Arthur G. Birchenough

A High Efficiency DC Bus Regulator / RPC for Spacecraft Applications

DC bus voltage regulation may be required in future high powered spacecraft due to the length of the busses or because they are not generated at precise voltage levels. In these cases the regulation range is often only a few percent increase or decrease, but conventional DC voltage regulators switch all the power passing through them, and this level of power switched determines the size and losses in the regulator. A recently developed concept uses a low power DC‐DC converter in series with the bus to raise or lower the bus voltage over a small range. This partial power processing technique combines the small size and power losses of the low power converter with the ability to regulate, (over a small range) a high power bus. The Series Connected Buck Boost Regulator (SCBBR) described herein provides bus regulation with an efficiency of 98%. The circuit also provides bus switching and overcurrent limiting functions of a Remote Power Controller (RPC). This paper describes the circuit design and performance ...

Experimental Results from a 2 kW Brayton Power Conversion Unit

This paper presents experimental test results from operation of a 2 kWe Brayton power conversion unit. The Brayton converter was developed for a solar dynamic power system flight experiment planned for the Mir Space Station in 1997. The flight experiment was cancelled, but the converter was tested at Glenn Research Center as part of the Solar Dynamic Ground Test Demonstration system which included a solar concentrator, heat receiver, and space radiator. In preparation for the current testing, the heat receiver was removed and replaced with an electrical resistance heater, simulating the thermal input of a steady-state nuclear source. The converter was operated over a full range of thermal input power levels and rotor speeds to generate an overall performance map. The converter unit will serve as the centerpiece of a Nuclear Electric Propulsion Testbed at Glenn. Future potential uses for the Testbed include high voltage electrical controller development, integrated electric thruster testing and advanced radiator demonstration testing to help guide high power Brayton technology development for Nuclear Electric Propulsion (NEP).

Development of High-Power Hall Thruster Power Processing Units at NASA GRC

NASA GRC successfully designed, built and tested four different power processor concepts for high power Hall thrusters. Each design satisfies unique goals including the evaluation of a novel silicon carbide semiconductor technology, validation of innovative circuits to overcome the problems with high input voltage converter design, development of a direct-drive unit to demonstrate potential benefits, or simply identification of lessonslearned from the development of a PPU using a conventional design approach. Any of these designs could be developed further to satisfy NASAs needs for high power electric propulsion in the near future.

Single Phase Passive Rectification versus Active Rectification Applied to High Power Stirling Engines

Stirling engine converter s are being considered a s potential candidate s for high power energy conversion system s required by future NASA explorations missions. These types of engines typically contains two major moving parts, the displacer and the piston , in which a linear alternator is attached to the piston to pro duce a single phase sinusoidal waveform at a specific electric frequency. Since all Stirling engines per form at low electrical frequencies (less or equal to 100 Hz), space explorations missions that will employ these engines will be required to use DC powe r management and distribution (PMAD) system instead of an AC PMAD system to sa ve on space and weight . Therefore, to supply such DC power an AC to DC converter is connected to the Stirling engine. There are t wo types of AC to DC converters that can be emplo yed, a passive full bridge diode rectifier and an active switching full bridge rectifier. Due to the inherent line inductance of the Stirling Engine -Linear Alternator (SE -LA), their sinusoidal voltage and current will be phase shifted producing a power f actor below 1. In order to keep power the factor close to unity, both AC to DC converters topologies will implement power factor correction. This paper discusses these power factor correction methods as well as their impact on overall mass for expl oration applications . Simulation results on both AC to DC converters topologies with power factor correction as a function of output power and SE -LA line inductance impedance are presented and compared.

High Input Voltage, Silicon Carbide Power Processing Unit Performance Demonstration

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.

Operational Results from a High Power Alternator Test Bed

The Alternator Test Unit (ATU) in the Lunar Power System Facility (LPSF) located at the NASA Glenn Research Center (GRC) in Cleveland, OH was used to simulate the operating conditions and evaluate the performance of the ATU and its interaction with various LPSF components in accordance with the current Fission Surface Power System (FSPS) requirements. The testing was carried out at the breadboard development level. These results successfully demonstrated excellent ATU power bus characteristics and rectified user load power quality during steady state and transient conditions. Information gained from this work could be used to assist the design and primary power quality considerations for a possible future FSPS. This paper describes the LPSF components and some preliminary test results.

Test Results from a High Power Linear Alternator Test Rig

Stirling cycle power conversion is an enabling technology that provides high thermodynamic efficiency but also presents unique challenges with regard to electrical power generation, management, and distribution. The High Power Linear Alternator Test Rig (HPLATR) located at the NASA Glenn Research Center (GRC) in Cleveland, OH is a demonstration test bed that simulates electrical power generation from a Stirling engine driven alternator. It implements the high power electronics necessary to provide a well regulated DC user load bus. These power electronics use a novel design solution that includes active rectification and power factor control, active ripple suppression, along with a unique building block approach that permits the use of high voltage or high current alternator designs. This report describes the HPLATR, the test program, and the operational results.

Test Results From a Simulated High-Voltage Lunar Power Transmission Line

The Alternator Test Unit (ATU) in the Lunar Power System Facility (LPSF) located at the NASA Glenn Research Center (GRC) in Cleveland, OH was modified to simulate high voltage transmission capability. The testbed simulated a 1 km transmission cable length from the ATU to the LPSF using resistors and inductors installed between the distribution transformers. Power factor correction circuitry was used to compensate for the reactance of the distribution system to improve the overall power factor. This test demonstrated that a permanent magnet alternator can successfully provide high frequency AC power to a lunar facility located at a distance.

Status of the Development of Flight Power Processing Units for the NASAs Evolutionary Xenon Thruster - Commercial (NEXT-C) Project

A pathfinder prototype unit and two flight power processing units (PPUs) are being developed by the Aerojet Rocketdyne Corporation in Redmond, Washington and ZIN Technologies in Cleveland, Ohio, in support of the NEXT-C Project. This project is being led by the NASA Glenn Research Center in Cleveland, Ohio, and will also yield two flight thrusters. This hardware is being considered to be provided as Government Furnished Equipment for the New Frontiers Program, and is applicable to a variety of planetary science missions and astrophysics science missions. The design of the NEXT-C PPU evolves from the hardware fabricated under the NEXT technology development project. The power processing unit operates from two sources: a wide input 80 to 160 V high-power bus and a nominal 28 V low-power bus. The unit includes six power supplies. Four power supplies (beam, accelerator, discharge, and neutralizer keeper) are needed for steady state operation, while two cathode heater power supplies (neutralizer and discharge) are utilized during thruster startup. The unit in total delivers up to 7 kW of regulated power to a single gridded-ion thruster. Significant modifications to the initial design include: high-power adaptive-delay control, upgrade of design to EEE-INST-002 compliance, telemetry accuracy improvements, incorporation of telemetry to detect plume-mode operation, and simplification of the design in select areas to improve manufacturability and commercialization potential. The project is presently in the prototype phase and preparing for qualification level environmental testing.