High Efficiency Hybrid Forward Converter Module
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power processing power technology power converter↗
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Materials technology for Stirling space power converters
This program was conducted in support of the NASA LeRC development of the Stirling power converter (SPC) for space power applications. The objectives of this contract were: (1) to perform a technology review and analyses to support the evaluation of materials issues for the SPC; (2) to evaluate liquid metal compatibility issues of the SPC; (3) to evaluate and define a transient liquid phase diffusion bonding (TLPDB) process for the SPC joints to the Udimet 720 heater head; and (4) to evaluate alternative (to the TLPDB) joining techniques. In the technology review, several aspects of the current Stirling design were examined including the power converter assembly process, materials joining, gas bearings, and heat exchangers. The supporting analyses included GLIMPS power converter simulation in support of the materials studies, and system level analysis in support of the technology review. The liquid metal compatibility study evaluated process parameters for use in the Stirling power converter. The alternative joining techniques study looked at the applicability of various joining techniques to the Stirling power converter requirements.
Baggenstoss, William↗
Transmitter experiment package for the communications technology satellite
The operating requirements, system design characteristics, high voltage packaging considerations, nonstandard components development, and test results for the transmitter experiment package (TEP) are described. The TEP is used for broadcasting power transmission from the Communications Technology Satellite. The TEP consists of a 12 GHz, 200-watt output stage tube (OST), a high voltage processing system that converts the unregulated spacecraft solar array power to the regulated voltages required for OST operation, and a variable conductance heat pipe system that is used to cool the OST body.
Farber, B.↗
Goals of thermionic program for space power
The thermionic and Brayton reactor concepts were compared for application to space power. For a turbine inlet temperature of 15000 K the Brayton powerplant weighted 5 to 40% less than the thermionic concept. The out of core concept separates the thermionic converters from their reactor. Technical risks are diminished by: (1) moving the insolator out of the reactor; (2) allowing a higher thermal flux for the thermionic converters than is required of the reactor fuel; and (3) eliminating fuel swelling's threat against lifetime of the thermionic converters. Overall performance can be improved by including power processing in system optimization for design and technology on more efficient, higher temperature power processors. The thermionic reactors will be larger than those for competitive systems with higher conversion efficiency and lower reactor operating temperatures. It is concluded that although the effect of reactor size on shield weight will be modest for unmanned spacecraft, the penalty in shield weight will be large for manned or man-tended spacecraft.
English, R. E.↗
Resistojet- and arcjet-propulsion power processing
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.
Palaszewski, Bryan↗
Status of a Power Processor for the Prometheus-1 Electric Propulsion System
NASA is developing technologies for nuclear electric propulsion for proposed deep space missions in support of the Exploration initiative under Project Prometheus. Electrical power produced by the combination of a fission-based power source and a Brayton power conversion and distribution system is used by a high specific impulse ion propulsion system to propel the spaceship. The ion propulsion system include the thruster, power processor and propellant feed system. A power processor technology development effort was initiated under Project Prometheus to develop high performance and lightweight power-processing technologies suitable for the application. This effort faces multiple challenges including developing radiation hardened power modules and converters with very high power capability and efficiency to minimize the impact on the power conversion and distribution system as well as the heat rejection system. This paper documents the design and test results of the first version of the beam supply, the design of a second version of the beam supply and the design and test results of the ancillary supplies.
Pinero, Luis R.↗
Stirling Space Engine Program: Appendixes A, B, C and D - Volume 2
The objective of this program was to develop the technology necessary for operating Stirling power converters in a space environment and to demonstrate this technology in full-scale engine tests. Volume 2 of the report includes the following appendices: Appendix A: Heater Head Development (Starfish Heater Head Program, 1/10th Segment and Full-Scale Heat Pipes, and Sodium Filling and Processing); Appendix B: Component Test Power Converter (CTPC) Component Development (High-temperature Organic Materials, Heat Exchanger Fabrication, Beryllium Issues, Sodium Issues, Wear Couple Tests, Pressure Boundary Penetrations, Heating System Heaters, and Cooler Flow Test); Appendix C: Udimet Testing (Selection of the Reference Material for the Space Stirling Engine Heater Head, Udimet 720LI Creep Test Result Update, Final Summary of Space Stirling Endurance Engine Udimet 720L1 Fatigue Testing Results, Udimet 720l1 Weld Development Summary, and Udimet 720L1 Creep Test Final Results Summary), and Appendix D: CTPC Component Development Photos.
Dhar, Manmohan↗
Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)
Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.
