NASA Contractor Report CR-191136 /___'/-_/ F Power Conditioning System Modelling for Nuclear Electric Propulsion Kenneth J. Metcalf Rockwell International Rocketdyne Division Canoga Park, California November 1993 PREPARED FOR LEWIS RESEARCH CENTER UNDER CONTRACT NAS3-25808 N/ A National Aeronautics and Space Administration O_ p_ I ,-- u'_ ,,1" U 0'- O- _ ,-4 ",!" https://ntrs.nasa.gov/search.jsp?R=19940016706 2020-06-16T17:20:12+00:00Z 7ii__ -_ i Z i i_,i _-r':: ! :__L_ _;_ iir i__ -__i_,;_i_, _2_ illI ITi-_-_ -i:_iii_i : 71 - -7---:-i _ -i- - - _ _ i: _ _ - _ _ - i _ _ _ _ - i- 7 i ! = i Foreword Systems engineering efforts initiated by NASA's Lewis Research Center (LeRC) in FY92 under RTOP 593-72, for Nuclear Electric Propulsion (NEP), have enabled the development of detailed mathematical (computer) models to predict NEP subsystem performance and mass. The computer models are intended to help provide greater depth to NEP subsystem (and system) modeling, required for more accurately verifying performance projections and assessing the impact of specific technology developments. The following subsystem models have been developed: 1) liquid-metal-cooled pin-type, and 2) gas-cooled NERVA (Nuclear Engine for Rocket Vehicle Applications) -derived for reactor/shield; 3) Potassium-Rankine, and 4) Brayton for power conversion; 5) heat rejection general model (includes direct Brayton, pumped loop Brayton, and shear flow condenser (Potassium-Rankine); ....6) power management and distribution (PMAD) general model| and 7) ion electric engine, and 8) magnetoplasmadynamic thruster for the electric propulsion subsystem. 'L These subsystem models for NEP were authored by the Oak Ridge National Laboratory (ORNL) for the reactor (NASA CR-IgI133), by the Rocketdyne Division of Rockwell International for Potassium Rankine (NASA CR-Ig1134) and Brayton (NASA CR-191135) power conversion, heat rejection (NASA CR-191132), and power management and distribution (NASA CR-Ig1136), and by Sverdrup Technology for the thrusters (NASA CR-Ig1137). At the time of this writing, these eight VAX/FORTRAN source and executable codes are resident on one of LeRC's Scientific VAX computers. iii PRII_ PAC_ BLAIeK NOT FILMED 3.0 4.0 CONTENTS Summary ........................................................... I Introduction...,._,_L._._, ....................... _._,. .......... 2 2.1 DC versus AC Power Transmission ............................. 2 2.2 Low Frequency versus High Frequency Power Transmission ...... 5 End-to-End Power Management and Distribution Model,., ............. 8 3.] Ion Power Processing Unit w/o Beam Power Supply Transformer. 16 3.2 Ion Power Processing Unit with Beam Power Supply Transformer 27 3.3 3.4 3.5 3.6 3.7 3.8 3.9 MPD Power Processing Unit..,., ...... ,_,,.._.._,. ........... 40 AC Switchgear Unit .......................................... 48 Phase Lock Transformer ...................................... 56 Speed Regulator ........_............ _.,_ ....................... 63 Parasitic Load Radiator ..................................... 70 Litz Wire Transmission Line 75 Electronics Radiator ........................................ 86 Conclusions and RecomRDdations ................................... 87 References .............................................................. 89 Appendix A - Component Efficiency-Temperature Algorithms ................ 90 Appendix B - End-to-End PMAD Model ...................................... 97 Appendix C - Ion Power Processing Unit w/o Beam Power Supply ............ 120 Transformer Model Appendix D - Ion Power Processing Unit with Beam Power Supply ........... 126 Transformer Model Appendix E - MPD Power Processing Unit Model ............................ 132 Appendix F - AC Switchgear Unit Model ................................... 136 .....Appendix G - Phase Lock Transformer Model ............................... 141 Appendix H - Speed Regulator Model ...................................... 145 Appendix I - Parasitic Load Radiator Model .............................. 149 Appendix J - Litz Wire Transmission Line Model .......................... 152 iv Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 FIGURES DC vs AC NEP Vehicle PMAD Comparison .......................... 3 Low vs High Frequency NEP Vehicle PMAD Comparison ............ 6 Figure 6 Figure 7 Figure 8 _ Figure g z Figure 10 Figure 11 Figure 12| i Figure 13 i Figure 14 = Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Low Frequency PMAD Architecture .............................. 9 NEP PMAD Top Level Flow Chart ................................ 11 Low Frequency Ion Thruster PPU Topology ...................... 17 (w/o Beam Power Supply Transformer) Ion Thruster PPU Option #i FlowChart ........................ 19 Low Frequency Ion Thruster PPU Topology ...................... 28 (with Beam Power Supply Transformer) Ion Thruster PPU Option #2 Flow Chart ........................ 30 Low Frequency MPD Thruster PPU Topology ...................... 41 MPD Thruster PPU Flow Chart .................................. 43 AC Switchgear Unit Block Diagram ............................. 4g AC Switchgear (SWGR) Flow Chart .............................. 51 Phase Lock Transformer Block Diagram ......................... 57 Phase Lock Transformer unit (PLT) Flow Chart ................. 58 Speed Regulator Block Diagram ................................ 64 Alternator Speed Regulato_ _ (ASR) FlowCfiart. 66 Parasitic Load Radiator (PLR) Flow chart ..................... 71 Modelled Litz Wire Cable Construction ........................ 76 NEP PMAD Transmission Line Flow Chart ........................ 78 Power Conditioning Element NormaiizedEfficiencies vs ........ 95 Temperature i i i TABLES Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table ]0 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 DC vs AC Comparison for Ion and MPD Thrusters ................. 4 Low vs High Frequency Comparison for Ion and MPD Thrusters .... 7 End-to-End NEP PMAD System Model Input Parameter Ranges ....... 14 End-to-End NEP PMAD System Model Variable Definitions ......... 15 Ion Thruster PPU Option #1 Model (w/o Beam Power Supply..._... 20 : Transformer) Primary Input Parameter Ranges Ion Thruster PPU Option #I Model (w/o Beam Power Supply ....... 21 Transformer) Secondary Input Parameter Ranges Efficiency Corrections for Discharge and_Neutr_l_z_r .......... 22 Power supply Rectifier Mass Estimates Efficiency Corrections for Discharge and Neutralizer .......... 22 Power Supply Filter Mass Estimates Ion Thruster PPU Option #1 Model (w/o Beam Power Supply ....... 23 Transformer) Variable Definitions Ion Thruster PPU Option #2 Model (with Beam Power Supply ...... 31 Transformer) Primary Input Parameter Ranges Ion Thruster PPU Option #2 Model (with Beam Power Supply ...... 32 Transformer) Secondary Input Parameter Ranges Efficiency Corrections for Discharge and N_utralizer .......... 34 Power Supply Rectifier Mass Estimates Efficiency Corrections for Discharge and Neutralizer .......... 34 Power Supply Filter Mass Estimates Ion Thruster PPU Option #2 Model (with Beam Power Supply ...... 35 Transformer) Variable Definitions MPD Thruster PPU Model Primary Input Parameter Ranges ......... 44 MPD Thruster PPU Model Secondary Input Parameter Ranges ....... 45 Table 17 MPD Thruster PPU Model Variable Definitions ................... 46 Table 18 AC Switchgear Unit Model Input Parameter Ranges ............... 52 Table 19 AC Switchgear Model Variable Definitions ...................... 53 Table 20 Phase Lock Transformer Unit Model Input Parameter Ranges ...... 59 Table 21 Phase Lock Transformer Unit Model Variable Definitions ........ 61 Table 22 Alternator Speed Regulator Model Input Parameter Ranges ....... 67 Table 23 Alternator Speed Regulator Model Variable Definitions ......... 68 Table 24 Parasitic Load Radiator Model Input Parameter Ranges .......... 72 Table 25 Parasitic Load Radiator Variable Definitions .................. 73 Table 26 Litz Wire Transmission Line Model Input Parameter Ranges ...... 82 Table 27 Transmission Line Model Variable Definitions .................. 83 Table 28 Component Loss Allocations .................................... 95 vi 1.0 Summary NASA LeRC is currently developing a Fortran based model of a complete nuclear electric propulsion (NEP) vehicle that would be used for piloted and cargo missions to the Moon or Mars. The proposed vehicle design will use either a Brayton or K-Rankine power conversion cycle to drive a turbine coupled with a rotary alternator. Two thruster types are also being studied, ion and MPD. In support of this NEP model, Rocketdyne has developed power conversion, heat rejection, and power management and distribution (PMAD) subroutines. These subroutines will be incorporated into the NEP vehicle model and be driven by a master module to be written by NASA LeRC. The purpose of this report is to document the end-to-end PMAD model subroutine and the component model subrou- tines called by it. The PMAD system subroutine is designed to provide parametric outputs based on externally defined characteristics such as the alternator operating voltage and frequency, the thruster type, the system power level, and the electronics coldplate temperature. These parametrics will then be used by the master NEP module to determine the NEP vehicle mass and efficiency, and to conduct system level trades. It is intended that the models developed during this study be used only for conceptual design studies requiring "ballpark" PMAD mass esti- mates. To determine specific PMAD design choices such as component topolo- gies, and accurate transmission and distribution voltages and frequencies re- quires specific power system requirements and far more detailed analyses. | The end-to-end PMAD model described in this report is based on the direct use of the alternator voltage and frequency for transmitting power to either ion or magnetoplasmadynamic (MPD) thrusters. This low frequency transmission approach was compared with dc and high frequency ac designs, and selected on the basis of mass, efficiency, and qualitative assessments of reliability and development costs. The low frequency architecture has the lowest mass, high- est efficiency, and on the basis of complexity it is judged to have the high- est reliability and lowest development costs. While its power quality is not as good as that provided by a high frequency system, it was considered ade- quate for both ion and MPD engine applications. The low frequency architec- ture will be used as the reference in future NEP PMAD studies. YL L The PMAD model development is based on the fact that power conditioning compo- nents have common stages and that their interconnection and control determines the function and operation of the component. The component models permit pas- sive or active thermal management and estimate component heat sink, coldplate, and radiator masses (the hardware that connects the coldplate to the radiator is not included). The transmission line model is based on a litz wire config- uration and it uses first order electrical and thermal principles to calculate attributes such as line mass, diameter, and temperature. It is recommended that other transmission line models be developed when funding permits so that alternate transmission line configurations can be evaluated. z The model documentation includes a block diagram of the component and shows the logic employed during the model development. Valid input ranges are also defined and suitable component applications discussed. The end-to-end PMAD model documentation shows the basic PMAD architecture form and explains how certain inputs are used to define a particular architecture configuration. 2.0 Introduction The PMAD models presented in this report were developed to allow a previously selected PMAD architecture to be evaluated within the context of an overall NEP power system. This architecture is based on the use of ac power transmis- sion at a designated alternator voltage and frequenCy, and it was selected at the conclusion of the Task Order ]4 studies (Ref. II-1, II-2). These studies evaluated methods of supplying power from a 3-phase rotary alternator to ei- ther ion or MPD thrusters. The primary discriminators were mass and efficien- cy, but complexity, development costs, and reliability were also considered. Initially, dc and ac transmission approaches were evaluated. Subsequent anal- yses addressed single- and 3-phase ac, and low and high frequency transmis- sion. The Task Order 14 results determined the types of PMAD models and their form; therefore, an overview of these results is presented below. If the user is not interested in this background information and simply wishes to run the PMAD models, they should read the following paragraph carefully and then skip to Section 3.0 which contains the PMAD model documentation. The model docu L me_a_on-has_a description of the system dr component the model is based on, suggestions on how to properly apply the models, a flow chart depicting the model operating logic, and a table defining valid input ranges. This documen- tation is followed by a section that discusses the conclusions reached during this study and the recommendations for future work. The PMAD model subroutines are encoded in Fortran 77 and located on the accom- panying computer disk. Generally, a four step process is used to run a PMAD case; (I) the user creates an input file with the desired PMAD input data, (2) "MAIN" is typed to run the case, (3) the selected input file name is provided, and (4) the generated output data is examined. It is probably best to create a new input file by editing an existing input file. This can be accomplished with any ASCII editor and an input file, "PMAD. IN", is available for this pur- pose. The user may want to view the input file "PMAD. IN" and note its form. The data is arranged in blocks. The first block defines the PMAD architecture and system operating values; subsequent blocks define specific component data. If the user does not supply a value, a default value will be used. The model input names and their defaults are defined in the individual model documenta- tion sections. The Fortran code listings in Appendixes A through H also list the input value defaults. After creating an input file, the user types "MAIN" to start a run. "MAIN.EXE" is an executable file that requests an input file and then directs the ensuing calculation steps. This file is temporary; the NEP system driver to be written by NASA LeRC will replace it. After an input file name is provided, the computer runs the case. The output data is printed to a file having the same filename as the input file, but the extension "OUT". For example, the input file "PMAD.IN" generates the output file "PMAD.OUT". 2.1 DC versus AC Power Transmission Two basic power transmission methods, dc and ac, were evaluated for the NEP vehicle on the basis of mass, efficiency, reliability, and development costs. Figure I compares the basic operating steps employed in these two approaches. The dc approach would utilize a rectifier immediately following the alternator to convert the alternator's ac output into dc. A dc transmission line would then carry this power to the power processing units (PPUs) located next to the thrusters. Within the PPUs, a chopper converts the dc into high frequency ac OO O ! t- O Ol O_ E t_ c- O I-- b- O n r_ .O O O ! m O_ < Figure 1 3 < n ,- __ t 0 m (-- 0--. > E._ Z L CI. r- < 0 i so that a subsequent transformer can step this high transmission line voltage down to a level suitable for the thrusters. The lower voltage ac is then con- verted into dc for the thrusters. It is possible to design a simpler transmission system based on the alternator 3-phase ac output. If a high voltage alternator design is used, power can be efficiently conducted from the alternator to the PPUs using an ac transmission line. Within the PPUs, a transformer steps the high voltage ac down and a rectifier converts it into dc for the thrusters. Comparing the two approaches, it is apparent that the dc system is much more complex. This leads to mass, efficiency, and reliability penalties. Key PMAD parameters are compared in Table I for the two approaches. Although the dc system is notably heavier, the mass difference would be even larger except for the fact that the chopper in the dc to dc PPU operates at a high frequency. This reduces the subsequent PPU transformer and filter masses, and improves the quality of the power provided to the thruster. However, there are disad- vantages associated with the use of complex dc to dc converters instead of transformers. The added conversion steps substantially lower the end-to-end PMAD efficiency. This means a larger power source is needed to offset the losses. The dc system development and hardware costs are also probably high- er, and the added conversion steps will tend to reduce system reliability. In fact because of the megawatt power levels, the chopper stage in the dc to dc PPU would probably be a high risk development item. Table 1 DC vs AC Comparison for Ion and MPD Thrusters Parameter Mass Efficiency Power Quality Complexity Low Frequency Transmission (Alternator Frequency) Ion 48,350 kg 1.68 kg/kWe 95.0% Good Low MPD 50,450kg 1.75 kg/kWe 95.1% Good Low DC Power Transmission Ion r r 64,080kg 2.32 kg/kWe 88.9% Excellent High MPD 65,170 kg 2.36 kg/kWe 89.0% Excellent High (I) PMAD values based on 3 channels providing a total of 30 MWe, 150 meter main transmission line length, 81300 Volt transmission voltage, and 1000 C eleetronles eoldplate temperature. The chopper stage switches dc power at a high rate to generate an alternating voltage and current. High frequency ac is generated to reduce the mass of the subsequent transformer. Switch synchronization is critical in a chopper, but it can be quite difficult in a high power, high voltage chopper because numer- ous switches must be paralleled or connected in series to handle the high cur- rent and/or voltage levels. If an individual switch fails to operate proper- ly, it can result in an internal short and cause the switch at fault to fail. To reduce the chances of this occurring, special circuits force the switches to load share, and snubbers are used to protect against voltage spikes. While they can be very effective, they add to the massof the chopper. Due to these problems, there are programs currently in progress to develop higher power and voltage switching devices that are rugged and have improved switching charac- teristics. The development of these devices is crucial to the fabrication of a dc to dc converter rated for megawatt power levels. Although it is not shown in Figure I, another dc power transmission component that will require extensive development is a dc switchgear unit. The remote bus isolators (RBIs) in the dc switchgear unit must use a mechanical and/or semiconductor switch capable of interrupting the maximum calculated bus volt- age. Depending on the design, these switches will draw an arc or encounter high electromagnetic forces during opening that will generate high stresses and concentrated heating. This forces the dc RBI construction to be heavier. A comparable ac RBI switch can open during the zero current crossing. This dramatically reduces the stresses encountered and consequently its mass. At the present time, a major design issue is the development of a suitable dc RBI for the Space Station Freedom (SSF) electrical power system. The power levels on SSF are on the order of tens of kilowatts; the power levels on the proposed NEP vehicle are on the order of megawatts. Based on this comparison, a dc RBI rated for megawatt power levels would be a feasibility issue. Based on the results of Task Order 14, briefly summarized above, ac transmis- sion was selected over dc. It appears to have several advantages, lower de- velopment costs, higher projected component reliabilities, simplified fault protection, and a higher overall PMAD system efficiency. For a dc system to be competitive, it would need to offer substantial mass savings. This is not the case. Results to date indicate a dc system would actually be heavier. 