Parametric studies of phase change thermal energy storage canisters for Space Station Freedom

Phase Change Materials (PCM) canister parametric studies are discussed wherein the thermal-structural effects of changing various canister dimensions and contained PCM mass values are examined. With the aim of improving performance, 11 modified canister designs are analyzed and judged relative to a baseline design using five quantitative performance indicators. Consideration is also given to qualitative factors such as fabrication/inspection, canister mass production, and PCM containment redundancy. Canister thermal analyses are performed using the finite-difference based computer program NUCAM-2DV. Thermal-stresses are calculated using closed-form solutions and simplifying assumptions. Canister wall thickness, outer radius, length, and contained PCM mass are the parameters considered for this study. Results show that singular canister design modifications can offer improvements on one or two performance indicators. Yet, improvement in one indicator is often realized at the expense of another. This confirms that the baseline canister is well designed. However, two alternative canister designs, which incorporate multiple modifications, are presented that offer modest improvements in mass or thermal performance, respectively

Two-dimensional model of a Space Station Freedom thermal energy storage canister

The Solar Dynamic Power Module being developed for Space Station Freedom uses a eutectic mixture of LiF-CaF2 phase change salt contained in toroidal canisters for thermal energy storage. Results are presented from heat transfer analyses of the phase change salt containment canister. A 2-D, axisymmetric finite difference computer program which models the canister walls, salt, void, and heat engine working fluid coolant was developed. Analyses included effects of conduction in canister walls and solid salt, conduction and free convection in liquid salt, conduction and radiation across salt vapor filled void regions and forced convection in the heat engine working fluid. Void shape, location, growth or shrinkage (due to density difference between the solid and liquid salt phases) were prescribed based on engineering judgement. The salt phase change process was modeled using the enthalpy method. Discussion of results focuses on the role of free-convection in the liquid salt on canister heat transfer performance. This role is shown to be important for interpreting the relationship between ground based canister performance (in l-g) and expected on-orbit performance (in micro-g). Attention is also focused on the influence of void heat transfer on canister wall temperature distributions. The large thermal resistance of void regions is shown to accentuate canister hot spots and temperature gradients

Solar dynamic modules for Space Station Freedom: The relationship between fine-pointing control and thermal loading of the aperture plate

Dynamic simulations of Space Station Freedom (SSF) configured with solar dynamic (SD) power modules were performed. The structure was subjected to Space Shuttle docking disturbances, while being controlled with a 'natural' vibration and tracking control approach. Three control cases were investigated for the purpose of investigating the relationship between actuator effort, SD pointing, and thermal loading on the receiver aperture plate. Transient, one-dimensional heat transfer analyses were performed to conservatively predict temperatures of the multi-layered receiver aperture plate assembly and thermal stresses in its shield layer. Results indicate that the proposed aperture plate is tolerant of concentrated flux impingement during short-lived structural disturbances. Pointing requirements may be loosened and the requirement control torques lessened from that previously specified. Downsizing and simplifying the joint drive system should result in a considerable savings mass

Lunar Surface-to-Surface Power Transfer

A human lunar outpost, under NASA study for construction in the 2020's, has potential requirements to transfer electric power up to 50-kW across the lunar surface from 0.1 to 10-km distances. This power would be used to operate surface payloads located remotely from the outpost and/or outpost primary power grid. This paper describes concept designs for state-of-the-art technology power transfer subsystems including AC or DC power via cables, beamed radio frequency power and beamed laser power. Power transfer subsystem mass and performance are calculated and compared for each option. A simplified qualitative assessment of option operations, hazards, costs and technology needs is also described. Based on these concept designs and performance analyses, a DC power cabling subsystem is recommended to minimize subsystem mass and to minimize mission and programmatic costs and risks. Avenues for additional power transfer subsystem studies are recommended

Multi-dimensional modeling of a thermal energy storage canister

The Solar Dynamic Power Module being developed for Space Station Freedom uses a eutectic mixture of LiF-CaF2 phase change material (PCM) contained in toroidal canisters for thermal energy storage. Presented are the results from heat transfer analyses of a PCM containment canister. One and two dimensional finite difference computer models are developed to analyze heat transfer in the canister walls, PCM, void, and heat engine working fluid coolant. The modes of heat transfer considered include conduction in canister walls and solid PCM, conduction and pseudo-free convection in liquid PCM, conduction and radiation across PCM vapor filled void regions, and forced convection in the heat engine working fluid. Void shape, location, growth or shrinkage (due to density difference between the solid and liquid PCM phases) are prescribed based on engineering judgment. The PCM phase change process is analyzed using the enthalpy method. The discussion of the results focuses on how canister thermal performance is affected by free convection in the liquid PCM and void heat transfer. Characterizing these effects is important for interpreting the relationship between ground-based canister performance (in 1-g) and expected on-orbit performance (in micro-g). Void regions accentuate canister hot spots and temperature gradients due to their large thermal resistance. Free convection reduces the extent of PCM superheating and lowers canister temperatures during a portion of the PCM thermal charge period. Surprisingly small differences in canister thermal performance result from operation on the ground and operation on-orbit. This lack of a strong gravity dependency is attributed to the large contribution of container walls in overall canister energy redistribution by conduction

