and general requirements for the PPS design are tabulated. The paper covers the PPS design as to critical TWT/PPS interface requirements, high voltage cathode/collector supply, high voltage components material, packaging, grounding and isolation, and electrical performance. The use of a single two loop control system for the regulation of cathode and collector voltages is shown to give high efficiency, excellent steady-state and transient performance characteristics, and complete protection for TWT and PPS components under transient conditions.
Power-processing unit uses AC buses (30, 32) to supply all current dependent needs such as connections (54, 56) to an ion thruster through an inductor (88) and the primary of a transformer (90), to assure limited currents to such loads. Where temperature control is also required, such as to the main discharge vaporizer heater connection (36, 38), switches (100, 102) are serially connected with inductor (96) and the primary of transformer (98). Temperature sensor (104) controls the switches (100, 102) for temperature regulation.
Power processor interfaces, internal functions, and design techniques established for the 30-cm ion engine power processor are discussed. The interfaces include the ion engine interface, the spacecraft interface, source/load interactions, protection, and optimization criteria. In the analysis, particular attention is given to the interaction and protection aspects. A breadbord system designed and built for the 30-cm ion engine is discussed which will be used as an engineering tool to establish guidelines for electric propulsion systems.
A review is given of future power processing systems planned for the next 20 years, and the state-of-the-art of power processing design modeling and analysis techniques used to optimize power processing systems. A methodology of modeling and analysis of power processing equipment and systems has been formulated to fulfill future tradeoff studies and optimization requirements. Computer techniques were applied to simulate power processor performance and to optimize the design of power processing equipment. A program plan to systematically develop and apply the tools for power processing systems modeling and analysis is presented so that meaningful results can be obtained each year to aid the power processing system engineer and power processing equipment circuit designers in their conceptual and detail design and analysis tasks.
A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources: a nominal 300 Volt high voltage input bus and a nominal 28 Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power auxiliary supplies, and two parallel 7.5 kilowatt (kW) discharge power supplies that are capable of providing up to 15 kilowatts of total power at 300 to 500 Volts (V) to the thruster. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall effect thruster. The performance of the unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate exceptional performance with full power efficiencies exceeding 97%. The unit was also tested with a 12.5kW Hall effect thruster to verify compatibility and output filter specifications. With space-qualified silicon carbide or similar high voltage, high efficiency power devices, this would provide a design solution to address the need for high power electric propulsion systems.
A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources - a nominal 300-Volt high voltage input bus and a nominal 28-Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power supplies that provide power to the thruster auxiliary supplies, and two parallel 7.5 kilowatt power supplies that are capable of providing up to 15 kilowatts of total power at 300-Volts to 500-Volts to the thruster discharge supply. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall Effect Thruster. The performance of unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate the exceptional performance with full power efficiencies exceeding 97. With a space-qualified silicon carbide or similar high voltage, high efficiency power device, this design could evolve into a flight design for future missions that require high power electric propulsion systems.
Processing of electric power has been presented as a discipline that draws on almost every field of electrical engineering, including system and control theory, communications theory, electronic network design, and power component technology. The cost of power processing equipment, which often equals that of expensive, sophisticated, and unconventional sources of electrical energy, such as solar batteries, is a significant consideration in the choice of electric power systems.
Power distribution subsystems are required for three elements of the SPS program: (1) orbiting satellite, (2) ground rectenna, and (3) Electric Orbiting Transfer Vehicle (EOTV). Power distribution subsystems receive electrical power from the energy conversion subsystem and provide the power busses rotary power transfer devices, switchgear, power processing, energy storage, and power management required to deliver control, high voltage plasma interactions, electric thruster interactions, and spacecraft charging of the SPS and the EOTV are also included as part of the power distribution subsystem design.
A design for a greatly simplified power-processing unit (SPPU) for the 8-cm diameter mercury-ion-thruster subsystem is discussed. This SPPU design will provide a tenfold reduction in parts count, a decrease in system mass and cost, and an increase in system reliability compared to the existing power-processing unit (PPU) used in the Hughes/NASA Lewis Research Center Ion Auxiliary Propulsion Subsystem. The simplifications achieved in this design will greatly increase the attractiveness of ion propulsion in near-term and future spacecraft propulsion applications. A description of a typical ion-thruster subsystem is given. An overview of the thruster/power-processor interface requirements is given. Simplified thruster power processing is discussed.
Advanced technologies developed in support of Ion Propulsion power processing, including the power circuitry portion of the Series L-C Resonant Inverter, Beam Supply, power components, packaging and heat pipe cooling of the 30 cm Ion Engine Power Processor are described. Both the transistorized and SCR versions of the Series L-C Resonant Inverter Beam Supply are discussed. A BIMOD Ion Thruster/Power Processor Prototype Assembly is undergoing environmental and life testing. These advanced technologies can be applied advantageously to other applications of future high power space power processing equipment.
The work in power processing is reported. Input-output models, and Lie groups in control theory are discussed along with the methods of analysis for time invariant electrical networks.