2.2 Low Frequency versus High Frequency Power Transmission After selecting ac power transmission, further studies were conducted to de- termine the best ac transmission approach. Basically two methods are avail- able, a low frequency approach that bases the transmission voltage and fre- quency on the alternator output, and a high frequency approach that utilizes a frequency converter following the alternator to generate a selected high fre- quency output. Diagrams for the two approaches, displaying the required com- ponents and internal conversion steps, are shown in Figure 2. The low frequency system, because it uses the alternator voltage and frequency directly, is less complex. The 3-phase ac alternator output is good for high power delivery. A 3-phase power system delivers a steadier power flow, where- as a single-phase system exhibits a pulsating power effect. 3-phase systems also have a higher power transfer capability which promotes the design of an efficient, light weight transmission line. Finally, because the transmission frequency is relatively low, line inductance and skin effect losses are less of a problem. However, low frequency distribution is not optimum for trans- former and filter design and it causes the transformers and dc output filters located in the PPUs to be relatively heavy. Consequently, high frequency dis- tribution was evaluated. .O O E O ll (/) C O I. t.1- I. @ O O_ O >,, (O c_r Q_ I, O 1J c- >., O .1 C .__ 1J _ u) _J Q_ E I, L1 a_ _ c 6 .O O c- O C O !. F1- I- @ O Q. (O >., O E @ O" Q) I. !, i- "1- (- _, 0 U _ .I: C m E 1 @ 0 ! ¢) c @ 1 i l (-. @ CY > @ L_ _ I l I, C @ @ LI_ (- ll > 0 ._J ..J The high frequency approach utilizes a frequency converter following the al- ternator to convert the alternator's low frequency output into high frequency ac. It can be designed to provide a single- or 3-phase output, and a wide range of frequencies. Hence, the number of phases and transmission frequency can be selected to yield the optimum PMAD system design. This allows signifi- cant mass savings in the PPUs due to the reduced transformer and filter mass, and because high frequency power is easier to filter it improves the quality of the power fed to the thrusters. However, a high frequency PMAD system has certain drawbacks. The addition of the frequency converter increases system mass, and reduces the end-to-end efficiency and reliability. Also at megawatt power levels, the chopper stage in the frequency converter would probably be a high risk development item for the same reasons previously presented in the discussion regarding the dc to dc PPU. Three power distribution techniques using low and high frequency, and single- and 3-phase distribution are compared in Table 2. Based on this evaluation, the low frequency approach was selected. It has the lowest mass, highest efficiency, and on the basis of complexity it was judged to have the highest reliability and lowest development costs. While its power quality is not as good as a high frequency system, it was considered adequate for both ion and MPD engine applications. The low frequency architecture was designated the reference configuration and component models based on it were developed to support the creation of a Fortran based model of a PMAD system. This PMAD subroutine will be included in a Fortran program being developed by NASA LeRC for the purpose of conducting system level trade studies on a complete NEP vehicle. Table 2 Low vs High Frequency Comparison for Ion and MPD Thrusters Low Frequency Single-Phase 3-Phase Parameter (Alternator Frequency) High Frequency High Frequency Ion MID Ion MPD Ion MPD 68,020 kg 69,170 kg Mass Efficiency Power Quality Complexity 48,350 kg 1.68 kg/kWe 95.0% Poorest Lowest 50,450 kg 1.75 kg/kWe 95.1% Poorest Lowest 2.36 kg/kWe 88.4% Much Better Much More Complex 2.40 kg/kWe 88.6% Much Better Much More Complex 67,880 kg 2.36 kg/kWe 88.5% Best Most Complex 68,470 kg 2.38 kg/kWe 88.6% Best Most Complex (1) PMAD values based on 3 channels providing a total-of 30 MWe, 150 meter main transmission line length, 8000 Vrms transmission voltage, and 100" C electronics eoldplate temperature. 7 3.0 End-to-End Power Nanagement and Distributlon Model The end-to-end power management and distribution (PMAD) model is based on an alternator power input that determines the transmission voltage and frequency. This approach was selected because supporting studies showed it was the light- est weight and most efficient. It is also the most simple, which should re- duce development costs and enhance reliability. A block diagram of this ar- chitecture, entitled "Low Frequency PMAD Architecture" is shown in Figure 3. This particular figure shows three parallel channels and counter rotating alternators, but the user can define other configurations. The alternator provides 3-phase ac power, and depending on its design, a wide range of volt- ages (1000 to 10,000 Vrms) and frequencies (60 Hz to 5 kHz) can be specified. The alternator Operating frequency is generally obtained from the power con- version module; however, one should be aware of fundamental alternator operat- ing limits. The permissible alternator frequency range is largely determined by the alternator type. A two-pole, toothless alternator is a lightweight ma- chine, but its two pole design results in a lower freq_¢y output. Con_'erse_ ly, the homopolar induction alternator can operate at high frequencies, but it is heavier and often less efficient. The operating frequency of multiple pole, permanent magnet and wound rotor machines lies between these two. Fur- thermore, for a specific alternator type the operating frequency is inversely proportional to the power level. This occurs because the rotor in a high power alternator is larger in diameter and it is subject to higher stresses at a given rotational speed. While the allowable operating voltage is more vari- able, it too is subject to limits. Large alternators can provide high voltag- es; however, because the insulation occupies considerable space, it probably would not be practical to design a high voltage, low power alternator. Following the alternator is a speed regulator. It controls the alternator- turbine speed by matching the power demand with the power supply, and shunts excess power to a parasitic load radiator. The phase lock transformer is only required if counter rotating alternators are specified. Its function is to force the alternators to operate in synchronism. A c_hange in the rotational speed of one alternator is opposed by an equal change in the other alternator, thus cancelling the moments applied to the vehicle. The switchgear unit ener- gizes the individual power processing units (PPUs), interrupts fault currents, and isolates failed components. The PPUs convert the ac power supplied by the alternators into dc for the thrusters. They also regulate the voltage output to control the thruster operation and startup. Each of these components is interconnected by transmission lines. The power conditioning components rely on heat pipe based radiators for cooling; the transmission lines radiate di- rectly to space. Application Notes: The low frequency PMAD architecture model is designed to provide overall PMAD system mass and efficiency information. It is capable of modelling the effects of different alternator and thruster types; and it can accept powers ranging from 10 kWe to 100 MWe, transmission voltages ranging from 1000 to 10,000 Vrms, and alternator frequencies ranging from 60 Hz to 5 kHz. Coldplate temperatures ranging from 60 to 200 ° C can also be input to allow preliminary assessments of high temperature electronics devices. Be- cause the component efficiencies are automatically adjusted to correspond to the coldplate temperature, the impact of these devices on the complete power 8 I I I I I I I I I I I I I I I I I I I I I I t I I I I I I I I I .... .J L I • I ! } IIIIII +°_+_ system can be evaluated (See Appendix A for a discussion on the efficiency- temperature algorithm development). Finally, solar and earth insolation in- formation that can be obtained from the heat rejection module can be used to evaluate the thermal impact of different solar distances on the PMAD system. Model Specifics: The flow chart shown in Figure 4 shows the logic employed during the development of the PMAD model. The overall mass, area, and effi- ciency information listed in the right hand column represents an estimate of the users needs. Additional information can be obtained from a Fortran common block data statement containing detailed component design details. The basic model operations are shown in the middle column, and the system inputs are listed in the boxes on the left. Default values are provided for these in- puts, but the user can use a data input file to change these values as long as they stay within the specified model limits. The PMAD model is suitable for a specific range of input parameters. Using input parameters outside of these ranges could result in inaccurate mass esti- mates or errors, and it is not recommended. Table 3 lists appropriate input ranges and recommended values for selected cases. These values are suggested if the PMAD model is being run outside of the NEP power system model. Param- eters normally obtained from external modules are addressed by the notes. The parameters listed in Table 3 are used to define the PMAD system architec- ture. The notes and comments associated with these values specify limits and identify information sources, but they do not explain how these values are used to define the overall PMAD architecture. Hence, a brief explanation is offered. It is expected that the user will know the total power required for the mission, and that they will generally define a PMAD architecture that con- tains multiple channels. The power level input by the user defines the total power provided to the PPUs to operate all the thrusters, and not the power per channel. The "Required PMAD Channels" (RPC) defines the number of channels actually needed to supply full power to the load. The "Available PMAD Chan- nels" (APC) value is used to determine how many spare channels exist. For example, suppose a 10 MWe system is under study, and RPC is set equal to 2, and APC to 3. The resulting PMAD architecture would have 3 channels each sized to handle 5 MWe; consequently, only 2 channels are required to deliver full power to the load and the third channel is in effect a spare. Within a channel, single or counter rotating alternators can also be defined. If a counter rotating alternator is selected, a phase lock transformer is automati- cally incorporated into the architecture. The variables and constants utilized in the NEP PMAD model are listed in Table 4 in alphabet_ical order. A complete listing of the PMAD model subroutine, the PMAD driver, the common block statement, and the print output Fortran source codes are presented in Appendix A. These subroutines are called "PMAD.FOR", "MAIN.FOR", "COMMON.FOR", and "PRINTO.FOR", respectively. The code "MAIN.FOR" is a temporary driver. It is assumed that the master module code to be writ- ten by NASA LeRC Will largely replace it, and also incorporate the elements of "PRINTO.FOR" desired for print output. The subroutine "COMMON.FOR" is simply a large common block containing detailed component input and output design information. Selected information can be obtained by modifying the print out- put subroutine. All four files are located on the accompanying computer disk, along with the executable file "MAIN.EXE". A sample PMAD input file entitled "PMAD.IN" is also located on the disk to show the user how alternate design configurations can be generated. 10 NEP PMAD TOP LEVEL FLOW CHART -,SK2OC INPUTS FUNCTION OUTPUTS BASIC PARAMETERS TOTAL POWER, ALTERNATOR FREQUENCY, AVAILABLE PMAD CHANNELS, REQUIRED PMAD CHANNELS, PPU TYPE, NUMBER OF ALTERNATORS PER CHANNEL, THRUSTERS PER CHANNEL. INITIAL CABLE EFFICIENCIES, CONDUCTORS AND INSULATION PARAMETERS COLDPLATE TEMPERATURE, COLDPLATE - RADIATOR TEMPERATURE DELTA, RADIATOR SINK TEMPERATURE NOTE ON PPU TYPE: ION W/O TRANSFORMER - 1 ION W/ TRANSFORMER = 2 MPD " 3 NO_,_F PPU TYPE = 11 YES ION PPU W/O TRANSFORMER SPECIFIC PARAMETERS POWER SUPPLY VOLTAGES, COMPONENT EFFtCIENCIES, RIPPLE FACTOR. AVAILABLE MODULES, REQUIRED MODULES IF PPU TYPE ,,, 2 _> / YES r ION PPU WITH TRANSFORMER SPECIFIC PARAMETERS ppu INPUT VOLTAGE, POWER SUPPLY VOLTAGES, COMPONENT EFFICIENCIES, RIPPLE FACTOR. AVAILABLE MODULES, REQUIRED MODULES 3 F PPU TYPE = 3> YES MPD PPU SPECIFIC PARAMETERS PPU INPUT VOLTAGE. POWER SUPPLY VOLTAGES, COMPONENT EFFICIENCIES. RIPPLE FACTOR. AVAILABLE MODULES. REQUIRED MODULES F_V O DATE 3/24192 PERFORM ION PPU CALCULATIONS CALCULATE INPUT VOLTAGE PERFORM ION PPU CALCULATIONS t PERFORM MPD PPU CALCULATIONS _gure 4 11 I TOTAL MASS W/ RADIATOR. TOTAL MASS W/O RADIATOR, SPECIFIC MASSES, ASSEMBLY VOLUME AND DIMENSIONS, RADIATOR AREA. TOTAL EFFICIENCY ,-I=,----- TOTAL MASS W/ RADIATOR. _-4 TOTAL MASS W/O RADIATOR, SPECIFIC MASSES, ASSEMBLY VOLUME AND DIMENSIONS, R DIATOR AREA, TOTAL EFFICIENCY I TOTAL MASS W/ RADIATOR, TOTAL MASS W/O RADIATOR, SPECIFIC MASSES, ASSEMBLY VOLUME AND DIMENSIONS, R DIATOR AREA, TOTAL EFFICIENCY NFP PMAD TOP LEVEL FLOW CHART INPUTS FUNCTION OUTPUTS TASK_ SWITCHGEAR TO THRUSTER PPU TRANSMISSION LINE SPECIFIC PARAMETERS AVAILABLE CIRCUITS, REQUIRED CIRCUITS, DISTANCE, LOAD POWERFACTOR, CABLE CONFIGURATION SWlTCHGEAR SPECIFIC PARAMETERS NUMBER OF INPUT RBIS (EQUALS NUMBER OF ALTERNATORS), AVAILABLE SWITCHGEAR MODULES. REQUIRED SWlTCHGEAR MODULES, RBI EFFICIENCY SWITCHGEAR TO SWlTCHGEAR TRANSMISSION LINE SPECIFIC PARAMETERS AVAILABLE CIRCUITS, REQUIRED CIRCUITS, DISTANCE, LOAD POWERFACTDR, CABLE CONFIGURATION ALTERNATOR TO SWITCHGEAR TRANSMISSION LINE SPECIFIC PARAMETERS AVAILABLE TRANSMISSION CIRCUITS, REQUIRED TRANSMISSION CIRCUITS, DISTANCE, LOAD POWERFACTOR, CABLE CONFIGURATION PHASE LOCK TRANSFORMER SPECIFIC PARAMETERS AVAILABLE MODULES, REQUIRED MODULES, TRANSFORMER EFFICIENCY. TRANSFORMER POWER PERCENTAGE 0 DATE 3/24/'!2 PERFORM TRANSMISSION lLINE CALCULATION TEMPERATURES, EF-"ICIENCY, CALCULATE INPUT VOLTAGE CALCULATE INPUT POWER I [ PERFORM SWlTCHGEAR CALCULATIONS (PPU TO TRANSMISSION LINE &: SWlTCHGEAR TO SWITCHGEAR) CALCULATE INPUT VOLTAGES CALCULATE INPUT POWERS CALCULATE SWITCHGEAR TO SWITCHGEAR POWER LEVEL 1 PERFORM TRANSMISSION LINE CALCULATIONS LINE MASS, SPECIFC MASS, EXTERNAL CABLE RADIUS j PERFORM TRANSMISSION LINE CALCULATIONS CALCULATE INPUT VOLTAGE CALCULATE INPUT POWER , r OUNTE" ALTERNATORS/ YES PERFORM TRANSFORMER CALCULATIONS I Figure 4 (conO 12 / TOTAL MASS W/ RADIATOR. / TOTAL MASS W/O RADIATOR, SPECIFIC MASSES, ASSEMBLY VOLUME AND DIMENSIONS, RADIATOR AREA. TOTAL EFFICIENCY I LINE MASS. SPECIFIC MASS. TEMPERATURES, EFFICIENCY, EXTERNAL CABLE RADIUS LINE MASS, SPECIFIC MASS, TEMPERATURES, EFFICIENCY, EXTERNAL CABLE RADIUS TOTAL MASS W/ RADIATOR, TOTAL MASS W/O RADIATOR, SPECIFIC MASSES, ASSEMBLY _ VOLUME AND DIMENSIONS. R DIATOR AREA. TOTAL EFFICIENCY = NEP PMAD TOP LEVEL FLOW CHART INPUTS FUNCTION OUTPUTS l ALTERNATOR SPEED REGULATOR SPECIFIC PARAMETERS PWM FREQUENCY, REOUIRED MODULES, REDUNDANCY FACTOR. BUS CONDUCTOR EFFICIENCY. SHUNT SWITCH EFFICIENCY. FILTER EFFICIENCY SHUNT REGULATOR TO PLR TRANSMISSION LINE SPECIFIC PARAMETERS REDUNDANCY FACTOR. REQUIRED TRANSMISSION CIRCUITS, DISTANCE, LOAD POWERFACTOR, CABLE CONFIGURATION PERFORM ALTERNATOR SPEED REGULATOR CALCULATIONS b1 PERFORM TRANSMISSION LINE CALCULATIONS CALCULATE OUTPUT VOLTAGE CALCULATE OUTPUT POWER PARASITIC LOAD RADIATOR SPECIFIC PARAMETERS PLR OPERATING TEMPERATURE, WIRE-PLATE DELTA TEMPERATURE. REDUNDANCY FACTOR, REOUIREO NUMBER OF NICHROME V CIRCUITS, CONDUCTOR CHARACTERISTICS. PLR MATERIAL CHARACTERISTICS, AVAILABLE PLRS, REQUIRED PLRS PERFORM PLR CALCULATIONS I PERFORM SUMMARYCALCULATIONS TOTAL MASS W/ RADIATOR, TOTAL MASS W/O RADIATOR, SPECIFIC MASSES. ASSEMBLY VOLUME AND DIMENSIONS. RADIATOR AREA. EFFICIENCY LINE MASS, SPECIFIC MASS, TEMPERATURES, EFFICIENCY. EXTERNAL CABLE RADIUS / MASS, SURFACE AREA, DIMENSIONS I 1_ ¸ _ _ I SYSTEM MASS, SYSTEM I SPECIFIC WEIGHT. SYSTEM _IEFFICIENCY, TOTAL COMPONEN1 _1 MASS W/O RADIATOR, TOTAL I RADIATOR MASS, TOTAL I TRANSMISSION LINE MASS ! IIEv 0 DATE 3/24/92 Pigure 4 (conO 13 End-to-End Input Input Parameter Total PMAD System Power Level (Measured at the Thruster PPU Input) Thruster PPU Input Voltage Level (See Available PMAD Channels Table 3 NEP PMAD System Model Parameter Ranges Recommended Input Ranqe Note i) 100 kWe to 100 MWe (Limited to 10 MWe/Channel) 1500 to 10,000 Vrms Equal to or Greater than Required Channels Required PMAD Channels (See Note 2) No Limit Number of Alternators per Channel (See Note 2) No Limit Number of Thrusters per Channel (See Note 2) No Limit Counter Rotating Alternators Yes=l, No=O Power Processing Unit Type Ion PPU w/o Transformer = I Ion PPU with Transformer = 2 MPD PPU = 3 Alternator Operating Frequency (See Note 3) 60 Hz to 5 kHz 0.8 kHz is Recommended Coldplate Temperature 60 to 200 ° C 100° C Suggested as Initial Value Coldplate to Radiator Temperature Delta 0 to 20° C 16.67 ° C is Recommended Radiator Sink Temperature See Note 4 247.67 K Calculated for LEO 1. A PPU input voltage level is only specified when the Ion PPU with Transformer, Option #2; or the MPD PPU, Option 03, is selected. The PPU input voltage level is calculated by the model when the Ion PPU W/o Transformer, Option #1, is selected. 2. The PMAD model does not have a limit regarding _e number of Required PMAD Channels (R.PC), the Number of Alternators per Channel (NAC), and the Number of Thruster per Channel (NTC); however, there are of course practical limits on these values. The user is responsible for selecting appropriate values. 