Analysis of solar receiver flux distributions for US/Russian solar dynamic system demonstration on the MIR Space Station

The United States and Russia have agreed to jointly develop a solar dynamic (SD) system for flight demonstration on the Russian MIR space station starting in late 1997. Two important components of this SD system are the solar concentrator and heat receiver provided by Russia and the U.S., respectively. This paper describes optical analysis of the concentrator and solar flux predictions on target receiver surfaces. The optical analysis is performed using the code CIRCE2. These analyses account for finite sun size with limb darkening, concentrator surface slope and position errors, concentrator petal thermal deformation, gaps between petals, and the shading effect of the receiver support struts. The receiver spatial flux distributions are then combined with concentrator shadowing predictions. Geometric shadowing patterns are traced from the concentrator to the target receiver surfaces. These patterns vary with time depending on the chosen MIR flight attitude and orbital mechanics of the MIR spacecraft. The resulting predictions provide spatial and temporal receiver flux distributions for any specified mission profile. The impact these flux distributions have on receiver design and control of the Brayton engine are discussed

Full-size solar dynamic heat receiver thermal-vacuum tests

The testing of a full-size, 120 kW, solar dynamic heat receiver utilizing high-temperature thermal energy storage is described. The purpose of the test program was to quantify receiver thermodynamic performance, operating temperatures, and thermal response to changes in environmental and power module interface boundary conditions. The heat receiver was tested in a vacuum chamber with liquid nitrogen cold shrouds and an aperture cold plate to partly simulate a low-Earth-orbit environment. The cavity of the receiver was heated by an infrared quartz lamp heater with 30 independently controllable zones to allow axially and circumferentially varied flux distributions. A closed-Brayton cycle engine simulator conditioned a helium-xenon gas mixture to specific interface conditions to simulate the various operational modes of the solar dynamic power module on the Space Station Freedom. Inlet gas temperature, pressure, and flow rate were independently varied. A total of 58 simulated orbital cycles, each 94 minutes in duration, was completed during the test conduct period

Off-Nominal Performance of the International Space Station Solar Array Wings Under Orbital Eclipse Lighting Scenarios

This paper documents testing and analyses to quantify International Space Station (ISS) Solar Array Wing (SAW) string electrical performance under highly off-nominal, low-temperature-low-intensity (LILT) operating conditions with nonsolar light sources. This work is relevant for assessing feasibility and risks associated with a Sequential Shunt Unit (SSU) remove and replace (R&R) Extravehicular Activity (EVA). During eclipse, SAW strings can be energized by moonlight, EVA suit helmet lights or video camera lights. To quantify SAW performance under these off-nominal conditions, solar cell performance testing was performed using full moon, solar simulator and Video Camera Luminaire (VCL) light sources. Test conditions included 25 to 110 C temperatures and 1- to 0.0001-Sun illumination intensities. Electrical performance data and calculated eclipse lighting intensities were combined to predict SAW current-voltage output for comparison with electrical hazard thresholds. Worst case predictions show there is no connector pin molten metal hazard but crew shock hazard limits are exceeded due to VCL illumination. Assessment uncertainties and limitations are discussed along with operational solutions to mitigate SAW electrical hazards from VCL illumination. Results from a preliminary assessment of SAW arcing are also discussed. The authors recommend further analyses once SSU, R&R, and EVA procedures are better defined

The Effect of Reaction Control System Thruster Plume Impingement on Orion Service Module Solar Array Power Production

NASA's new Orion Crew Exploration Vehicle has geometry that orients the reaction control system (RCS) thrusters such that they can impinge upon the surface of Orion's solar array wings (SAW). Plume impingement can cause Paschen discharge, chemical contamination, thermal loading, erosion, and force loading on the SAW surface, especially when the SAWs are in a worst-case orientation (pointed 45 towards the aft end of the vehicle). Preliminary plume impingement assessment methods were needed to determine whether in-depth, timeconsuming calculations were required to assess power loss. Simple methods for assessing power loss as a result of these anomalies were developed to determine whether plume impingement induced power losses were below the assumed contamination loss budget of 2 percent. This paper details the methods that were developed and applies them to Orion's worst-case orientation

Radiation Heat Transfer Modeling Improved for Phase-Change, Thermal Energy Storage Systems

Spacecraft solar dynamic power systems typically use high-temperature phase-change materials to efficiently store thermal energy for heat engine operation in orbital eclipse periods. Lithium fluoride salts are particularly well suited for this application because of their high heat of fusion, long-term stability, and appropriate melting point. Considerable attention has been focused on the development of thermal energy storage (TES) canisters that employ either pure lithium fluoride (LiF), with a melting point of 1121 K, or eutectic composition lithium-fluoride/calcium-difluoride (LiF-20CaF2), with a 1040 K melting point, as the phase-change material. Primary goals of TES canister development include maximizing the phase-change material melt fraction, minimizing the canister mass per unit of energy storage, and maximizing the phase-change material thermal charge/discharge rates within the limits posed by the container structure