36 MATERIALS SCIENCE↗
Developing Urban Air Mobility Vehicle Models to Support Air Traffic Management Concept Development
To support Urban Air Mobility (UAM) research efforts at NASA, the Airspace Target Generator (ATG) software used in the FutureFlight Central (FFC) air traffic control tower simulator is undergoing updates to support physics-based UAM vehicle models. A process was developed to integrate UAM vertical takeoff and landing (VTOL) aircraft into the fixed-wing ATG modeling environment without significant change to the underlying equations of motion and vehicle model database. The VTOL aircraft models were converted from a six degrees-of-freedom (6-DOF) representation into a four degrees-of-freedom (4-DOF) representation for integration within ATG. Three vehicle designs from the NASA Revolutionary Vertical-Lift Technologies (RVLT) project were selected: a lift-plus-cruise (LPC) aircraft model and quadrotor, electric-powered (QEP) 1-seater and 6-seater models. With the LPC model comprised of a nonlinear force and moment build-up, and the QEP models comprised of linearized stability derivatives, two separate processes were developed to convert the lift, drag, and propulsion characteristics of each model into the ATG model database. Key aircraft performance characteristics including climb, cruise, and descent performance were preserved during the conversion process. Because ATG simulates fixed-wing aircraft through ground taxi and takeoff to approach and landing, acceleration command algorithms were developed to model the vertical takeoff and vertical landing phase of UAM operations. A strategy was then developed to transition the aircraft model to- and from- the new control mode.
urban air mobility↗
Development of CMOS Active Pixel Image Sensors for Low Cost Commercial Applications
JPL, under sponsorship from the NASA Office of Advanced Concepts and Technology, has been developing a second-generation solid-state image sensor technology. Charge-coupled devices (CCD) are a well-established first generation image sensor technology. For both commercial and NASA applications, CCDs have numerous shortcomings. In response, the active pixel sensor (APS) technology has been under research. The major advantages of APS technology are the ability to integrate on-chip timing, control, signal-processing and analog-to-digital converter functions, reduced sensitivity to radiation effects, low power operation, and random access readout.
solid-state image sensors active pixel sensor APS ↗
NASA thermionic-conversion program
Technological processes in out-of-core thermionic energy conversion are described. The emphasis was on high temperature electrode materials and system engineering of converter geometries to produce practical power densities.
Morris, J. F.↗
Lightweight Battery Charge Regulator Used to Track Solar Array Peak Power
A battery charge regulator based on the series-connected boost regulator (SCBR) technology has been developed for high-voltage spacecraft applications. The SCBR regulates the solar array power during insolation to prevent battery overcharge or undercharge conditions. It can also be used to provide regulated battery output voltage to spacecraft loads if necessary. This technology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. The high-voltage SCBR shown in the photograph has demonstrated power densities of over 1000 watts per kilogram (W/kg). Using four 150-W dc-dc converter modules, it can process 2500 W of power at 120 Vdc with a minimum input voltage of 90 Vdc. Efficiency of the SCBR was 94 to 98 percent over the entire operational range. Internally, the unit is made of two separate SCBR s, each with its own analog control circuitry, to demonstrate the modularity of the technology. The analog controllers regulate the output current and incorporate the output voltage limit with active current sharing between the two units. They also include voltage and current telemetry, on/off control, and baseplate temperature sensors. For peak power tracking, the SCBR was connected to a LabView-based data acquisition system for telemetry and control. A digital control algorithm for tracking the peak power point of a solar array was developed using the principle of matching the source impedance with the load impedance for maximum energy transfer. The algorithm was successfully demonstrated in a simulated spacecraft electrical system at the Boeing PhantomWorks High Voltage Test Facility in Seattle, Washington. The system consists of a 42-string, high-voltage solar array simulator, a 77-cell, 80-ampere-hour (A-hr) nickel-hydrogen battery, and a constant power-load module. The SCBR and the LabView control algorithm successfully tracked the solar array peak power point through various load transients, including sunlight discharge transients when the total load exceeded the maximum solar array output power.
Soeder, James F.↗
High Power Silicon Carbide (SiC) Power Processing Unit Development
NASA GRC successfully designed, built and tested a technology-push power processing unit for electric propulsion applications that utilizes high voltage silicon carbide (SiC) technology. The development specifically addresses the need for high power electronics to enable electric propulsion systems in the 100s of kilowatts. This unit demonstrated how high voltage combined with superior semiconductor components resulted in exceptional converter performance.