3. The Alternator Operating Frequency (AOF) is normally obtained from the Power Conversion module (CR-19i134 or CR-191135). If the PMAD module is run separately, a value must be input by the user. 4. The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 14 AOF APC CPT CRTD EEPE IDPPU KRA NAC NTC PMADPO PPUVI RPC RST TERA TERM TPCM TPM TPSM TT[_ Table 4 End-to-End NEP PMAD System Model Variable Definitions Alternator Operating Frequency (kHz) Available PMAD Channels Electronics Coldplate Temperature (°C) Electronics Coldplate to Radiator Temperature Delta (°C) End-to-End PMAD System Efficiency (%) Variable to Select Power Processing Unit Type Variable to Select Counter Rotating Alternators Number of Alternators per PMAD Channel Number of Thrusters per PMAD Channel PMAD System Power Output (kWe) cvrms)Power Processing Unit Input Voltage Required PMAD Channels Electronics Radiator Sink Temperature (K) Total Electronics Radiator _ (m 2) Total Electronics Radiator Mass (kg) Total Power Conditioning Component Mass (kg) Total PMAD System Mass (kg) Total PMAD System Specific Mass (kg/kWe) Total Transmission Line Mass (kg) 15 3.1 Ion Power Processing Unit w/o Beam Power Supply Transformer Two ion power processing unit (PPU) models are available. They utilize simi- lar topologies, but the individual power supply designs differ. Because the first type, designated option #I, does not contain a beam power supply trans- former, the user can not specify the PPU input voltage level. Instead, the PPU input voltage is calculated by the model from the user defined beam volt- age level. This design feature affects the operation of the PPU, and largely determines its suitable applications. These items are discussed further in the subsequent application notes. A block diagram of the option #I ion PPU design is shown in Figure 5. Note that there are four distinct power supplies, beam, discharge, accelerator, and neutralizer. Each of these supplies can be controlled independently to facil- itate engine startup and provide flexibility when responding to off-normal conditions. Because the operating voltage of the discharge, accelerator, and neutralizer power supplies is much lower than the beam power supply voltage, a step down transformer is incorporated into the design of each of these sup- plies. All four power supplies contain a switching rectifier, and an output dc filter. The switching rectifier converts the ac power supplied by the alternator into dc for the engine, and employs pulse-width-modulation (PWM) switching to precisely regulate the output voltage of each power supply. The dc filter stage reduces the ripple content to a level acceptable for the en- gine. The model is completed with the addition of control and monitoring hardware, identified in the figure as the main engine controller, and an en- closure assumed to be largely constructed from carbon'carbon, it is assumed that the enclosure mounting plate is firmly bonded to the assembly coldplate to facilitate heat transfer. This improves component thermal management, but makes it more difficult to replace. The assumption is that maintenance will be very limited if not precluded on a nuclear electric propulsion vehicle once a mission has begun. Application Notes: It was previously mentioned that the beam power supply in the option #I PPU does not have a transformer stage. Eliminating this trans- former greatly reduces PPU mass, but there are two drawbacks. Because the PPU input voltage is determined by the beam supply output voltage, and this volt- age is relatively low (1800 Vdc), the mass of all upstream transmission lines will be increased. Consequently, this PPU configuration is really only prac- tical if the transmission distance is fairly short, probably less than a 150 meters. For distances greater than this, the option #2 PPU appears to be a better choice. The other drawback associated with this design is it is not possible to pro- vide the isolation between the PMAD system and the thrusters that a transform- er would afford. Electromagnetic interference (EMI) will be generated by the thrusters and the PWM switching. This may cause the PMAD system to have a fairly high level of EMI, and diminish power system grounding effectiveness. While detailed analysis is required to determine the implications associated with this approach, it should be reasonable to design the power system to withstand this level of EMI. Furthermore, the components connected to the PMAD system, the alternators and thrusters, can tolerate high levels of EMI if they are suitably designed for this environment. 16 LJ zz_ O0 --Z sB _o 0 I]_ _! ,_I__I I '|_ , I '1 I L-IH-_J -_i j Z_ 17 Model Specifics: The flow chart shown in Figure 6 depicts the logic employed during the development of the option #I PPU model. It should be noted that the outputs listed in the right column represent a best estimate of the users needs. A limited number of parameters are printed, but many more are avail- able. These outputs can be accessed by modifying the print routine so that it prints additional data contained in the Fortran common block. The basic model operations are shown in the middle column, and the inputs are listed in the boxes on the left. Default values are provided for each of these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. The model is designed to cover a specific range of input parameters. Using input parameters outside of these ranges could result in inaccurate mass esti- mates and it is not recommended. Table 5 lists the appropriate input ranges and values recommended to yield the best results for the primary input parame- ters. Certain parameters are normally obtained from external modules. The notes identify the modules that are the sources of this data. Many of the input values, particularly the component efficiencies, are rela- tively fixed, and they should only be changed if the user is quite familiar with the model operation and power conditioning component designs in general. Although component efficiencies change with temperature, normally downward as temperature rises, it is not necessary to manually adjust these values. The models contain algorithms that will automatically adjust the component effi- ciencies based on the selected coldplate temperature. These temperature ad- justed efficiencies are then used by the component mass estimation algorithms. The only reason to manually change these values would beto conduct mass-effi _ ciency tradeoffs. In general, the efficiency of a component can be increased by enlarging its internal conductors and other power elements. While this re- duces radiator and power source mass, it increases the mass of the component itself. The default efficiency values utilized by the model were carefully selected to yield mass and total component efficiency estimates consistent with the pro- posed applications and the specified time period. These individual element efficiency values are referred to as secondary input parameters, and accept- able ranges and default values are listed for them in Table 6. Because the discharge and neutralizer power supply voltages are quite low, less than 120 Vdc, it will be necessary for the user to adjust the efficiencies of the rec- tifier and filter stages if he changes the default voltage levels. The pres- ent rectifier and filter default efficiency values are for discharge and neu- tralizer power supply voltages of 30 Vdc and 20 Vdc, respectively. This ad- justment would be necessary to maintain representative efficiencies and obtain realistic mass estimates. Suitable efficiencies for voltages ranging from 20 to i20 Vdc are shown in Tables 7 and 8. The variables and constants utilized in the option #I PPU model are listed in Table 9 in alphabetical order. A complete listing of the Fortran source code is presented in Appendix B. This subroutine is located on the accompanying computer disk and it has the file name "IONPU].FOR". 18 ION THRUSTER PPU OPTION #1 FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS POWER PROCESSING UNIT POWER LEVEL, AVAILABLE MODULES, REQUIRED MODULES, BEAM, DISCHARGE, ACCELERATOR, & NEUTRALIZER OUTPUT VOLTAGES, FREQUENCY RIPPLE FACTOR, COLDPLATE TEMPERATURE, COLDPLATE TO RADIATOR DELTA T,, RAOtA TOR :SINK TE_IPERA TORE SET DEFAULT VALUES: INPUT FILTER EFFICIENCY - 0,995 BEAM POWER RECTIFIER EFFICIENCY = 0.98 BEAM FILTER EFFICIENCY - 0.995 DISCHARGE TRANSFORMER EFFICIENCY = 0.99 DISCHARGE RECTIFIER EFFICIENCY = 0.972.5 DISCHARGE FILTER EFFICIENCY = 0.992 ACCELERATOR TRANSFORMER EFFICIENCY = 0.99 ACCELERATOR RECTIFIER EFFICIENCY = O.9B ACCELERATOR FILTER EFFICIENCY = 0.995 NEUTRALIZER TRANSFORMER EFFICIENCY - 0.99 NEUTRALIZER RECTIFIER EFFICIENCY = 0.955 NEUTRALIZER FILTER EFFICIENCY - 0.99 TASK20L REV 0 DATE 4/I/|2 1 CORRECT POWER SUPPLY STAGE EFFICIENCIES FOR COLDPLATE TEMPERATURE, CALCULATE PPU INPUT VOLTAGE, CALCULATE PPU CONTROL & MONITORING POWER REQUIREMENTS I CALCULATE PPU EFFICIENCY CALCULATE PPU STAGE EFFICIENCY CALCULATE BEAM SUPPLY EFFICIENCY CALCULATE POWER SUPPLY POWER LEVELS. CALCULATE PPU TOTAL OUTPUT POWER CALCULATE BEAM, DISCHARGE, ACCELERATOR. & NEUTRALIZER COMPONENT MASSES CALCULATE PPU CONTROL & MONITORING MASS SUM PPU ELECTRONICS MASSES CALCULATE PPU VOLUMES & DIMENSIONS (SINGLE MODULE AND COMPLETE ASSEMBLY] CALCULATE ENCLOSURE MASSES (SINGLE MODULE & COMPLETE ASSEMBLY] CALCULATE PPU RADIATOR AREA AND MASS CALCULATE PPU MASSES AND SPECIFIC MASSES WITH AND WITHOUT THE RADIATOR MASS Figure 6 19 -I PPU EFFICIENCY IPPU BEAM SUPPLY EFFICIENCY ASSEMBLY VOLUME, ASSEMBLY DIMENSIONS RADIATOR AREA PPU MASS WITHOUT RADIATOR PPU MASS WITH RADIATOR PPU SPECIFIC MASS WITHOUT RADIATOR PPU SPECIFIC MASS WiTH RADIATOR Table 5 Ion Thruster PPU Option #1 Model (w/o Beam Power Supply Transformer) Primary Input Parameter Ranges Power Processing Unit primary Input Parameter Recommended Input Ra_nge PPU Input Power Level 100 kWe to 10 MWe PPU Input Voltage Level See Note 1 Beam Power Supply Output Voltage Level 120 to 10,000 Vdc Discharge Power Supply Output Voltage Level 20 to 200 Vdc Accelerator Power Supply Output Voltage Level Neutralizer Power Supply Output Voltage Level Ripple Factor Percentage 120 to 10,000 Vdc 20 to 200 Vdc 0.5 to 8% PPU Available Modules Equal to or Greater than Required Modules PPU Required Modules No Limit Alternator Operating Frequency (See Note 2) 60 Hz to 5 kHz 0.8 kHz is Recommended Col@late Temperature 60 to 200* C 100" C Suggested as Initial Value Coldplate to Radiator Temperature Delta 0 to 20* C 16.67" C is Recommended Radiator Sink Temperature See Note 3 247.67 K Calculated for LEO E . . . The input voltage level is calculated from the beam supply output voltage level. It will be approximately 0.72 times the output voltage level. The alternator operating frequency (AOF) will normally be obtained from the power conversion module (CR-191134 or CR-191135). If the PMAD module is run separately, AOF must be input. The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR'191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 2O Table 6 Ion Thruster PPu Option//1 Model (w/o BeamPower Supply Transformer) SecondaryInput Parameter Ranges Power ProcessingUnit Seconda_ Input Parameter Recommended Input Range Input AC Filter Efficiency Range: 99.0 to 99.9% 99.5 % is Recommended Beam Power Supply Rectifier Efficiency Normal Range: 97.0 to 99.0% 98.0% is Recommended Beam Power Supply Output DC Filter Efficiency Range: 99.0 to 99.9% 99.5 % is Recommended Discharge Power Supply Transformer Efficiency Range: 97.5 to 99.5 % 99% is Recommended Discharge Power Supply Rectifier Efficiency (See Note 1) Normal Range: 95.5 to 98.0% 97.25% Recommended for 30 Vdc Discharge Power Supply Output DC Filter Efficiency (See Note 2) Range: 99.0 to 99.5% 99.2% Recommended for 30 Vdc Accelerator Power Supply Transformer Efficiency Range: 97.5 to 99.5 % 99% is Recommended Accelerator Power Supply Rectifier Efficiency Normal Range: 97.0 to 99.0% 98.0% is Recommended Accelerator Power Supply Output DC Filter Efficiency Range: 99.0 to 99.9% 99.5 % is Recommended Neutralizer Power Supply Transformer Efficiency Range: 97.5 to 99.5 % 99% is Recommended Neutralizer Power Supply Rectifier Efficiency (See Note 1) Normal Range: 95.5 to 98.0% 95.5 % Recommended for 20 Vdc Neutralizer Power Supply Output DC Filter Efficiency (See Note 2) Range: 99.0 to 99.5 % 99.0% Recommended for 20 Vdc 1. Refer to Table 7 for corrected rectifier efficiencies when the voltage output is less than 120 Vdc. 2. Refer to Table 8 for corrected de filter effieieneies when the voltage output is less than 120 Vdc. 21 Table 7 Efficiency Corrections for Discharge and Neutralizer Power Supply Rectifier Mass Estimates Input Voltage (Vdc) 120 110 100 90 80 70 60 50 30 20 Switching Rectifier Input Efficiency (percent) 98.00 98.00 97.98 97.96 97.94 97.86 97.80 97.68 97.50 97.25 95.50 Table 8 Efficiency Corrections for Discharge and Neutralizer Power Supply Filter Mass Estimates Input Output Filter Voltage Input Efficiency (Vdc) Cperomt) 120 99.50 110 99.50 100 99.49 90 99.48 80 99.47 70 99.45 60 99.42 50 99.38 40 99.31 30 99.20 20 99.00 22 ACCM AFE AFET AFM AOF AOP AOV ARE ARET ARM ATE ATET ATM BCCM BFE BFET BFM BOP BOV Table 9 Ion Thruster PPU Option #1 Model (w/o Beam Power Supply Transformer) Variable Def'mitions Accelerator Power Supply Conductor and Connector Mass (kg) Accelerator Power Supply Filter Efficiency (%) Accelerator Power Supply Filter Efficiency at the Coldplate Temperature (%) Accelerator Power Supply Filter Mass (kg) Alternator Operating Frequency (kHz) Accelerator Supply Output Power Level (kWe) Accelerator Supply Output Voltage (Vdc) Accelerator Power Supply Rectifier Efficiency (%) Accelerator Power Supply Rectifier Efficiency at the Cold- plate Temperature (%) Accelerator Power Supply Rectifier Mass (kg) Accelerator Power Supply Transformer Efficiency (%) Accelerator Power Supply Transformer Efficiency at the Coldplate Temperature (%) Accelerator Power Supply Transformer Mass (kg) Beam Power Supply Conductor and Connector Mass (kg) Beam Power Supply Filter Efficiency (%) Beam Power Supply Filter Efficiency at the Coldplate Temperature (%) Beam Power Supply Filter Mass (kg) Beam Supply Output Power Level (kWe) Beam Supply Output Voltage (Vdc) 23 BRE BRET BRM CACH CACL CACPEM CACV CACW CMM CMP CPT CRTD DCCIVI DFE DFET DFM DOP DOV DRE DRET Table 9 (cont) Ion Thruster PPU Option//1 Model (w/o Beam Power Supply Transformer) Variable Def'mitions Beam Power Supply Rectifier Efficiency (%) Beam Power Supply Rectifier Efficiency at the Coldplate Temperature (%) Beam Power Supply Rectifier Mass (kg) Complete Assembly Component Height (m) Complete Assembly Component Length (m) Complete Assembly Coldplate Based Enclosure Mass (kg) Complete Assembly Component Volume (m 3) Complete Assembly Component Width (m) Control and Monitoring Mass (kg) Control and Monitoring Power Demand (Watts) Coldplate Temperature (* C) Coldplate to Radiator Temperature Delta (*C) Discharge Power Supply Conductor and Connector Mass (kg) Discharge Power Supply Filter Efficiency (%) Discharge Power Supply Filter Efficiency at the Coldplate Temperature (%) Discharge Power Supply Filter Mass (kg) Discharge Supply Output Power Level (kWe) Discharge Supply Output Voltage (Vdc) Discharge Power Supply Rectifier Efficiency (%) Discharge Power Supply Rectifier Efficiency at the Cold- plate Temperature (%) 24 DRM DTE DTET DTM IFE IFET IFM NCCM NFE NFET NFM NOP NOV NRE NRET NRM NTE NTET NTM Table 9 (cont) Ion Thruster PPU Option #I Model (w/o Beam Power Supply Transformer) Variable Def'mitions Discharge Power Supply Rectifier Mass (kg) Discharge Power Supply Transformer Efficiency (%) Discharge Power Supply Transformer Efficiency at the Coldphte Temperature (%) Discharge Power Supply Transformer Mass (kg) Power Processing Unit Input Filter Efficiency (%) Power Processing Unit Input Filter Efficiency at the Cold- plate Temperature (%) Power Processing Unit Input Filter Mass (kg) Neutralizer Power Supply Conductor and Connector Mass (kg) Neutralizer Power Supply Filter Efficiency (%) Neutralizer Power Supply Filter Efficiency at the Coldplate Temperature (%) Neutralizer Power Supply Filter Mass 0cg) Neutralizer Supply Output Power Level 0eWe) Neutralizer Supply Output Voltage (Vdc) Neutralizer Power Neutralizer Power plate Temperature Neutralizer Power Neutralizer Power Neutralizer Power Supply Rectifier Efficiency (%) Supply Rectifier Efficiency at the Cold- (%) Supply Rectifier Mass (kg) Supply Transformer Efficiency (%) Supply Transformer Efficiency at the Col@late Temperature (%) Neutralizer Power Supply Transformer Mass (kg) 25 PPAM PPBE PPE PPEM PPIP PPIV PPM PPMR PPOP PPRM PPSE PPSM PPSMR RA RAM RF RST SMCH SMCL SMCPEM SMCV SMCW Table 9 (cont) Ion Thruster PPU Option #1 Model (w/o BeamPower Supply Transformer) Variable Def'mitions PowerProcessingUnit AvailableModules Power Processing Unit Beam Supply Efficiency Measure (%) Power Processing Unit Efficiency (%) Power Processing Unit Electronics Mass (kg) Power Processing Unit Input Power Level (kWe) Power Processing Unit Input Voltage Level (Vrms) Power Processing Unit Mass w/o Radiator (kg) Power Processing Unit Mass with Radiator (kg) Power Processing Unit Output Power Level (kWe) Power Processing Unit Required Modules Power Processing Unit Stage Efficiency (%) Power Processing Unit Specific Mass w/o Radiator (kg/kWe) Power Processing Unit Specific Mass with Radiator (kg/kWe) Radiator Area (m _) Radiator Mass (kg) Ripple Factor (%) Radiator Sink Temperature (K) Single Module Component Height (m) Single Module Component Length (m) Single Module Col@late Based Enclosure Mass (kg) Single Module Component Volume (m 3) Single Module Component Width (m) 26 3.2 Ion Power Processing Unit with Beam Power Supply Transformer The option #2 ion power processing unit (PPU) topology is similar to the op- tion #I PPU configuration; however, the design of the power supplies, espe- cially the beam power supply, differs. Because the option #2 design contains a beam power supply transformer to allow higher transmission voltages, the user is free to specify a wide range of PPU input voltages This allows the option #2 PPU to be used in a wider range of applications and in certain cases it should improve the overall operation of the PMAD system. A block diagram of the option #2 ion PPU design is shown in Figure 7. There are four separate power supplies, beam, discharge, accelerator, and neutraliz- er; each independently controllable to facilitate engine startup and improve flexibility. The beam and accelerator power supplies each use a single trans- former to step down the high transmission line voltage to a level suitable for the engine. However, the discharge and neutralizer power supplies require two transformers because their output voltage is extremely low. The voltage ratio of power supply input over output is too large for a single transformer. The difference in the number of prlmary and secondary turns would be so high that the magnetic coupling between turns would be very poor, and the resulting flux leakage would cause a single transformer to be inefficient. Using two series connected transformers to sequentially step down the voltage is better. The turns ratio for each is cut in half; therefore, good coupling between the pri- mary and secondary coils can be achieved. The voltage transformation effici- ency is thus higher and the overall electrical performance is much better. Each of the four power supplies also contains a switching rectifier, and an output dc filter. The rectifier converts the ac power supplied by the alter- nator into dc for the engine. It also utilizes pulse-width-modulation (PWM) switching to accurately regulate the output voltage of each power supply. The dc filter stage reduces the ripple content to a level acceptable for the en- gine. The model is completed with the addition of control and monitoring hardware, identified in the figure as the main engine controller, an enclosure assumed to be largely constructed from carbon-carbon, and a carbon-carbon heat pipe radiator. It is assumed that the enclosure mounting plate is bonded to the assembly coldplate to facilitate heat transfer. This improves component thermal management, but makes it more difficult to replace. The assumption is that maintenance will be very limited if not precluded on a nuclear electric propulsion vehicle once a mission has begun. Application Notes: The option #2 ion PPU with the transformer in the beam power supply has greater versatility and better operating characteristics, but its mass is considerably larger. Because the user can specify a wide range of PPU input voltages, they can utilize lighter weight transmission lines and op- timize the PMAD system based upon voltage. Consequently, this PPU configura- tion can be used with virtually any transmission line length. In fact, for distances greater than 150 meters, it is probably the only practical approach. The option #1PPU only appears superior if mass is an overriding concern and the transmission distance is quite short. This PPU design also enhances the isolation between the PMAD system and the thrusters. The electromagnetic interference (EMI) introduced into the PMAD system by the thrusters and the PWM switching will be greatly reduced. This design also improves grounding flexibility, because the transformer allows the designer to establish two separate ground planes. This should improve ground- 27 z_ © I I 28 ing effectiveness, since the ground currents generated by the thruster and PWM switching will not circulate through out the rest of the PMAD system. This may ultimately simplify the thruster and PMAD system designs; however, it is necessary to conduct detailed system analyses to determine the operating qual- ities of this approach. Model Specifics: The flow chart shown in Figure 8 presents the logic that was followed during the development of the option #2 PPU model. The outputs list- ed in the right column represent a best estimate of the users needs and many more parameters are available. These parameters can be accessed by modifying the print routine so that it prints the desired additional data contained in the Fortran common block. The basic model operations are shown in the middle column, and the inputs are listed in the boxes on the left. Default values are provided for each of these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. The model is designed to cover a specific range of input parameters. Using input parameters outside of these ranges could result in inaccurate mass esti- mates and it is discouraged. Table 10 lists the input ranges and values that were determined to yield the best results for the primary input parameters. The notes that accompany certain input parameters identify the modules that will normally provide these values. In general, the default efficiency values should not be changed unless the user is quite familiar with the model operation and power conditioning compo- nent designs in general. Although component efficiencies generally decline with temperature, it is not necessary to manually adjust these values. The models utilize algorithms to automatically adjust the efficiency values for the selected coldplate temperature. The component algorithms then use these temperature adjusted efficiencies to estimate mass. The only reason to manu- ally change these values would be to conduct mass-efficiency tradeoffs. The efficiency of a component can generally be increased by enlarging its internal conductors and other power elements. This reduces radiator and power source mass, but it increases the mass of the component itself. The recommended efficiency values were selected to yield mass and total compo- nent efficiency estimates consistent with the proposed applications and the specified time period. These device efficiency values are referred to as sec- ondary input parameters, and acceptable ranges and default values are listed for them in Table 11. Because the discharge and neutralizer power supply out- put voltages are quite low, less than 120 Vdc, the user will need to adjust the rectifier and filter efficiency inputs if a different output voltage level is specified. The present rectifier and filter default efficiency values are for discharge and neutralizer power supply voltages of 30 Vdc and 20 Vdc, re- spectively. These adjustments are necessary to maintain proper component ef- ficiencies and obtain realistic mass estimates. Appropriate efficiencies for voltages ranging from 20 to 120 Vdc are shown in Tables 12 and 13. The variables and constants utilized in the option #2 PPU model are listed in Table 14 in alphabetical order. A complete listing of the Fortran source code is presented in Appendix C. This subroutine has the file name "IONPU2.FOR", and it is located on the accompanying computer disk. 29 ION THRUSTER PPU OPTION #2 FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS POWER PROCESSING UNIT POWER LEVEL, PPU INPUT VOLTAGE, AVAILABLE MODULES, REQUIRED MODULES, BEAM, DISCHARGE, ACCELERATOR, & NEUTRALIZER OUTPUT VOLTAGES, FREQUENCY, RIPPLE FACTOR, COLOPLATE TEMPERATURE, COLDPLATE TO RADIATOR DELTA T, RADIATOR SINK TEMPERATURE SET DEFAULT VALUES: INPUT FILTER EFFICIENCY - 0.995 BEAM TRANSFORMER EFFICIENCY - 0.99 BEAM POWER RECTIFIER EFFICIENCY - 0,98 BEAM FILTER EFFICIENCY - 0.995 DISCHARGE TRANSFORMER _1 EFFICIENCY - 0.99 DISCHARGE TRANSFORMER 1_2 EFFICIENCY " 0.99 DISCHARGE RECTIFIER EFFICIENCY = 0.9725 DISCHARGE FILTER EFFICIENCY - 0.992 ACCELERATOR TRANSFORMER EFFICIENCY " 0.99 ACCELERATOR RECTIFIER EFFICIENCY - 0.98 ACCELERATOR FILTER EFFICIENCY - 0.995 NEUTRALIZER TRANSFORMER #1 EFFICIENCY = 0.99 NEUTRALIZER TRANSFORMER 1112 EFFICIENCY - 0.99 NEUTRALIZER RECTIFIER EFFICIENCY = 0.955 NEUTRALIZER FILTER EFFICIENCY = 0.99 TA_20M REV • OATE 4/g/12 1 CORRECT POWER SUPPLY STAGE EFFICtENCIES FOR COLDPLATE TEMPERATURE, CALCULATE PPU CONTROL & MONITORING POWER REQUIREMENTS CALCULATE PPU EFFICIENCY I B CALCULATE PPU STAGE EFFICIENCY I CALCULATE BEAM SUPPLY EFFICIENCYI' CALCULATE POWER SUPPLY POWER LEVELS, CALCULATE PPU TOTAL OUTPUT POWER CALCULATE BEAM, DISCHARGE, ACCELERATOR, & NEUTRALIZER COMPONENT MASSES CALCULATE PPU CONTROL &: MONITORING MASS SUM PPU ELECTRONICS MASSES CALCULATE PPU VOLUMES & DIMENSIONS (SINGLE MODULE AND COMPLETE ASSEMBLY) CALCULATE ENCLOSURE MASSES (SINGLE MODULE & COMPLETE ASSEMBLY) CALCULATE PPU RADIATOR AREA AND MASS CALCULATE PPU MASSES AND SPECIFIC MASSES WITH AND WITHOUT THE RADIATOR MASS ]L e 8 30 :-_ _ PPU EFFICIENCY jPPU BEAM SUPPLY EFFICIENCY ASSEMBLY VOLUME, ASSEMBLY DIMENSIONS RADIATOR AREA PPU MASS WITHOUT RADIATOR PPU MASS WITH RADIATOR PPU SPECIFIC MASS WITHOUT RADIATOR PPU SPECIFIC MASS WITH RADIATOR Table 10 Ion Thruster PPU Option//2 Model (with Beam Power Supply Transformer) Primary Input Parameter Ranges Power Processing Unit primary Input Parameter PPU Input Power Level PPU Input Voltage Level Beam Power Supply Output Voltage Level Discharge Power Supply Output Voltage Level Accelerator Power Supply Output Voltage Level Neutralizer Power Supply Output Voltage Level Ripple Factor Percentage PPU Available Modules PPU Required Modules Alternator Operating Frequenc_ (See Note 1) Coldplate Temperature Col@late to Radiator Temperature Delta Radiator Sink Temperature Recommended Input Range 100 kWe to 10 MWe 200 to 10,000 Vrms 120 to 10,000 Vdc 20 to 200 Vdc 120 to 10,000 Vdc 20 to 200 Vdc 0.5to 8% Equal to or Greater than Required Modules No Limit 60 I-Iz to 5 kI-Iz 0.8 kHz is Recommended 60 to 200* C 100" C Suggested as Initial Value 0 to 20* C 16.67" C is Recommended See Note 2 247.67 K Calculated for LEO . . The alternator operating frequency (AOF) will normally be obtained from the power conversion module (CR-191134 or CR-191135). If the PMAD module is run separately, AOF must be input. The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 31 Table 11 Ion Thruster PPU Option #2 Model (with Beam Power Supply Transformer) Secondary Input Parameter Ranges Power Processing Unit Secondary Input Parameter Recommended Input Ranee Input AC Filter Efficiency Range: 99.0 to 99.9% 99.5% is Recommended Beam Power Supply Transformer Efficiency Beam Power Supply Rectifier Efficiency Beam Power Supply Ou_ut DC Filter Efficiency Range: 97.5 to 99.5 % 99% is Recommended Normal Range: 97.0 to 99.0% 98'0% is _mmended Range: 99.0 to 99.9% 99._5_ is Recommendekt Discharge Power Supply Transformer #1 Efficiency Range: 97.5 to 99.5 % 99% is Recommended Discharge Power Supply Transformer #2 Efficiency Range: 97.5 to 99.5% 99% is Recommended Discharge Power Supply Rectifier Efficiency (See Note 1) Normal Range: 95.5 to 98.0% 97.25% Recommended for 30 Vdc Discharge Power Supply Output DC Filter Efficiency (See Note 2) Range: 99.0 to 99.5% 99.2 % Recommended for 30 Vdc Accelerator Power Supply Transformer Efficiency Range: 97.5 to 99.5 % 99% is Recommended Accelerator Power Supply Rectifier Efficiency Normal Range: 97.0 to 99.0% 98.0% is Recommended Accelerator Power Supply Output DC Filter Efficiency Range: 99.0 to 99.9% 99.5% is Recommended 1. Refer to Table 12 for corrected rectifier efficiencies when the voltage output is less than 120 Vdc. 2. Refer to Table 13 for corrected dc filter efficieneies when the voltage output is less than 120 Vde. 32 Table 11 (cont) Ion Thruster PPU Option #2 Model (with Beam Power Supply Transformer) Secondary Input Parameter Ranges Power Processing Unit Secondary Input Parameter Neutralizer Power Supply Transformer #1 Efficiency Recommended Input Range Neutralizer Power Supply Transformer #2 Efficiency Range: 97.5 to 99.5 % 99% is Recommended Neutralizer Power Supply Rectifier Efficiency (See Note 1) Range: 97.5 to 99.5 % 99% is Recommended Neutralizer Power Supply Output DC Filter Efficiency (See Note 2) Normal Range: 95.5 to 98.0% 95.5 % Recommended for 20 Vdc Range: 99.0 to 99.5 % 99.0 % Recommended for 20 Vdc 1. Refer to Table 12 for corrected rectifier effieieneies when the voltage output is less than 120 Vdc. 2. Refer to Table 13 for corrected de filter effieiencies when the voltage output is less than 120 Vde. 33 Table 12 Efficiency Corrections for Discharge and Neutralizer Power Supply Rectifier Mass Estimates Input Switching Rectifier Voltage Input Efficiency _dc) (percent) 120 98.00 110 98.00 IO0 97.98 90 97.96 80 97.94 70 97.86 60 97.80 50 97.68 40 97.50 30 97.25 20 95.50 Table 13 Efficiency Corrections for Discharge and Neutralizer Power Supply Filter Mass Estimates Input Output Filter Voltage Input Efficiency (percent) 120 99.50 110 99.50 100 99.49 90 99.48 80 99.47 70 99.45 60 99.42 50 99.38 40 99.31 30 99.20 20 99.00 34 ACCIVI AFE AFET AFM AOF AOP AOV ARE ARET ARM ATE ATET ATM BCCM BFE BFET BFIVl BOP BOV Table 14 Ion Thruster PPU Option #2 Model (with Beam Power Supply Transformer) Variable Def'mitions Accelerator Power Supply Conductor and Connector Mass (kg) Accelerator Power Supply Filter Efficiency (%) Accelerator Power Supply Filter Efficiency at the Coldplate Temperature (%) Accelerator Power Supply Filter Mass (kg) Alternator Operating Frequency (kHz) Accelerator Supply Output Power Level (kWe) Accelerator Supply Output Voltage (Vdc) Accelerator Power Supply Rectifier Efficiency (%) Accelerator Power Supply Rectifier Efficiency at the Cold- plate Temperature (%) Accelerator Power Supply Rectifier Mass (kg) Accelerator Power Supply Transformer Efficiency (%) Accelerator Power Supply Transformer Efficiency at the Coldplate Temperature (%) Accelerator Power Supply Transformer Mass (kg) Beam Power Supply Conductor and Connector Mass (kg) Beam Power Supply Filter Efficiency (%) Beam Power Supply Filter Efficiency at the Coldplate Temperature (%) Beam Power Supply Filter Mass (kg) Beam Supply Output Power Level (kWe) Beam Supply Output Voltage (Vdc) 35 BRE BRET BRM BTE BTET BTIVI CACH CACL CACPEM CACV CACW ClVlM ClVH' CPT CRTD DCCM DFE DFET DFIVI DIV Table 14 (cont) Ion Thruster PPU Option//2 Model (with BeamPower Supply Transformer) Variable Def'mitions BeamPower SupplyRectifier Efficiency (%) Beam Power Supply Rectifier Efficiency at the Col@late Temperature (%) Beam Power Supply Rectifier Mass (kg) Beam Power Supply Transformer Efficiency (%) Beam Power Supply Transformer Efficiency at the Cold- plate Temperature (%) Beam Power Supply Transformer Mass (kg) Complete Assembly Component Height (m) Complete Assembly Component Length (m) Complete Assembly Coldplate Based Enclosure Mass (kg) Complete Assembly Component Volume (m 3) Complete Assembly Component Width (m) Control and Monitoring Mass (kg) Control and Monitoring Power Demand (Watts) Coldplate Temperature (*C) Coldplate to Radiator Temperature Delta (*C) Discharge Power Supply Conductor and Connector Mass (kg) Discharge Power Supply Filter Efficiency (%) Discharge Power Supply Filter Efficiency at the Coldplate Temperature (%) Discharge Power Supply Filter Mass (kg) Intermediate Discharge Supply Output Voltage (Vdc) 36 Table 14 (cont) Ion Thruster PPU Option #2 Model (with Beam Power Supply Transformer) Variable Definitions DOP DOV DRE DRET DRM DTIE DTIET DT2E DT2ET DTIM DT2M IFE IFET IFIVI NCCM NFE NFET NFlVI NIV Discharge Supply Output Power Level (kWe) Discharge Supply Output Voltage (Vdc) Discharge Power Supply Rectifier Efficiency (%) Discharge Power Supply Rectifier Efficiency at the Cold- plate Temperature (%) Discharge Power Supply Rectifier Mass (kg) Discharge Power Supply Transformer #1 Efficiency (%) Discharge Power Supply Transformer #1 Efficiency at the Coldplate Temperature (%) Discharge Power Supply Transformer #2 Efficiency (%) Discharge Power Supply Transformer #2 Efficiency at the Coldplate Temperature (%) Discharge Power Supply Transformer #1 Mass (kg) Discharge Power Supply Transformer #2 Mass (kg) Power Processing Unit Input Filter Efficiency (%) Power Processing Unit Input Filter Efficiency at the Cold- plate Temperature (%) Power Processing Unit Input Filter Mass (kg) Neutralizer Power Supply Conductor and Connector Mass (kg) Neutralizer Power Supply Filter Efficiency (%) Neutralizer Power Supply Filter Efficiency at the Coldplate Temperature (%) Neutralizer Power Supply Filter Mass (kg) Intermediate Neutralizer Supply Output Voltage (Vdc) 37 NOP NOV NRE NRET NRM NTIE NTIET NT2E NT2ET NT1M NI2M PPAM PPBE PPE PPEM PPIP PPIV PPM PPMR PPOP Neutralizer Supply Neutralizer Supply Neutralizer Power Neutralizer Power plate Temperature Neutralizer Power Neutralizer Power Table 14 (cont) Ion Thruster PPU Option t/2 Model (with Beam Power Supply Transformer) Variable Def'mitions Output Power Level (kWe) Output Voltage (Vdc) Supply Rectifier Efficiency (%) Supply Rectifier Efficiency at the Cold- (%) Supply Rectifier Mass (kg) Supply Transformer #1 Efficiency (%) Neutralizer Power Supply Transformer #1 Efficiency at the Coldplate Temperature (%) Neutralizer Power Supply Transformer #2 Efficiency (%) Neutralizer Power Supply Transformer #2 Efficiency at the Coldplate Temperature (%) Neutralizer Power Supply Transformer #1 Mass (kg) Neutralizer Power Supply Transformer #2 Mass (kg) Power Processing Unit Available Modules Power Processing Unit Beam Supply Efficiency Measure (%) Power Processing Unit Efficiency (%) Power Processing Unit Electronics Mass (kg) Power Processing Unit Input Power Level (kWe) Power Processing Unit Input Voltage Level (Vrms) Power Processing Unit Mass w/o Radiator (kg) Power Processing Unit Mass with Radiator (kg) Power Processing Unit Output Power Level (kWe) 38 PPRM PPSE PPSM PPSMR RA RAM RF RST SMCH SMCL SMCPEM SMCV SMCW Table 14 (cant) Ion Thruster PPU Option #2 Model (with Beam Power Supply Transformer) Variable Def'mitions Power Processing Unit Required Modules Power Processing Unit Stage Efficiency (%) Power Processing Unit Specific Mass w/o Radiator (kg/kWe) Power Processing Unit Specific Mass with Radiator (kg/kWe) Radiator Area (m 2) Radiator Mass (kg) Ripple Factor (%) Radiator Sink Temperature (K) Single Single Single Single Single Module Component Height (m) Module Component Length (m) Module Coldplate Based Enclosure Mass (kg) Module Component Volume (m 3) Module Component Width (m) . _x r . 39 3.3 HPD Power Processing Unit The MPD power processing unit (PPU) topology differs considerably from the ion PPU configurations in that it has one main power supply, not four separate supplies. Because the MPD thruster operates at a relatively low voltage, 300 Vdc, the MPD PPU has an integral transformer. This allows the user to specify a wide range of PPU input voltages and results in greater isolation between the PMAD system and the MPD thruster. The features of this design are dis- cussed in detail in the following paragraphs. A block diagram of the MPD PPU design is shown in Figure 9. Its single power supply has four stages, an input filter, a step down transformer, a switching rectifier, and an output filter. The input filter limits the EMI introduced into the PMAD system by the thruster and rectifier, while the output filter reduces the ripple content in the power feed to the MPD thruster. The trans- former steps down the transmission line voltage, which is normally well above 1000 Vrms, to a level suitable for the engine. The MPD engine input voltage is high enough that a single transformer should be adequate in most cases. However, if a homopolar induction alternator operating at frequencies above 2 kHz is used in conjunction with a transmission line voltage that exceeds 7000 Vrms, it may be necessary to use two series connected step down transformers. This case is considered unusual, but a MPD PPU model addressing these condi- tions can be quickly generated if analysis indicates it is a viable alterna- tive. The reason two series connected transformers would be required is the voltage ratio at this frequency is too large for a single transformer. The difference in the number of primary and secondary turns would be so high that the magnetic coupling between turns would be very poor and a phenomenon known as ringing might occur. Ringing is caused when the leakage inductance and turn-to-turn capacitance transfer energy back and forth and generate circulat- ing currents. These circulating currents increase the 12R losses. It is pri- marily a function of the turn¢ ratio and frequency. Poor turn-to-turn coup- ling causes high flux leakage which leads to poor transformer efficiency. Two series connected transformers that sequentially step down the voltage are bet- ter. The turns ratio for each is cut in half; therefore, the coupling between the primary and secondary coils is improved and the likelihood of ringing is greatly reduced. The end result is a more efficient voltage transformation. The remaining stage in the MPD PPU is a switching rectifier. It converts the ac input power into dc for the engine, and uses pulse-width-modulation (PWM) switching to regulate the PPU output voltage. Voltage control is necessary to control engine startup and operation. Control and monitoring hardware, iden- tified in the figure as the main engine controller, and an enclosure assumed to be largely constructed from carbon-carbon complete the model. The enclo- sure mounting plate was assumed to be firmly bonded to the assembly coldplate to enhance heat transfer. This improves component thermal management, but makes it more difficult to replace. PMAD maintenance was considered imprac- tical on a nuclear electric propulsion vehicle once a mission has begun. Application Notes: The MPD PPU design includes a transformer; consequently, the model can accept a wide range of input voltages. The MPD input voltage, approximately 300 Vdc, is much too low for practical power transmission from the alternator to the thruster. The mass of the transmission lines would be 40 >- r] J [13 r] D CL n, tJ p- D n, i p- EL Z >- 0 Z Ld D C_ LJ rY L Eli L_ W mmw_mT_m_m I I F--] L,_mmmm _4 _ nm_m_m t'v W _z bJ_3 ZI-- 41 prohibitive. However, a transformer allows the user to select the PPU input voltage that optimizes PMAD system mass for transmission line lengths ranging from 25 to 300 meters. The transformer in the PPU provides isolation between the PMAD system and the thrusters. It reduces the electromagnetic interference (EMI) generated by the thrusters and PWM switching. System grounding is also improved, because sepa- rate grounds can be established for the PMAD system and the engine. Conse- quently, ground currents generated by the thruster and PWM switching elements will not interfere with the operation of the rest of the PMAD system. Model Specifics: The logic employed during the development of the MPD PPU model is depicted by the flow chart shown in Figure 10. The outputs in the right hand column represent a best estimate of the users needs and more param- eters are available. These outputs can be accessed by modifying the print routine so that it prints additional data contained in the Fortran common block. The basic model operations are shown in the middle column, and the inputs are listed in the boxes on the left. Default values are provided for each of these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. The model is designed to cover a specific range of input parameters. Using input parameters outside of these ranges may result in inaccurate mass esti- mates and it is not recommended. Table 15 lists the input ranges and values that were determined to yield the best results for the primary input parame- ters. In certain instances, operating information will be obtained from other modules. The notes associated with some of the input parameters identify the modules that are the sources of this information. The listed component efficiencies are relatively fixed and they should only be changed if the user is quite familiar with the model operation and power con- ditioning component designs in general. Although component efficiencies gen- erally decline with temperature, it is not necessary to manually adjust these values. The models utilize algorithms to automatically adjust the efficiency values for the selected coldplate temperature. The component algorithms then use these temperature adjusted efficiencies to estimate mass. The only reason to manually change these values would be to conduct mass-efficiency tradeoffs. Component efficiency can be increased if larger internal conductors and power elements are utilized. This reduces radiator and power source mass, but it increases the mass of the component itself. The default values utilized by the model were selected to yield mass and efficiency estimates consistent with the proposed applications and the specified time period. These component efficiency values are referred to as secondary input parameters, and accept- able ranges and default values are listed for them in Table 16. The variables and constants utilized in the MPD PPU model are listed in Table 17 in alphabetical order. A complete listing of the Fortran source code is presented in Appendix D. This subroutine is located on the accompanying com- puter disk under the file name "MPDPPU.FOR". 