Power Processing↗
Compact, Lightweight Adsorber and Sabatier Reactor for CO2 Capture and Reduction for Consumable and Propellant Production
The utilization of CO2 to produce (or recycle) life support consumables, such as O2 and H2O, and to generate propellant fuels is an important aspect of NASA's concept for future, long duration planetary exploration. One potential approach is to capture and use CO2 from the Martian atmosphere to generate the consumables and propellant fuels. Precision Combustion, Inc. (PCI), with support from NASA, continues to develop its regenerable adsorber technology for capturing CO2 from gaseous atmospheres (for cabin atmosphere revitalization and in-situ resource utilization applications) and its Sabatier reactor for converting CO2 to methane and water. Both technologies are based on PCI's Microlith(R) substrates and have been demonstrated to reduce size, weight, and power consumption during CO2 capture and methanation process. For adsorber applications, the Microlith substrates offer a unique resistive heating capability that shows potential for short regeneration time and reduced power requirements compared to conventional systems. For the Sabatier applications, the combination of the Microlith substrates and durable catalyst coating permits efficient CO2 methanation that favors high reactant conversion, high selectivity, and durability. Results from performance testing at various operating conditions will be presented. An effort to optimize the Sabatier reactor and to develop a bench-top Sabatier Development Unit (SDU) will be discussed.
Junaedi, Christian↗
Polycrystalline silicon study: Low-cost silicon refining technology prospects and semiconductor-grade polycrystalline silicon availability through 1988
Photovoltaic arrays that convert solar energy into electrical energy can become a cost effective bulk energy generation alternative, provided that an adequate supply of low cost materials is available. One of the key requirements for economic photovoltaic cells is reasonably priced silicon. At present, the photovoltaic industry is dependent upon polycrystalline silicon refined by the Siemens process primarily for integrated circuits, power devices, and discrete semiconductor devices. This dependency is expected to continue until the DOE sponsored low cost silicon refining technology developments have matured to the point where they are in commercial use. The photovoltaic industry can then develop its own source of supply. Silicon material availability and market pricing projections through 1988 are updated based on data collected early in 1984. The silicon refining industry plans to meet the increasing demands of the semiconductor device and photovoltaic product industries are overviewed. In addition, the DOE sponsored technology research for producing low cost polycrystalline silicon, probabilistic cost analysis for the two most promising production processes for achieving the DOE cost goals, and the impacts of the DOE photovoltaics program silicon refining research upon the commercial polycrystalline silicon refining industry are addressed.
Costogue, E. N.↗
Satellite analog FDMA/FM to digital TDMA conversion
The results of a study which investigated design issues regarding the use of analog to digital (A/D) conversion on board a satellite are presented. The need for A/D, and of course D/A as well, conversion arose from a satellite design which required analog FDMA/FM up and down links to/from a digitally modulated intersatellite link. There are also some advantages when one must interconnect a large number of various spot beams which are using analog, and therefore cannot take advantage of SS/TDMA switching among the beams, thus resulting in low fill factors. Various tradeoffs were performed regarding the implementation of on-board A/D processing, including mass, power, and costs. The various technologies which were considered included flash ADCs, surface acoustic wave (SAW) devices, and digital signal processing (DSP) chips. Impact analyses were also performed to determine the effect on ground stations to convert to digital if the A/D approach were not implemented.
Driggers, T.↗
Fabrication methods for construction from lunar materials
Cost-driving parameters of space industrialization are discussed, specifically cost of transportation from earth to low earth orbit and productivity of labor in space. A design procedure for a space manufacturing facility (SMF) is outlined, and the design of a reference SMF is described. This SMF receives lunar materials and converts them to components of space structures such as solar power satellites. The effect of machine reliability is discussed. The SMF appears versatile and productive, and the space environment has some beneficial characteristics which may simplify manufacturing processes. Technology demonstration programs are needed, but prototypes of SMF equipment can be small devices.
Miller, R. H.↗
Project Longshot: A mission to Alpha Centauri
Project Longshot, an exercise in the Advanced Design Program for Space, had as its destination Alpha Centauri, the closest star system to our own solar system. Alpha Centauri, a trinary star system, is 4.34 light years from earth. Although Project Longshot is impossible based on existing technologies, areas that require further investigation in order to make this feat possible are identified. Three areas where advances in technology are needed are propulsion, data processing for autonomous command and control functions, and reliability. Propulsion, possibly by antimatter annihilation; navigation and navigation aids; reliable hardware and instruments; artificial intelligence to eliminate the need for command telemetry; laser communication; and a reliable, compact, and lightweight power system that converts energy efficiently and reliably present major challenges. Project Longshot promises exciting advances in science and technology and new information concerning the universe.
West, Curtis↗