42 MPD THRUSTER PPU FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS PPU INPUT POWER LEVEL, INPUT VOLTAGE, PPU OUTPUT VOLTAGE, AVAILABLE MODULES, REQUIRED MODULES, FREOUENCY, RIPPLE FACTOR, COLDPLATE TEMPERATURE, COLDPLATE TO RADIATOR DELTA TEMPERATURE, RADIATOR SINK TEMPERATURE SET DEFAULT VALUES: INPUT FILTER EFFICIENCY - 0.995 TRANSFORMER EFFICIENCY ,, 0.g9 RECTIFIER EFFICIENCY = 0.98 OUTPUT FILTER EFFICIENCY = 0,992 I_V O DATE4/3/|2 CORRECT POWER SUPPLY STAGE EFFICIEHCIES FOR COLDPLATE TEMPERATURE, CALCULATE PPU CONTROL & MONITORING POWER REQUIREMENTS 1 CALCULATE PPU EFFICIENCY 1 CALCULATE PPU OUTPUT POWER 1 CALCULATE COMPONENT MASSES: PPU INPUT AC FILTER, TRANSFORMER, RECTIFIER, OUTPUT FILTER 1 CALCULATE PRO CONDUCTOR MASSES, CALCULATE PPU CONTROl & MONITORING MASS, SUM PPU ELECTRONICS MASSES 1 CALCULATE PPU VOLUMES &: DIMENSIONS (SINGLE MODULE & COMPLETE ASSEMBLY) CALCULATE ENCLOSURE MASSES {SINGLE MODULE & COMPLETE ASSEMBLY) 1 CALCULATE PPU RADIATOR AREA AND MASS 1 CALCULATE PPU MASSES AND SPECIFIC MASSES WITH AND WITHOUT THE RADIATOR MASS i Figure 10 43 _1 PPU EFFICIENCYI _1 ASSEMBLY VOLUME. - I ASSEMBLY DIMENSIONS RADIATOR AREA i PPU MASS WITHOUT RADIATOR PPU MASS WITH RADIATOR Ilk PPU SPECIFIC MASS WITHOUT RADIATOR PPU PECIFIC MASS WI H RADIATOR Power Processing Unit l_'ima_ Input Parameter PPU Input Power Level PPU Input Voltage Level PPU Output Voltage Level Ripple Factor Percentage PPU Available Modules PPU Required Modules Alternator Operating Frequency (See Note l) Coldplate Temperature Coldplate to Radiator Temperature Delta Radiator Sink Temperature Table 15 MPD Thruster PPU Model Primary Input Parameter Ranges Recommended Input Range 100 kWe to 10 MWe 200 to 1O,000 Vrms 120 to 10,000 Vdc 0.5to 8% Equal to or Greater than Required Modules No Limit 60 Hz to 5 kHz 0.8 kHz is Recommended 60 to 2000 C 100" C Suggested as Initial Value 0to20 ° C 16.67" C is Recommended See Note 2 247.67 K Calculated for LEO ° . The alternator operating frequency (AOF) will normally be obtained from the power conversion module (CR-191134 or CR-191135). If the PMAD module is run separately, AOF must be input. The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 44 Power Processing Unit Secondary Input l_rameter Input AC Filter Efficiency Transformer Efficiency Rectifier Efficiency Output DC Filter Efficiency Table 16 MPD Thruster PPU Model Secondary Input Parameter Ranges Recommended Inuut Range Range: 99.0 to 99.9 % 99.5% is Recommended Range: 97.5 to 99.5% 99% is Recommended Normal Range: 97.0 to 99.0% 98.0% is Recommended Range: 99.0 to 99.9% 99.5 % is Recommended 45 AOF CACH CACL CACPEM CACV CACW CCM CMM CMP CPT CRTD WE IFET IFM OFE OFET OFM PPAM PPE PPEM PPIP PPIV Table 17 MTD Thruster PPU Model Variable Dermitions Alternator Operating Frequency (kHz) Complete Assembly Component Height (m) Complete Assembly Component Length (m) Complete Assembly Coldplate Based Enclosure Mass (kg) Complete Assembly Component Volume (m 3) Complete Assembly Component Width (m) Conductor and Connector Mass (kg) Control and Monitoring Mass (kg) Control and Monitoring Power Demand (Watts) Coldplate Temperature (°C) Coldplate to Radiator Temperature Delta (°C) Input Filter Efficiency (%) Input Filter Efficiency at the Coldplate Temperature (%) Input Filter Mass (kg) Output Filter Efficiency (%) Output Filter Efficiency at the Coldplate Temperature (%) Output Filter Mass (kg) Power Processing Unit Available Modules Power Processing Unit Efficiency (%) Power Processing Unit Electronics Mass (kg) Power Processing Unit Input Power Level (kWe) Power Processing Unit Input Voltage Level (Vrms) 46 i PPM PPMR PPOP PPOV PPRM PPSE PPSM PPSMR RA RAIVI RE PET RST SMelt SMCL SMCPEM SMCV SMCW TE TET TM Power Processing Power Processing Power Processing Power Processing Power Processing Power Processing Power Processing Power Processing Radiator Area (m 2) Radiator Mass 0cg) Rectifier Efficiency (%) Table 17 (cont) MPD Thruster PPU Model Variable Definitions Unit Mass w/o Radiator (kg) Unit Mass with Radiator (kg) Unit Output Power Level (kWe) Unit Output Voltage Level (Vrms) Unit Required Modules Unit Stage Efficiency (%) Unit Specific Mass w/o Radiator (kg/kWe) Unit Specific Mass with Radiator (kg/kWe) Rectifier Efficiency at the Coldplate Temperature (%) Ripple Factor (%) Rectifier Mass (kg) Radiator Sink Temperature (K) Single Module Component Height (m) Single Module Component Length (m) Single Module Coldplate Based Enclosure Mass (kg) Single Module Component Volume (m 3) Single Module Component Width (m) Transformer Efficiency (%) Transformer Efficiency at the Coldplate Temperature (%) Transformer Mass (kg) 47 3.4 AC Switchgear Unit The ac switchgear unit employs remote bus isolators (RBIs) to turn power feeds on and off and provide circuit protection. RBIs are high power switching and circuit protection devices that are equipped with sensors to provide voltage and current information. Because RBIs are the primary means of circuit pro- tection, they contain rugged switch modules that are specifically designed to interrupt high fault currents. Fault interruption is normally performed dur- ing the zero current crossing point. During each half cycle of an ac waveform the current becomes zero. Opening the switch at this point greatly reduces electromagnetic and thermal stress, since it is a function of the current level. This is the main advantage of the ac RBI over its dc counterpart and it allows them to be utilized at much higher power levels. An ac RBI switch module can employ one of two designs, a hybrid arrangement consisting of a fast acting mechanical relay paralieled with a back-to-back pair of semiconductor switches, or just a back-to-back pair of semiconductor switches. A solitary mechanical relay is not fast enough to open during the zero current crossing; consequently, this configuration is not practical. The hybrid arrangement has certain advantages because the relay and semiconductor switch can function together to improve the operating characteristics of the RBI switch. The relay carries the bulk of the current during normal operation because its conduction losses are low. This results in a high efficiency RBI. The main need for the semiconductor switch is during opening and closing peri- ods. It closes immediately before relay closing to quell relay chatter tran- sients, and opens after the relay to suppress opening transients. The design that only uses a semiconductor switch exhibits very good opening and closing characteristics, but the conduction resistance of a semiconductor is higher than a relay contact. This would cause the RBI losses to be significantly higher and necessitate larger heat sinks and associated thermal management hardware. The ac RBI algorithm utilized by the switchgear unit model is based on a hy- brid switch configuration. This design was considered to provide the best combination of mass, efficiency, and switching characteristics. Near term RBIs would probably use a vacuum switch in parallel with back-to-back silicon controlled rectifiers (SCRs) or MOS controlled thyristors (MCTs). However, because the specified time frame is 2005 to 2020, a more advanced device, the optical switch was assumed to be available. Optical switches consist of a silicon wafer that is turned on and off by means of a laser. They are cur- rently being developed for Space Defense Initiative applications. Results to date indicate they will be very lightweight, but capable of interrupting tens of megawatts. A block diagram of the switchgear unit is shown in Figure 11. The number of thrusters determines the number of output RBIs, while the number of input RBIs is equivalent to the number of alternator power feeds. A cross tie RBI, that is normally open, is available to conduct power from one switchgear unit to the next if alternator, thruster, or PPU failures occur. A central bus dis- tributes the input RBI power to the output RBIs. This bus is sized to handle the maximum current level and withstand the worst case electromagnetic stress- es resulting from a direct short. The switchgear model is completed by incor- 48 Alterntor //i Power Input Alterntor #2 Power Input Input RBI #1 Input RBI //2 I Control and Monitoring I i ..................... i ................. i i...................... | 1 m .S 0 i ............. i ti Cross Tie RBI I , I .......... Output RBI //1 Output RBI #2 Output RBI #3 Output RBI #4 PPU //I Power Output PPU #2 Power Output PPU #,3 Power Output PPU //4 Power Output Power Link with Adjocent Switchgeor Unit AC Switchgeor Unit Figure Block 11 Diogrom ACSWGR 49 4-27-92 porating algorithms for the control and monitoring hardware, and an enclosure assumed to be largely constructed from carbon-carbon. The enclosure mounting plate was assumed to be bonded to the assembly coldplate to facilitate heat transfer. This makes it difficult to remove the switchgear unit; however, it was assumed that PMAD maintenance would not be performed during the mission. Application Notes: The switchgear unit model is designed to be used over the full power and voltage range in any application requiring power switching and fault protection. In the case of the currently envisioned PMAD architecture, it would simulate a switchgear unit that is located near the thruster PPUs. This switchgear unit would be utilized to selectively power individual PPUs, interrupt thruster or PPU based faults, and isolate these components if they are defective. Model Specifics: The flow chart in Figure 12 shows the logic employed in the ac switchgear unit model. The outputs in the right hand column represent a best estimate of the users needs and more parameters are available. These values can be accessed by modifying the print routine so that it prints other data elements contained in the Fortran common block. The basic model opera- tions are shown in the middle column, and the inputs are listed in the boxes on the left. Default values are provided for each of these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. The model is designed to cover a wide range of input parameters; however, us- ing parameters outside of these ranges may result in inaccurate mass estimates and it is not recommended. Table 18 lists the acceptable input ranges and certain recommended values. Some input parameters will normally be obtained from other modules. The notes associated with these parameters identify the modules that provide these inputs. The default RBI efficiency contained in Table 18 is relatively fixed and it should only be changed if the user is quite familiar with the model operation and power conditioning component designs in general. Although component effi- ciencies typically decline with temperature, it is not necessary to manually adjust this value. An algorithm automatically adjusts this efficiency based on the selected coldplate temperature. The RBI algorithms use this tempera- ture adjusted efficiency to estimate mass. The only reason to manually change this value would be to conduct a mass-efficiency tradeoff. RBI efficiency can be increased by using larger conductors and switch modules. This would reduce the mass of the switchgear radiator and the power source feeding it, but the mass of the RBI itself would increase. The default value produces mass and efficiency estimates consistent with the proposed application and the speci- fied time period. The variables and constants utilized in the ac switchgear model are listed in Table 19 in alphabetical order. A complete listing of the Fortran source code is presented in Appendix E. This subroutine is located on the accompanying computer disk under the file name "ACSWGR.FOR". 50 AC SWITCHGEAR (SWGR) FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS NUMBER OF INPUT RBIs, NUMBER OF OUTPUT RBIs, OUPUT RBI OUTPUT POWER LEVEL, OUTPUT RBI OUTPUT VOLTAGE LEVEL, RBI EFFICIENCY, SWlTCHGEAR AVAILABLE MODULES, SWITCHGEAR REQUIRED MODULES, COLDPLATE TEMPERATURE, COLDPLATE TO RADIATOR DELTA TEMPERATURE, RADIATOR SINK TEMPERATURE p I CORRECT RBI EFFICIENCYFOR COLDPLATE TEMPERATURE CALCULATE SWlTCHGEAR UNIT BUSI POWER, CALCULATE CONTROL & I MONITORING POWER DEMAND I p I CALCULATE SWITCHGER UNIT IEFFICIENCY CALCULATE INPUT RBI OUTPUT & INPUT POWER LEVELS, CALCULATE CROSS TIE RBI OUTPUT & INPUT POWER LEVELS ;ISWlTCHGEAR UNIT EFFICIENCY CALCULATE SWITCHGEAR UNIT VOLTAGES CALCULATE RBI MASSES: OUTPUT RBI, INPUT RBI, CROSS TIE RBI CALCULATE SWITCHGEAR UNIT CONDUCTOR MASSES CALCULATE SWITCHGEAR UNIT CONTROL & MONITORING MASS | I ..= J _TAS<2OK i I R_V 0 DAT{ 4/I/12 I SUM SWITCHGEAR UNIT ELECTRONICS MASSES 1 CALCULATE SWITCHCEAR UNIT VOLUMES & DIMENSIONS (SINGLE MODULE & COMPLETE ASSEMBLY) CALCULATE ENCLOSURE MASSES (SINGLE MODULE & COMPLETE ASSEMBLY) 1 CALCULATE SWITCHGEAR UNIT RADIATOR AREA AND MASS l CALCULATE SWITCHGEAR UNIT MASSES & SPECIFIC MASSES WITH &: WITHOUT THE RADIATOR MASS Figure 12 51 II ASSEMBLY VOLUME,ASSEMBLY DIMENSIONS RADIATOR AREA SWlTCHGEAR MASS WITHOUT RADIATOR SWITCHGEAR MASS WITH RADIATOR SWITCHGEAR SPECIFIC MASS WITHOUT RADIATOR SWITCHGEAR SPECIFIC MASS WITH RADIATOR Table 18 AC Switchgear Unit Model Input Parameter Ranges AC RBI Switchgear Unit Input Parameter Number of Input RBI Units (See Note 1) Number of Output RBI Units (See Note 2) RBI Unit Output Power Level RBI Unit Output Voltage Level RBI Efficiency Available Switchgear Modules Required Switchgear Modules Col@late Temperature Col@late to Radiator Temperature Delta Radiator Sink Temperature Recommended No Limit No Limit 10 kWe to 10 MWe 100 to 10,000 Vrms Range: 99.8 to 99.9% 99.85 % is Recommended Equal to or Greater than Required Modules No Limit 60 to 2000 C 100" C Suggested as Initial Value 0 to 20" C 16.67 ° C is Recommended See Note 3 247.67 K Calculated for LEO . . . The number of input RBIs equals the number of alternators and it will normally be obtained from the master PMAD module. However, if this Switchgear model is run separately the number of input RBIs must be provided by the user. The number of output RBIs equals the number of PPUs and it will normally be obtained from the master PMAD module. However, if this Switchgear model is run separately the number of output RBIs must be provided by the user. The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 52 CACH CACL CACPEM CACV CACW CCM CMM CMP CPT CRTD IRBM IRBIP IRBIV IRBOP IRBOV NIRB NORB Table 19 AC Switchgear Model Variable Def'mitions Complete Assembly Component Height (m) Complete Assembly Component Length (m) Complete Assembly Coldplate Based Enclosure Mass (kg) Complete Assembly Component Volume (m 3) Complete Assembly Component Width (m) Conductor and Connector Mass (kg) Control and Monitoring Mass (kg) Control and Monitoring Power (Watts) Coldplate Temperature (*C) Coldplate to Radiator Temperature Delta (°C) Mass of One Input RBI (kg) Input RBI Input Power Level (kWe) It is assumed that all input RBIs will have the same rating; consequently, a single power level is calculated. Input RBI Input Voltage Level (Vrms) It is assumed that all input RBIs will operate at the same voltage; conse- quently, a single voltage level is calculated. Input RBI Output Power Level (kWe) It is assumed that all input RBIs will have the same rating; consequently, a single power level is calculated. Input RBI Output Voltage Level (Vrms) It is assumed that all input RBIs will operate at the same voltage; conse- quently, a single voltage level is calculated. Number of Input RBIs Number of Output RBIs 53 ORBM ORBOP ORBOV RA RBE RBET RBSE RST SMCH SMCL SMCPEM SMCV SMCW SWAIVI SWBP SWBV SWE SWEM Table 19 (con0 AC Switchgear Model Variable Definitions Mass of One Output RBI (kg) Output RBI Output Power Level (kWe) It is assumed that all output RBIs will have the same rating; consequently, a single power level is specified. Output RBI Output Voltage Level (Vrms) It is assumed that all output RBIs will operate at the same voltage; conse- quently, a single voltage level is specified. Radiator Area (m 2) Radiator Mass (kg) RBI Unit Efficiency at 100" C (%) RBI Unit Efficiency at Coldplate Temperature (%) Combined RBI and Bus Section Efficiency (%) Radiator Sink Temperature (K) Single Module Component Height (m) Single Module Component Length (m) Single Module Coldplate Based Enclosure Mass (kg) Single Module Component Volume (m 3) Single Module Component Width (m) Switchgear Available Modules Switchgear Bus Power Level (kWe) Switchgear Bus Voltage Level (Vrms) Switchgear Unit Efficiency (%) Switchgear Unit Electronics Mass (kg) 54 SWM SWMR SWRM SWSM SWSMR XRBM XRBIP XRBIV XRBOP XRBOV Table 19 (cont) AC Switchgear Model Variable Definitions Switchgear Unit Mass w/o Radiator (kg) Switchgear Unit Mass with Radiator (kg) Switchgear Re.xluirod Modules Switchgear Unit Specific Mass w/o Radiator (kg/kWe) L Switchgear Unit Specific Mass with Radiator (kg/kWe) Mass of Cross Tie RBI (kg) Cross Tie RBI Input Power Level (kWe) Cross Tie RBI Input Voltage Level (Vrms) Cross Tie RBI Output Power Level (kWe) Cross Tie RBI Output Voltage Level (Vrms) 55 3.5 Phase Lock Transformer The phase lock transformer consists of a transformer module that is sized to transfer power back and forth between counter rotating alternators. A 3-phase transformer with a I to I voltage ratio is used. Its purpose is to ensure that the alternators share the common load equally and that a change in the rotational speed of one alternator is canceled by an equal change in the rota- tional speed of its alternator mate. This ensures that the NEP vehicle will not experience a torque moment due to unequal or unbalanced changes in alter- nator speed; the moments imparted by the two alternators will be fully can- celed. If the alternator acceleration rates are modest and carefully con- trolled, a relatively small power transfer should be adequate. Consequently the phase lock transformer power rating is relatively low and it is fairly small in size. A block diagram of the phase lock transformer is shown in Figure 13. It is a simple component, consisting only of a transformer and its associated monitor- ing hardware. Because a transformer is a passive component, there are not any control functions. Monitoring is required, however, to sense alternator oper- ating imbalances and to ensure the transformer is not overloaded or overheat- ing due to a hardware failure. In addition to the transformer stage mass algorithm, the phase lock transformer model contains algorithms that calculate the monitoring element and enclosure features. The enclosure is assumed to be largely constructed from carbon-carbon, with a mounting plate that is bonded to the assembly coldplate to facilitate heat transfer. This design makes it difficult to remove the phase lock transformer module, but it was assumed that PMAD maintenance would not be performed during the mission. If the phase lock transformer fails, it may be necessary to shut down the alternators connected to it. It would depend on the turbine speed control precision and the operat- ing situation at that point in time. If it is an emergency situation, it may be crucial to continue operating. Application Notes: The phase lock transformer model is relatively simple and it is designed to be used over the full transfer power, frequency, and voltage range in any case utilizing counter rotating alternators. If a power channel is fed by a single alternator, the phase lock transformer model is not used. Model Specifics: The logic employed during the development of the phase lock transformer model is depicted in the flow chart shown in Figure 14. The out- puts in the right hand column represent a best estimate of the users needs and additional parameters are available. These outputs can be accessed by modify- ing the print routine and instructing it to print other items in the Fortran common block. The basic model operations are shown in the middle column, and the inputs are listed in the boxes on the left. Default values are provided for each of these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. The model is designed to cover a wide range of input parameters; however, us- ing parameters outside of these ranges may result in inaccurate mass estimates and it is not recommended. Table 20 lists the acceptable input ranges and certain recommended values. Input parameters that are normally obtained from other modules are identified by the accompanying notes. 56 XN -J t 04 O O c- © <_ O 4--' O (-- © O_ O © O EL (3_ O O O O_ _# au!q UOISSlUJSUDJ.L _n (-- O (-- O O c-- O O E e.) Or) >, (/) ..Q UO i O E O O3 C- O F-- L= u!q uo!ss!uusuoJl O 04 (o 133 -_ rr qE cn_ c" O b- E_ c- o rn ._ rr (./') ._ c- O b-- E E) E) o r h L) © 03 q) E O G0 c- (3 F- x/ O © J 03 (3 c- O_ rO (D Wm I1 57 PHASE LOCK TRANSFORMER UNIT (PLT) FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS ALTERNATOR POWER OUTPUT, ALTERNATOR VOLTAGE OUTPUT, PLT POWER PERCENTAGE, PLT AVAILABLE MODULES, PLT REOUIRED MODULES, TRANSFORMER STAGE EFFICIENCY, COLDPLATE TEMPERATURE, COLDPLATE TO RADIATOR DELTA T, RADIATOR SINK TEMPERATURE CALCULATE PLT POWER OUTPUT, CALCULATE CONTROL & MONITORING POWER DEMAND, CORRECT PLT STAGE EFFICIENCY FOR COLDPLATE TEMPERATURE, CALCULATE PLT UNIT EFFICIENCY CALCULATE PLT STAGE MASS, CONDUCTOR MASS. CONTROL & MONITORING MASS & TOTAL ELECTRONICS MASS 1 CALCULATE PLT UNIT VOLUMES AND DIMENSIONS (SINGLE _ODULE AND COMPLETE ASSEMBLY CALCULATE ENCLOSURE MASSES (SINGLE MODULE AND COMPLETE ASSEMBLY) l CALCULATE PLT UNIT RADIATOR AREA & MASS CALCULATE PLT UNIT MASSES & SPECIFIC MASSES WITH AND WITHOUT THE RADIATOR MASS PLT UNIT EFFICIENCY ASSEMBLY VOLUME,IP ASSEMBLY DIMENSIONS -I RADIATOR AREA PLT MASS WITHOUT RADIATOR PLT MASS WITH RADIATOR ID, PLT SPECIFIC MASS WITHOUT RADIATOR PLT SPECIFIC MASS WI H RADIATOR TA_(20H RE;V0 DATE 4/2/112 Figure 14 58 Table 20 Phase Lock Transformer Unit Model Input Parameter Ranges Transformer Unit Intmt Parameter Alternator Output Power Level Alternator Output Voltage Level Phase Lock Transformer Power Percentage (%) Available Phase-Lock Transformer Modules Required Phase-Lock Transformer Modules Transformer Frequency Transformer Efftciency Coldplate Temperature Coldplate to Radiator Temperature Delta Radiator Sink Temperature Recommended Input Range 100 kWe to 10 MWe 200 to 10,000 Vrms 0.5 to 10% 2% is Recommended Equal to or Greater than Required Modules No Limit 60 Hz to 5 kHz Range: 97.5 to 99.5 % 99% is Recommended 60 to 200" C 100" C Suggested as Initial Value 0 to 20" C 16.67" C is Recommended See Note 1 247.67 K Calculated for LEO . The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 59 The default transformer efficiency listed in Table 20 is relatively fixed and it should only be changed if the user is quite familiar with the model opera- tion and power conditioning component designs in general. As the transformer operating temperature rises, transformer core losses decline but winding los- ses increase. The overall change in efficiency occurring with temperature is automatically calculated by an algorithm and it is not necessary to manually adjust this value. The transformer algorithms use this temperature adjusted efficiency to estimate mass. The only reason one would manually change the transformer efficiency would be to conduct a mass-efficiency tradeoff. Trans- former efficiency can be increased by using a larger core and winding conduc- tors. This would reduce the mass of the phase lock transformer radiator, but the mass of the transformer itself would increase. The phase lock transformer model will reflect these changes in mass if one changes the input efficiency. The default transformer efficiency was selected to produce mass and efficiency estimates consistent with the proposed application and the specified time period. The variables and constants utilized in the phase lock transformer model are listed in Table 21 in alphabetical order. A complete listing of the Fortran source code is presented in Appendix F. This subroutine is located on the accompanying computer disk under the file name "TRNFMR.FOR". 60 AOF APO AVO CACH CACL CACPEM CACV CACW CCM CMM CMP CPT CRTD PTAM PTE FrEM PTM FrMR PTPO PTPP Table 21 Phase Lock Transformer Unit Model Variable Dermitions Alternator Operating Frequency (kHz) Alternator Power Output (kWe) Alternator Voltage Output (Vrms) Complete Assembly Component Height (m) Complete Assembly Component Length (m) Complete Assembly Col@late Based Enclosure Mass (kg) Complete Assembly Component Volume (m 3) Complete Assembly Component Width (m) Conductor and Connector Mass (kg) Control and Monitoring Mass (kg) Control and Monitoring Power (Watts) Col@late Temperature (*C) Col@late to Radiator Temperature Delta (*C) Phase Lock Transformer Available Modules Phase Lock Transformer Efficiency (%) Phase Lock Transformer Electronics Mass (kg) Phase Lock Transformer Mass w/o Radiator (kg) Phase Lock Transformer Mass with Radiator (kg) Phase Lock Transformer Power Output (kWe) Phase Lock Transformer Power Percentage (%) 61 PTRM PTSM PTSMR RA RAM RST SMCH SMCL SMCPEM SMCV SMCW TSE TSET TSM Table 21 (cont) PhaseLock Transformer Unit Model Variable Def'mitions PhaseLock TransformerRequiredModules PhaseLock Transformer Specific Mass w/o Radiator (kg/kWe) Phase Lock Transformer Specific Mass with Radiator (kg/kWe) Radiator Area (m 2) Radiator Mass (kg) Radiator Sink Temperature (K) Single Module Component Height (m) Single Module Component Length (m) Single Module Coldplate Based Enclosure Mass (kg) Single Module Component Volume (m 3) Single Module Component Width (m) Transformer Stage Efficiency at 100 ° C (%) Transformer Stage Efficiency at Coldplate Temperature (%) Transformer Stage Mass (kg) 62 3.6 Speed Regulator The speed regulator controls the alternator and turbine speed by adjusting the connected load. The load is increased to slow the alternator and reduced to increase speed. The objective is to maintain the total connected load, thrus- ters and parasitic load, at a fairly constant level. Because the speed regu- lator may be forced to shunt all alternator power at times, it is necessary to size it for this case. For example, prior to engine startup it may be neces- sary for the parasitic load to dissipate all alternator power to allow the power source to stabilize. Power is then gradually shifted from the parasitic load to the engines as they are brought on line and ramped up. When the en- gines are operating at full power very little power is dissipated in the para- sitic load, only the power required to maintain a safe alternator operating margin. If a major fault or component failure should occur, the speed regu- lator would be required to immediately shunt full power until the alternator is shut down or the fault is cleared. This is necessary because the opening of an input RBI to isolate a fault would completely remove the normally con- nected engine load. A block diagram of the speed regulator is shown in Figure 15. The speed regu- lator contains numerous discreet shunt elements that are individually activat- ed to control the amount of power being dissipated in the parasitic load. The shunt switches are controlled by a frequency comparitor. Since frequency is directly related to speed, it is used to provide an accurate measurement of alternator speed. The measured speed signal and a reference signal are fed into a comparitor that generates a speed error signal. This error signal is utilized by the switch gate control logic to control the number of shunt ele- ments that are activated. The switches are capable of rapid switching speeds, which enables the speed regulator to respond to load changes in milliseconds. Coarse speed regulation is provided by turning on and off individual shunt elements, thereby shunting power in steps. To achieve fine speed regulation, the final shunt element can be pulse width modulated (PWM). This yields sta- ble speed control, and allows the shunted power to be precisely controlled. The speed regulator model is completed by incorporating algorithms for the control and monitoring hardware, and an enclosure assumed to be largely con- structed from carbon-carbon. It was assumed that the enclosure mounting plate would be bonded to the assembly coldplate to facilitate heat transfer. This makes it difficult to remove the speed regulator, and probably necessitates an alternator shut down if the speed regulator fails. However, the speed regula- tor can be designed for high reliability by incorporating additional shunt elements into the design and specifying redundant control elements. Several switch options are available for the speed regulator shunt elements. Near term shunt elements would probably use back-to-back metal-oxide-semicon- ductor field-effect-transistors (MOSFETs) for lower voltage applications, and back-to-back silicon controlled rectifiers (SCRs) or MOS controlled thyristors (MCTs) for high power, high voltage applications. However, because the speci- fied time frame is 2005 to 2020, there should be time to develop more advanced devices. Silicon Carbide (SIC) appears particularly promising in this appli- cation for two reasons. SiC exhibits high resistance to radiation and it can operate at high temperatures. The speed regulator must be located immediately 63 Alternotor to Switchgeor Unit Trensmission Line Control and Monitoring(Includes Frequency Comperitor) I i ! ........................F............................!...................................... i i [[ [ [ j ! ! i i \ . . ...... . _ .................................. r ..................| i i EMI i 1[ i [ I I i \ !...............\ Filter ! i | i ! !| [ ! ! i I t[ i 1\ , I i t i ,\\ i..... Number of Shunt Switches Determined by Speed Regulotion Requirements ond Power Level To Porositic Lood Rodiotor Resistive Elements J Speed Regulotor Figure Block 15 Diogrom 5PDREG 4-27-92 64 after the alternator to function most effectively. Since this is also near the reactor, the radiation levels will be high. In addition, the thermal environment will make high temperature switches particularly desirable. Fi- nally, because the speed regulator is not in the main power conduction path, see Figure 15, its efficiency is less of a concern. It is expected that SiC switches will not be as efficient as present day silicon devices. Application Notes: The speed regulator model is designed to be used over the full power and voltage range in any application requiring alternator speed regulation. In the currently envisioned NEP PMAD architecture, it would be located immediately after the alternator and shunt power to the parasitic load to regulate alternator speed. If a permanent magnet based alternator is spec- ified, the speed regulator would also regulate the alternator voltage because it is directly proportional to speed. Model Specifics: The flow chart in Figure 16 shows the logic employed during the development of the speed regulator model. The outputs in the right hand column represent a best estimate of the users needs and additional parameters are available. These values can be accessed by modifying the print routine so that it prints additional data elements contained in the Fortran common block. The basic model operations are shown in the middle column, and the inputs are listed in the boxes on the left. Default values are provided for each of these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. The model is designed to cover a wide range of input parameters; however, us- ing parameters outside of these ranges may result in inaccurate mass estimates and it is discouraged. Table 22 lists the acceptable input ranges and certain recommended values. The notes associated with some parameters identify mod- ules that will normally provide the values for these input parameters. The default bus, filter, and shunt switch efficiencies listed in Table 22 are relatively fixed and they should only be changed if the user is quite familiar with the model operation and power conditioning component designs in general. Although component efficiencies typically decline with temperature, it is not necessary to manually adjust this value. An algorithm automatically adjusts these efficiencies for different coldplate temperatures. The component mass estimation algorithms then use these temperature adjusted efficiencies. The only reason to manually change these values would be to conduct mass-efficien- cy tradeoffs. Conductor efficiency can be increased by increasing the conduc- tor size, shunt switch efficiency by choosing higher rated switching elements, and filter efficiency by using larger inductors and capacitors. Increasing the speed regulator efficiency would reduce the mass of its radiator, but the mass of the speed regulator itself would increase. The default bus, filter, and shunt switch efficiencies were chosen to produce mass and efficiency esti- mates consistent with the proposed application and the specified time period. The variables and constants utilized in the speed regulator model are listed in Table 23 in alphabetical order. A complete listing of the Fortran source code is presented in Appendix F. This subroutine is located on the accompany- ing computer disk under the file name "SPDREG.FOR". 65 ALTERNATOR SPEED REGULATOR (ASR) FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS ALTERNATOR POWER OUTPUT. ALTERNATOR VOLTAGE OUTPUT, REGULATOR AVAILABLE MODULES. REGULATOR REQUIRED MODULES. COLDPLATE TEMPERATURE. COLDPLATE TO RADIATOR DELTA TEMPERATURE. RADIATOR SINK TEMPERATURE SET DEFAULT VALUES: NUMBER OF SHUNT SWITCH ELEMENTS - 40 SHUNT REDUNDANCY FACTOR - 1.2 PULSE WIDTH MODULATION FREQUENCY = 20 BUS CONDUCTOR EFFICIENCY - 0.9965 SHUNT SWITCH EFFICIENCY m 0.994.5 EMI FILTER EFFICIENCY - 0.9993 1 CALCULATE CONTROL & MONITORING POWER DEMAND. CORRECT REGULATOR EFFICIENCIES FOR COLDPLATE TEMPERATURE. CALCULATE FULLY SHUNTED & COMBINED EFFICIENCY FULLY SHUNTED EFFICIENCY CALCULATE REGULATOR POWER OUTPUT ,e.,.OUTPUT VOLTAGE. CALCULATE CONDUCTOR MASS, CONTROL & MONITORING MASS, FILTER. SHUNT SWITCH & TOTAL ELECTRONICS MASS CALCULATE REGULATOR VOLUMES &DtMENSIONS (SINCLE MODULE & COMPLETE ASSEMBLY) CALCULATE ENCLOSURE MASSES (SINGLE MODULE & COMPLETE ASSEMBLY) CALCULATE REGULATOR RADIATOR AREA AND MASS 1 CALCULATE REGULATOR MASSES AND SPECIFIC MASSES WITH AND WITHOUT TNE RADIATOR MASS ASSEMBLY VOLUME, ASSEMBLY DIMENSIONS RADIATOR AREA REGULATOR MASS WITHOUT RADIATOR REGULATOR MASS WITH RADIATOR REGULATOR SPECIFIC MASS WITHOUT RADIATOR REGULATOR SPECIFIC MASS WITH RADIATOR Figure 16 ,,,<,oj ,_vo °"_'/'/'_ 66 Table 22 Alternator Speed Regulator Model Input Parameter Ranges Speed Regulator Input Parameter Recommended Input Range Alternator Output Power Level 100 kWe to 10 MWe Alternator Output Voltage Level 200 to 10,000 Vrms Available Speed Regulator Modules Equal to or Greater than Required Modules Required Speed Regulator Modules No Limit Number of Shunt Switch Elements 20to 100 40 is Suggested Shunt Redundancy Factor 100 to 150% 120% is Recommended Pulse-Width-Modulation Frequency 15 to 40 kHz 20 kHz is Recommended Bus Conductor Efficiency Range: 99.55 to 99.75 % 99.65 % is Recommended Shunt Switch Efficiency Range: 99.25 to 99.65% 99.45% is Recommended EM/Filter Efficiency Range: 99.90 to 99.95% 99.93% is Recommended Col@late Temperature 60 to 200* C 1000 C Suggested as Initial Value Coldplate to Radiator Temperature Delta 0 to 20* C 16.67" C is Recommended Radiator Sink Temperature See Note 1 247.67 K Calculated for LEO ° The radiator sink temperature (RST) will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the RST must be calculated for the environment being studied. The value for LEO is 247.67 K. 67 APO AVO BCE BCET BCM BFSE CACH CACL CACPEM CACV CACW CMM CMP CPT CRTD EFE EFET EFM FSE NSS PWMF Table 23 Alternator SpeedRegulator Model Variable Def'mitions Alternator Power Output (kWe) Alternator Voltage Output (Vrms) Bus Conductor Efficiency at 100" C (%) Bus Conductor Efficiency at Coldplate Temperature (%) Bus Conductor Mass (kg) Combined Bus, Filter, & Shunt Efficiency (%) Complete Assembly Component Height (m) Complete Assembly Component Length (m) Complete Assembly Coldplate Based Enclosure Mass (kg) Complete Assembly Component Volume (m 3) Complete Assembly Component Width (m) Control and Monitoring Mass (kg) Control and Monitoring Power (Watts) Coldplate Temperature (°C) Coldplate to Radiator Temperature Delta (*C) EMI Filter Efficiency at 100 ° C (%) EMI Filter Efficiency at Coldplate Temperature (%) EMI Filter Mass (kg) Fully Shunted Efficiency (%) Number of Shunt Switch Elements Pulse-Width-Modulation Frequency (kHz) 68 RA RAM RST SMCH SMCL SMCPEM SMCV SMCW SPO SRAM SREM SRF SRM SRMR SVO SRRM SRSM SRSMR SSE SSET SSM Table 23 (cont) Alternator Speed Regulator Model Variable Def'mitions Radiator Area (m 2) Radiator Mass (kg) Radiator Sink Temperature (K) Single Module Component Height (m) Single Module Component Length (m) Single Module Coldplate Based Enclosure Mass (kg) Single Module Component Volume (m 3) Single Module Component Width (m) Shunt Power Output (kWe) Speed Regulator Available Modules Speed Regulator Electronics Mass (kg) Shunt Redundancy Factor (%) Speed Regulator Mass w/o Radiator (kg) Speed Regulator Mass with Radiator (kg) Shunt Voltage Output (Vrms) Speed Regulator Required Modules Speed Regulator Specific Mass w/o Radiator (kg/kWe) Speed Regulator Specific Mass with Radiator (kg/kWe) Shunt Switch Efficiency at 100" C (%) Shunt Switch Efficiency at Coldplate Temperature (%) Shunt Switch Mass (kg) 69 3.7 Parasitic Load Radiator The parasitic load radiator (PLR) operates in conjunction with the speed regu- lator to dissipate excess power. Due to its thermal inertia, the reactor can not respond quick enough to changes in load. Consequently, faster responding devices, the speed regulator and PLR, are required to control power delivery to the engines and regulate alternator speed. The PLR should be designed to dissipate all alternator power, since this situation may occur prior to engine startup and if the switchgear unit input RBI opens to isolate a fault. The PLR model is based on a single sided, flat plate radiator. It contains numerous resistive elements that are fabricated from Nichrome V and connected in a delta configuration. Beryllium oxide was used to insulate them from the radiator plate because of its light weight, high temperature capability, and good thermal conductivity. The Nichrome V wire elements operate at a high temperature, 1255 K was used for this point design, and transfer their heat to a carbon-carbon plate that is radiating to space. Carbon-carbon was utilized for the radiator plate because of its light weight, high temperature capabili- ties, and structural strength. A coating would be applied to the radiating surface of the carbon-carbon plate to improve its emissivity. The structural members that support the PLR are also constructed from carbon-carbon. Application Notes: The PLR model is intended to be used in conjunction with the speed regulator model. It is designed to be used over the same power and voltage range as the speed regulator in any application using 3-phase ac pow- er. A 3-phase circuit can be connected in either a delta or wye configura- tion. Delta was selected for this application because the PLR can continue to dissipate power, albeit unevenly, even if one of the phases fails open. This is referred to as an open delta. Model Specifics: The logic employed during the development of the PLR model is shown in the flow chart in Figure 17. The selected outputs, surface area, mass, and specific mass represent a best estimate of the users needs. Other parameters are available. They can be obtained by changing the print routine that accesses the Fortran common block. The basic model functions are shown in the middle column, and the inputs are listed in the two boxes on the left. Default values are provided for these inputs, but the user is free to change any of these values as long as they stay within the specified model limits. Table 24 lists the acceptable input ranges and recommended values. The notes identify input parameters typically provided by other modules. The material constants utilized in the PLR model are based on Nichrome V resistive elements and a carbon-carbon radiator plate. Calculations indicated these materials had the best combination of mass, thermal, and electrical characteristics. It is not intended for the operator to use alternate materials, but it can be done by inserting the appropriate resistivity and density factors. The 120% redundancy factor was selected on the basis of preliminary analyses that indi- cated it was the best tradeoff between enhanced reliability and added mass. The variables and constants utilized in the PLR model are listed in Table 25 in alphabetical order. A complete listing of the Fortran source code is pre- sented in Appendix G. This subroutine is located on the accompanying computer disk under the file name "ACPLR.FOR". 70 PARASITIC LOAD RADIATOR (PLR) FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS PLR POWER DISSIPATION LEVEL, PLR INPUT VOLTAGE LEVEL, AVAILABLE MODULES, REQUIRED MODULES. PLR WIRE OPERATING TEMPERATURE, WIRE TO RADIATING SURFACE DELTA T, PARASITIC LOAD RADIATOR SINK TEMPERATURE + SET DEFAULT VALUES: NUMBER OF RESISTOR CIRCUITS - 40 RESISTIVE CIRCUIT REDUNDANCY FACTOR - 1.2 NICHROME V RESISTIVITY - 1.0806E-02 NICHROME V RESISTIVITY TEMPERATURE COEFFICIENT - 0,00011 NICHROME V DENSITY ,, B.4296 CARBON-CARBON DENSITY - 1,66 + t CALCULATE: CIRCUIT CURRENT LEVEL, CIRCUIT ELEMENT RESISTANCE, RESISTIVE WIRE CROSS-SECTIONAL AREA, RESISTIVE WIRE LENGTH. SINGLE MODULE PLR SURFACE AREA, SINGLE MODULE PLR FRAME AREA CALCULATE FOLLOWING COMPONENT MASSES FOR SINGLE MODULE: PLR WIRE, PLR PLATE, SUPPORT & MOUNTING, PLR FRAME & TOTAL FOR MODULE CALCULATE TOTAL PLR MASS & AREA i TOTAL PLR SURFACE AREA TOTAL PLR MASS TOTAL PLR SPECIFIC MASS ! ! 1 _TA13_20N IIrEV• DATE 4/10/92 Figure 17 71 Parasitic Load Radiator Input Parameter PLR Power Dissipation Level PLR Input Voltage Level Available PLR Modules Table 24 Parasitic Load Radiator Model Input Parameter Ranges Required PLR Modules PLR Wire Operating Temperature Wire to Radiating Surface Temperature Delta PLR Sink Temperature Number of Resistive Circuits Resistive Circuit Redundancy Factor Recommended Input Range 100 kWe to 10 MWe 200 to 10,000 Vrms Equal to or Greater than Required Modules No Limit 500 to 1350 K 1255 K Suggested as Initial Value 50 to 150 K 100 K is Recommended See Note 1 247.67 K Calculated for LEO 20to 100 40 is Suggested 100 to 150% 120% is Recommended . The PLR sink temperature (PSI') will normally be obtained from the heat rejection module (CR-191132). If the PMAD module is run separately, the PST must be calculated for the environment being studied. The value for LEO is 247.67 K. 72 APM CC CCD CER ND NR NRC NRTC PI PIV PPD PST FWOT RCRF RPM RWD RWL RWXA SIVIFA SMFIVI Table 25 ParasRic Load Radiator Model Variable Dermitions Available Parasitic Load Radiator Modules Circuit Current Level (Amps) Carbon-Carbon Density (g/cm a) Circuit Element Resistance (ohms) Nichrome V Density (g/cm 3) Nichrome V Resistivity (ohms-cm2/meter) Number of Resistive Circuits Nichrome V Resistivity Temperature Coefficient (/*C) a" (3.1416) PLR Input Voltage Level (Vrms) PLR Power Dissipation Level (kWe) Parasitic Load Radiator Sink Temperature (K) PLR Wire Operating Temperature (K) Resistive Circuit Redundancy Factor (%) Required Parasitic Load Radiator Modules Resistive Wire Diameter (cm) Resistive Wire Length (m) Resistive Wire Cross Sectional Area (cm 2) Single Module PIN Frame Area (m:) Single Module PIN Frame Mass (kg) 73 SMPA SMPLRM SMPM SMSM SMWM TPLRA TPIAtlVI TPLRSM WRTD Table 25 (cont) Parasitic Load Radiator Model Variable Def'mitions Single Module Parasitic Load Radiator Surface Area (m 2) Single Module Parasitic Load Radiator Mass (kg) Single Module PLR Plate Mass (kg) Single Module PLR Support & Mounting Mass (kg) Single Module PLR Wire Mass (kg) Total Parasitic Load Radiator Surface Area (m 2) Total Parasitic Load Radiator Mass (kg) Total Parasitic Load Radiator Specific Mass (kg/kWe) Wire to Radiating Surface Temperature Delta (K) 74 Ii I ! i | 3.8 Litz Wire Transmission Llne Transmission lines will be used in the PMAD system to conduct power between the following components: alternator to switchgear unit, speed regulator to PLR, switchgear unit to adjacent switchgear unit, and switchgear unit to PPU. There are several possible transmission line constructions, but the litz wire configuration was modelled because it is a low inductance, low ac resistance design that is capable of operating over a wide frequency range. (The program funding and duration precluded the development of additional transmission line models, but it is recommended for future work.) Even at the relatively low frequencies used in this model, 60 Hz to 5 kHz, skin effect losses and line inductance are a concern. They become even more critical at higher frequen- cies because they are a function of frequency. The skin effect is a phenomenon that occurs in ac transmission due to the rap- idly changing current intensity. It arises from the fact that the inductance encountered by the current is higher at the center of the wire than at the periphery. This causes an uneven current density over the conductor cross section; the current density is a minimum at the wire center and a maximum at the periphery. The net result is an increase in the effective resistance of the conductor and higher losses. This effect becomes more pronounced as the conductor size and frequency increase. Another issue in ac transmission line design is line inductance. The energy stored in a transmission line is proportional to its inductance; consequently, a highly inductive line can make power switching and fault interruption more difficult. The stored energy must be controlled and dissipated by the switch. 'A large inductive re*actance also results in a large reactive power demand. As a result the current levels in the system rise, causing higher 12R losses, and necessitating larger conductors in the transmission lines, power conditioning components, and alternators. This effect is further compounded as conductor size increases, because it causes the line inductance to increase. In addi- tion to _ncreasing thePMAD system mass, the power source must be oversized to feed the reactive power demand. From a system viewpoint, it is important to minimize line inductance and maximize the PMAD system power factor. - _ _ _ _._ _ _:_- . . The litz wire transmission line con_tructi_n-_as=_Specifically-devel_ed to reduce skin effect losses and line inductance. Figure 18 shows the internal construction of a seven bundle litz wire cable. Litz wire contains numerous ":wire strands, each individually insulated and packed in a conductor bundle. Because each strand is insulated, the conductor behaves like many small wires run in parallel. This dramatically reduces skin effect losses because the useful conductor cross section of several individual strands is much larger than that of a single large conductor. However, the cable mass is increased due to the added weight of this wire strand insulation. The litz wire cable is partitioned into multiple bundles to decrease the conductor separation dis- tance, since it is a large determinant of the line inductance. Ideally, to minimize line inductance, the conductors in a 3-phase circuit should occupy the same space. Clearly this is impossible; however, reducing the conductor size does reduce the separation distance and thus the line inductance. 75 W4_I O-- I C O ei .l..p %.. .i..I C_ %,- omen em | m l "O i n "O Because the litz wire model is based on physical principles, it exhibits the influences of skin effect losses and line inductance and allows the user to evaluate steps aimed at improving the transmission line design. Some general procedures for reducing skin effect losses and line inductance are listed in the section entitled "Application Notes". Generally, if the transmission line model calculates an excessive mass or will not converge, it indicates that the selected input parameters are impractical and it would be extremely difficult to fabricate an actual cable that is suitable for these particular conditions. Application Notes: The litz wire transmission line model is designed to work satisfactorily over the entire power, voltage, and frequency range. However, there are combinations of input parameters that will cause problems. Specify- ing a fairly high frequency (greater than 1.5 kHz) in conjunction with a low voltage (less than 2000 Vrms) and a long transmission line length (greater than 150 meters) may lead to poor results. To determine why an impractical value was calculated or identify the cause of a divergence error, first look at the calculated circuit power factor value. If it is below 0.8, this par- ticular transmission line design is highly inductive and most likely not prac- tical. Failure of the model to converge will almost always be marked by a very low power factor, 0.7 or less. It is necessary to change the input pa- rameters to obtain an acceptable model output and a good cable design. The following steps are offered as a guide in determining appropriate and effec- tive design input changes. It is assumed that the designated transmission line length is based on definite spacecraft design requirements and it can not be readily changed; however, if this is not true it is always desirable to shorten the line length since it will always improve transmission efficiency and reduce cable mass. It is recommended that the following steps be tried in the order they are listed. I. . o Consider increasing the transmission line voltage. (This may necessitate selecting the Option #2 PPU design.) This change is particularly effective if the transmission line length is long, greater than 150 meters, but it will also help if the line is required to operate at a high frequency. If the line length is greater than 100 meters and the speci- fied frequency is greater than 1.5 kHz, it may be necessary to change the number of bundles from 7 to ]7. This will reduce the line inductance, but it will increase the line mass and conductor temperature due to the added insulation. Converse- ly, if a low frequency is specified, it may be possible to realize mass and temperature benefits by utilizing one bundle. The final step is to separate the transmission line into mul- tiple lines using the ATC and RTC factors. For example, a single 3 MWe line can be broken into three I MWe lines by making ATC and RTC both equal to 3. Model Specifics: The flow chart in Figure Ig shows the logic employed during the development of the litz wire transmission line model. The outputs in the right hand column represent a best estimate of the users needs and additional parameters are available. This data is in a Fortran common block and it can 77 NEP PMAD TRANSMISSION LINE FLOW CHART INPUTS FUNCTION OUTPUTS BASIC PARAMETERS LINE OUTPUT POWER. LINE OUTPUT VOLTAGE. FREQUENCY, AVAILABLE CIRCUITS, REQUIRED CIRCUITS, INITIAL LINE EFFICIENCY, LINE LENGTH. LOAD POWERFACTOR, NUMBER OF BUNDLES IN CABLE, CONDUCTOR VOLUME RESISTIVITY, CONDUCTOR RESISTIVITY TEMPERATURE COEFFICIENT, CONDUCTOR & INSULATION MATERIAL DENSITY, LITZ WIRE RADIUS, INSULATION THERMAL CONDUCTIVITY, INSULATION DIELECTRIC STRENGTH. INSULATION SAFETY FACTOR EXTERNAL HEATING EFFECTS: ABSORPTiViTY. EMISSIVITY. & INSOLATION PARAMETERS & CONSTANTS SET I=0 SET LINE CONDUCTOR TEMPERATURE TO 150 C SET CIRCUIT POWERFACTOR TO LOAD POWERFACTOR 1 X FACTOR '= 2 ?_ l '° YES i SET J=O I I TAe-_20F _ X FACTOR < 2 ?_) YES _NO )IS X FACTOR - 2 AND • 10 '?_ YES _ NO X FACTOR c= 10> YES R(V 0 OAT| 413/|Z -I CALCULATE CONDUCTOR VOLUME RESISTIVITY AT TEMPERATURE CALCULATE X FACTOR CALCULATE K FACTOR CALCULATE K FACTOR CORRECT CONDUCTOR VOLUME RESISTIVITY FOR FREQUENCY, CALCULATE LINE LOSSES -1 CALCULATE CABLE PARAMETERS: CONDUCTOR CURRENT. CONDUCTOR RESISTANCE. CONDUCTOR RADIUS, LITZ WIRE INSULATION THICKNESS, EQUIVALENT LITZ WIRE INSULATION THICKNESS, CONDUCTOR INSULATION THICKNESS, CONDUCTOR INSULATION OUTER RADIUS, CEOMETRIC MEAN DISTANCE CALCULATE K' FACTOR CALCULATE K' FACTOR CALCULATE K' FACTOR Figure 19 78 NEP PMAD TRANSMISSION LINE FLOW CHART INPUTS FUNCTION OUTPUTS IS CHANG r INPOWERFACTOR /_ ,- o.ool ? / _YES IS VALUE OF >J • 1000 ? NO SET 1-1+1 CALCULATE ELECTRICAL PARAMETERS: CONDUCTOR REACTANCE. LOAD RESISTANCE. LOAD REACTANCE. CIRCUIT RESISTANCE, C_CUIT REACTANCE. CIRCUIT POWERFACTOR NO YES PRINT ERROR MESSAGE: I FAILED TO CONVERGE. PREVIOUS I I AND CURRENT POWERFACTOR VALUES I b-- CALCULATE DIMENSIONS & TEMPERATURES: BUNDLE JACKET THICKNESS, BUNDLE JACKET OUTER RADIUS. CABLE JACKET THICKNESS, CABLE JACKET OUTER RADIUS, EXTERIOR CABLE HEATING EFFECTS I ! ! IS VALUE OF I > 1000 ? i IN°/ ,s CHANGE,N\ _ CONDUCTOR TEMP. YES\ ,-o._ / : _ NO i /,s CONDOCTOR\ (% TEMPERATURE) i \ ,2ooc? / NO YES 55 i z TASK20C I "_i CALCULATE NEW EFFICIENCY I I I CALCULATE MASSES AND LINE INPUT VALUES: CONDUCTOR MASS, LITZ WIRE 7- INSULATION MASS. CONDUCTOR INSULATION MASS, BUNDLE JACKET MASS, CABLE JACKET MASS 0 OAT[ 4/3/t2 Figure 19 (cont) 79 T -I _1 CIRCUIT POWERFACTOR CABLE JACKET OUTER RADIUS, CABLE JACKET SURFACE TEMPERATURE, CONDUCTOR TEMPERATURE LINE EFFICIENCY / CABLE MASS, LINE INPUT | POWER, INPUT VOLTAGE J be accessed by modifying the print routine. The basic model operations are shown in the middle column, and the inputs are listed in the left column. Default values are provided for each of these inputs, but the user can change any of these values as long as they stay within the specified model limits. The model allows a wide range of input parameters, but using values outside the ranges defined in Table 26 may result in errors and it is not recommended. The notes identify input parameters normally obtained from other modules. The results of the Task Order 14 contract and its follow-on were factored into the transmission line model to reduce the number of options requiring evalua- tion (Ref. II-1, II-2). For example, aluminum conductors were selected over copper ones. Analyses showed that the mass of an aluminum conductor would be about half that of a copper conductor under comparable conditions. Although the resistivity of aluminum is approximately 66% higher, its density is about 30% of copper. The density-resistivity product is the important parameter in selecting the minimum mass conductor material, and calculations showed an aluminum line would be half the mass of a copper one (1.66 x 0.30 _ 0.50). Other materials, such as silver, beryllium, or molybdenum, have an even higher density-resistivity product. An aluminum conductor would be about 60% larger than a copper one, but this was considered to be a minor factor in designing a transmission line. Finally, individuals have expressed concerns about termi- nating aluminum conductors because of their cold flow tendencies. New termi- nation methods and hardware appear to have solved these problems. In fact, aluminum conductors and buses have become the norm in high power terrestrial switchgear units. There are several insulations that might be suitable for transmission line ca- bles; however, polyimide (trade name Kapton) was selected because it offers a good combination of thermal, electrical, radiation, and mechanical properties (Ref. Ill-]). A Kapton jacket is mechanically superior to Teflon because it is a tough, flexible insulation that is highly resistant to abrasion. It can be applied in a thin layer on wire strands; consequently, the resulting cable construction is light weight and small in diameter. Kapton also has a high dielectric strength and good thermal conductivity. Due to the close proximity of a reactor, a transmission line insulation must be highly resistant to radi- ation and capable of operating at high temperatures. Test results indicate that Kapton can operate at 200 ° C for over ten years and the weight loss due to outgassing will be under 3%. It can also withstand high radiation levels and is rated for a total dose of 10' Rads gamma. Due to the complicated construction of the litz wire cable, detailed thermal calculations would be very complex and computer intensive. To simplify these calculations, it was assumed that all conductor losses would originate from a single conductor located in the center of the cable. The calculated cross sectional area of this conductor is equal to the combined areas of all the individual litz wire stands. The litz wire, bundle jacket, and cable jacket insulations were assumed to be made from Kapton and they were consolidated to form a single jacket. The calculated mass of this jacket was equivalent to the summed masses of the individual insulations, and its thickness correspond- ed to the combined thicknesses of the separate insulations. It is clear that a model based on this simplified construction will not calculate temperatures as precisely as a comprehensive thermal model, and detailed thermal modelling should be performed when funding allows. However, this simplified analysis 80 technique should yield comparable values and allow the user to determine rep- resentative cable masses and operating conditions. The variables and constants utilized in the litz wire transmission line model are listed in Table 27 in alphabetical order. A complete listing of the For- tran source code is presented in Appendix H. This subroutine is located on the accompanying computer disk under the file name "LWTRLN.FOR". BI Table 26 Litz Wire Transmission Line Model Input Parameter Ranges Transmission Line Input Parameter Output Power Level Output Voltage Level Transmission Line Efficiency Transmission Line Length Alternator Operating Frequency (See Note 1) Available Transmission Circuits Required Transmission Circuits Number of Bundles Load Power Factor Solar Radiation Level (See Note 2) Earth Infrared Radiation Level (See Note 2) Cable-Earth View Factor (See Note 2) Albedo (See Note 2) Recommended Input Ranee 10 kWe to 10 MWe 1000 to 10,000 Vrms 80 to 99.999 % 25 to 300 meters 60 Hz to 5 kHz 0.8 kHz is Recommended Equal to or Greater than Required Circuits No Limit 1, 7, or 17 0.80 to 1.00 343 to 5488 w/m 2 LEO value is 1372 w/m 2 0 to 237 w/m 2 LEO value is 237 w/m 2 0to 1.0 LEO value is 0.8 0 to 0.5 LEO value is 0.3 1. . The alternator operating frequency (AOF) will normally be obtained from the power conversion module (CR-191134 or CR-191135). If the PMAD module is run separately, AOF must be input. These values will normally be obtained from the heat rejection module (CR-191132). The values for LEO (400 km orbit) are: solar insolation, 1372 w/m2; earth infrared, 237 w/m2; cable-earth view factor, 0.8; and albedo, 0.3. 82 ALBD ANti) AOF ARTC ATC AVR AVRF AVRT BIM BJOR BIT CABI CABS CCUR CEM CEVF CIM CIOR CIT CJM CJOR Table 27 Transmission Line Model Variable Definitions Albedo Aluminum Mass Density (g/cm 3) Alternator Operating Frequency (kHz) Aluminum Resistivity Temperature Coefficient (/°C) Available Transmission Circuits Aluminum Volume Resistivity at 20°C and 0 Hz (Ohm-m) Aluminum Volume Resistivity at Temperature and Frequency Aluminum Volume Resistivity at Conductor Temperature Bundle Jacket Mass (kg) Bundle Jacket Outer Radius (cm) Bundle Jacket Thickness (cm) Cable Absorptivity (Infrared) Cable Absorptivity (Solar) Conductor Current (Amps) Cable Emissivity Cable-Earth View Factor Conductor Insulation Mass (kg) Conductor Insulation Outer Radius (cm) Conductor Insulation Thickness (cm) Cable Jacket Mass (kg) Cable Jacket Outer Radius (cm) 83 CJST CJT CM COM CRAD CREA CRES CRP CXP ECHE ELWT GMD IDS IDSF IMD ITC KF KPF LPF LRP LWIM Table 27 (cont) Transmission Line Model Variable Definitions Cable Jacket Surface Temperature (K) Cable Jacket Thickness (cm) Cable Mass (kg) Conductor Mass (cm) Conductor Radius (cm) Conductor Reactance (Ohms) Conductor Resistance (Ohms) Circuit Resistance per Phase (Ohms) Circuit Reactance per Phase (Ohms) External Cable Heating Effects (w/m 2) Equivalent Litz Wire Insulation Thickness (cm) Geometric Mean Distance between Conductors (cm) Insulation Dielectric Strength (V/rail) Insulation Dielectric Strength Safety Factor Insulation Mass Density (g/cm 3) Insulation Thermal Conductivity (w/m-K) K Factor K' Factor Load Power Factor Load Resistance per Phase (Ohms) Litz Wire Insulation Mass (kg) 84 LWIT LWR LXP NOB PF QEIR QSOL RTC SBC TLCT TLE TLIP TLIV TLL TLOP TLOV TLPL XF Table 27 (cont) Transmission Line Model Variable Def'mitions Litz Wire Insulation Thickness (cm) Litz Wire Radius (cm) Load Reactance per Phase (Ohms) Number of Bundles Circuit Power Factor Earth Infrared Radiation Level (w/m 2) Solar Radiation Level (w/m 2) Required Transmission Circuits Stefan-Boltzmann Constant (w/m2-K _) Transmission Line Conductor Temperature (*C) Transmission Line Efficiency (%) Transmission Line Input Power Level (kWe) Transmission Line Input Voltage (Vrms) Transmission Line Length (m) Transmission Line Output Power Level (kWe) Transmlsston Line Output Voltage (Vrms) Transmission Line Power Losses (kWe) X Factor 85 3.9 Electronics Radiator Since all NEP vehicle power conditioning components will require cooling, algorithms were developed to estimate the size and mass of the electronics radiator. These algorithms were based on a flat-plate radiator that rejects heat to space from both sides, and are valid for the following ranges or variables: 1. Heat dissipation levels ranging from 10 kWt to 1 MWt, 2. Coldplate temperatures ranging from 50 to 250* C, 3. An operating life of 10 years, 4. Environments ranging from low earth orbit (LEO) to interplanetary space, and 5. A technology time frame of 2005 to 2020. The technology time frame largely determines the radiator construction and materials. The selected radiator design features were: 1. Water is the heat pipe working fluid, 2. Carbon-Carbon construction with a Monel liner, - Fin thickness = 0.05 cm, - Pipe wall thickness = 0,100 era, - Liner thickness = 0.0075 cm. 3. Radiation emissivity control coating, - Emissivity = 0.9, - Absorptivity = 0.2 (solar) Based on the above specified requirements and selected design features, the following algo- rithms were developed. RA = (14.80E + 09*PD)/((Tcp- 16.67) 4-Ts 4) RM = 3.418"RA where: RA = Radiator flat plate area (one-side) (sq-meters), PD = Required heat rejection capacity (kW0, Top = Coldplate operating temperature (K), Ts -- Heat sink temperature (247.67 K), RM = Radiator mass (kg). 86 4.0 Conclusions and Recommendations The PMAD models documented in this report are capable of evaluating the effect on component parameters of a wide range of power levels, voltages, and fre- quencies. Options are available for assessing ion and MPD thrusters, and single and counter rotating alternators. Because there is the potential for the utilization of high temperature electronics, the model also allows the use of coldplate temperatures ranging from 60 to 200 ° C. While this will allow an initial assessment of high temperature electronics, it is important to realize that the operating characteristics of these devices are poorly defined and it is difficult at this time to determine their true impact. Based on the se- lected inputs, the end-to-end PMAD model will supply total PMAD system mass, specific mass, end-to-end efficiency, and the total electronics radiator area. Additional component modelling data are located in a Fortran common block and they can be accessed by modifying the print output subroutine. The transmission line configuration modelled during this study is based on a litz wire construction. While this construction is suitable for a wide range of frequencies, it is primarily suited for high frequency operation. There are several other transmission line constructions, such as hollow conductor and ribbon cable, that should be evaluated since they may offer mass and per- formance gains. To develop these models in the most economical manner, it is recommended that an ac transmission line report authored by Dr. Loyde Gordon be consulted. This report should have been recently received by NASA LeRC. It is important to utilize this report because the models developed by Dr. Gordon are well documented and exhibit high fidelity. The litz wire transmission line model contained in this report is relatively simple due to the complexity and cost of developing a detailed thermal model. The calculation steps in a complete thermal model would also occupy consider- able computer time. Clearly, a thermal model based on a simplified construc- tion will not calculate temperatures as precisely as a thermal model based on a complete construction; therefore, a detailed model should be constructed to test the validity of this simplified analysis technique. The litz wire trans- mission line model contained in this report should also be compared with the litz wire model presumed to be in Dr. Gordon's ac transmission line report to test its accuracy. A near-term NEP vehicle may use an SP-IO0 thermoelectric power source. Later vehicles may utilize a thermionic power source. The output from thermoelec- tric and thermionic power sources, low voltage dc, is totally different from the 3-phase ac provided by a rotary alternator. Therefore, it is necessary to conduct studies to determine the best PMAD approach for these types of power sources. Based on these studies, PMAD models should be developed to compare different architecture configurations, perform system tradeoffs, and determine PMAD mass and efficiency as a function of power, voltage, and frequency if ac distribution is utilized. Because thermoelectric and thermionic power sources have similar electrical characteristics it may be possible to perform a single PMAD study involving the two power sources. The practicality of this approach would depend primarily on the proposed power levels and projected time periods for the two power sources. 87 The present PMAD codes contain algorithms designed to calculate the masses of the thruster PPU assemblies and radiators. However, certain thruster codes may already include the associated PPU masses or it may be desirable only to calculate the PMAD component masses on the power generation side of the thrus- ter buses. This can be accomplished by inputing a PPU identifier that will direct the code to zero out the PPU component and radiator masses. Although a skilled Fortran programmer is required to implement and debug the actual code changes, the following general code modifications are suggested: I) Near the beginning of fortran subroutine "PMAD.FOR", the comment line headed by "IDPPU", a statement indicating "O=no PPU assembly or radiator" should be added. 2) After the variable definition section of fortran subrou- tine "PMAD.FOR", the comment line stating "IDPPU should equal I, 2, or 3" must be modified to include O. The following execution line should include "IDPPU .NE. 0", and "IDPPU=3" should be changed to "IDPPU=O". 3) Near the end of fortran subroutine "PMAD.FOR", and imme- diately before the execution line "EEPE=PPE*PSTLE*SWE*SATLE" the following line should be added "If IDPPU=O, PPE=I" 4) Near the end of fortran subroutine "PMAD.FOR", and imme- diately before the execution line beginning "TPCM=APC*(NTC*PPM+..." the following line should be added "If IDPPU=O, PPM=O". s) Near the end of fortran subroutine "PMAD.FOR", and imme- diately before the execution line beginning "TERM=APC*(NTC*PPRAM+..." the following line should be added "If IDPPU=O, PPRAM=O". These code modifications are intended to remove the PPU mass and efficiency values from the system mass and efficiency totals; however, the programmer should verify these changes are accurate and that all necessary executable modifications are identified. It may also be necessary for the programmer to modify certain print statements to ensure they print the proper values. BB II-I II-2 Ill-] A-I A-2 A-3 A-4 A-5 A-6 References Meisner, John W. "Power Conditioninq Assessment for Nuclear_ Solar Electric Propulsion." Task Order 14 Final Report, Rockwell Interna- tional, Rocketdyne Division. NASA Contract Number NAS3-25808, July 1991 (Currently Unreleased). Metcalf, Kenneth J. "Power Conditioning Architecture Assessment for Nuclear Electric Propulsion", Task Order 14 Follow-On Presentation of Results, Rockwell International, Rocketdyne Division. NASA Con- tract Number NAS3-25808, February 1992. Du Pont. "Kapton", A brochure containing the electrical, mechanical, thermal, and chemical properties of the polyimide film Kapton. Thome, Frank and Donald King. "A Summary of High-Temperature Elec- tronics Research and Development." gth Symposium on Space Nuclear Power Systems, January 1992, Vol. I, pp. 254-259. Neudeck, Philip and Lawrence Matus. "An Overview of Silicon Carbide Device Technology." 9th Symposium on Space Nuclear Power Systems, January 1992, Vol. I, pp. 246-253. Fink, Donald and H. Wayne Beaty. "Standard Handbook for Electrical Enqineers", Eleventh Edition. New York, N.Y.: McGraw-Hill Book Company, 1978. Wong, See-pok. Temperature." 1988. "Loss in Switching Transistors vs. Hybrid Substrate Facsimile Transmission from Space Power Incorporated, Wieserman, William; Gene Schwarze, and Janis Niedra. "Comparison of High Frequency, High Temperature Core Loss and B-H Loop Characteris- tics of an 80 Ni-Fe Crystalline Alloy and Two Iron-Based Amorphous Alloys." 8th Symposium on Space Nuclear Power Systems, January 1991, Vol. Ill, pp. 974-981. AVX Corporation. "Ceramic Advanced Products", A brochure containing characteristic information on ceramic capacitors prepared by the AVX Corporation. 89 APPENDIX A Component Temperature-Efficiency Algorithms 9o L_ m Component Efficiency-Temperature Algorithms The efficiency of a component is calculated by multiplying the efficiencies of the stages together and subtracting the parasitic power demands. The power required to operate the control and monitoring hardware is termed parasitic power and it does not vary much with the component power level. Consequently, components rated for high power levels are more efficient than ones designed for low power. The efficiency of the stages, however, does change as the operating temperature of the component rises. Therefore, a component designed for high temperature operation will typically be less efficient than one de- signed for lower temperatures. This occurs because the resistivity of almost all elements, conductors, transformer windings, connections, switches, diodes, etc., rises with temperature. The only exception is that transformer core losses decline with temperature. Because of this effect, algorithms were developed to adjust component efficiency with temperature. Higher component operating temperatures are being investigated because they reduce the mass of the electronics radiators. The radiator calculations utilize the component coldplate temperature; hence, the radiator area and mass are automatically re- calculated when the coldplate temperature is changed. A four step process was used to develop algorithms relating component effi- ciency to temperature: (I) the main elements in a component were identified, (2) their losses were determined as a function of temperature, (3) the losses attributable to each of these elements were calculated for representative com- ponents, and (4) aig6k_hmS relating effic_e6_y tO temperature were developed for components based on their respective loss allocations. The power handling devices in a component are primarily composed of four elements, copper conduc- tors, semiconductors, magnetic materials, and capacitors. Existing tempera- ture-resistance equations, data sheets, and technical papers were consulted to obtain information relating losses to temperature. This data was utilized to generate algorithms _or_each of these elements. Loss breakdowns were then ob- tained for selected components to determine the losses attributable to each of these elements. Based on these loss breakdowns, and the algorithms previously developed for the elements, algorithms were'generated for a complete compo- nent. These algorithms are for representative components and they are general in nature. They should only be utilized to identify efficiency-temperature trends, and not be used to determine the losses of a specific component at a particular temperature. The rationale supporting these algorithm_ assumes that component developments will result in not only higher efficiency operation, but allow higher operat- ing temperatures as well. However, advanced materials are required to achieve substantially higher temperature operation. Since it takes approximately 15 to 20 twenty years to develop new power component materials, applied technolo- gy developments over the next ten years will concentrate primarily on enhanc- ing the capabilities of present materials. This will lead to innovative con- structions that utilize current materials to achieve superior characteristics. An example of this approach is the silicon-on-insulator (SOl) technology cur- rently _eing evaluated for use in power devices. Since this design approach reduces the leakage currents that limit device operating temperatures and rad- iation exposure, SOl devices are capable of operating at higher temperatures and radiation levels. However, these devices are limited to 200 ° C, and will gl probably need to operate at significantly lower temperatures if high reliabil- ity and long life are crucial. After including these factors and the thermal resistance from the coldplate to the device, actual componentcoldplate tem- peratures will probably range from 80 to 120° C. Although this represents a considerable improvement over present day coldplate temperatures of 30 to 60° C, higher coldplate temperatures are desired to fur- ther reduce radiator mass. Advanced heat sink designs incorporating new mate- rials such as carbon-carbon will lower the thermal resistance and enable high- er coldplate temperatures without increasing device junction temperatures. If carbon-carbon is oriented correctly it exhibits a higher thermal conductivity than copper, and its specific weight of 1.66 g/cm 3 is 19% of copper and 61% of aluminum. Furthermore, since the removal of waste heat is the limiting factor in higher density electronics packaging, utilizing carbon-carbon should reduce component volumes. This will result in shorter internal conductor lengths and reduce conductor losses. _ _ Current transformer and inductor materials are acceptable for envisioned high temperature, high radiation environments. However, advanced capacitor design approaches are required. Ceramic and glass dielectric capacitors can tolerate relatively high temperatures and radiation levels; however, they will require additional development to operate at temperatures above 200 ° C and radiation levels exceeding 107 Rad (Si) and 1015 n/cm2. Energy storage density improve- ments are also needed to reduce the mass and volume of ceramic and glass die- lectric capacitors. Presently, certain semiconductor technologies are being developed chiefly for high temperature, high radiation environments. Four of these, gallium arse- hide (GaAs), silicon carbide (SIC), diamond, and field emitter arrays (FEAs), are receiving considerable attention and they will be briefly discussed (Ref. A-I). GaAs is already used in high speed analog and digital circuits; how- ever, present GaAs power devices exhibit excessive leakage currents at temper- atures exceeding about 175° C. If GaAs power devices can be fully developed, they should be suitable for junction temperatures up to 250 ° C and radiation dosages of i0s Rad (Si) and 1015n/cm 2. SiC technology is less mature than GaAs, but these devices will be able to operate in higher temperature, _600 ° C, higher radiation environments (Ref. A-2). Research has resulted in the fabrication of simple diodes, MOSFETs, and BJTs; however, the operating life of these devices has been severely limited by ohmic contact and semiconductor- insulation boundary degradation. Diamond semiconductors hold great promise because the thermal conductivity of diamond, 20 W/cm-K, is better than copper, and its bandgap energy of 5.5 eV indicates operating temperatures of 900 ° C are possible. However, the diamond semiconductor technology is very immature and basic research is being conducted to improve substrate growth techniques and reduce defects. FEAs are vacuum microelectronic devices that consist of an array of emitter tips that provide an electron flow across a gap by means of field emission alone. These devices should be very radiation hard and suitable for very high temperature environments. The current densities possi- ble with these devices also make them candidates for power applications. The losses occurring in a conductor are determined by the formula 12R, where I is the current level and R is the resistance of the conductor. If the current level remains constant, the conductor losses become a function of resistance. When the conductor resistance changes with temperature, the losses in the con- ductor change proportionally. The following formula is used to calculate the resistance of a copper conductor at different operating temperatures (Ref. A-3). RT=1.7241*[l+O.OO393*(T-20)] where: RT Resistance at the conductor temperature 1.7241 Resistance of copper at 20° C in p_m 0.00393 copper temperature-resistance coefficient at 20° C T - conductor temperature in degrees C This formula was used to calculate resistance values for a copper conductor normalized about i00° C. From these normalized values, the following algo- rithm was developed. It calculates the percent change in losses in a copper conductor as a function in temperature. CUL=(O.75+O.OO25*CPT)*CULloo where: CUL - Copper conductor losses for specified coldplate temperature CPT - Coldplate temperature in degrees C CULIoo Copper conductor losses for I00 ° C coldplate temperature A single algorithm was developed to generate a common loss-temperature trend for different semiconductor switches and materials. Because high temperature semiconductor materials are in the early stages of development, the operating characteristics of proposed devices are largely undefined. Therefore, their operating characteristics at higher temperatures were estimated by extrapolat- ing from present silicon based device operating data. This approach is proba- bly optimistic because the primary material under consideration, SiC, exhibits lower electron and hole mobility than silicon and thus would be expected to have a _oorer efficiency. However, a slightly optimistic approach does allow one to more easily determine the potential of SiC devices. Furthermore, the change in resistivity as a function of temperature for silicon and SiC based semiconductors should be similar, and it was considered impractical to develop different algorithms for the many different materials and devices. The device selected for this algorithm was a metal-oxide-semiconductor field- effect-transistor (MOSFET) rated for 800 V and having a drain to source on-re- sistance of 0.8 ohms (Ref. A-4). The losses were determined for an operating frequency of 20 kHz and a current level of 2.8 amps. Several devices would be paralleled to handle large currents. MOSFETs are common devices and this ap- plication is consistent with a NEP vehicle PMAD system. The algorithm, shown below, calculates the percent change in losses for a temperature range of 60 to 200 ° C. It is normalized to yield a value of I at 100° C. SL=(O.43+O.OOS71*CPT)*SLlo 0 where: SL - Semiconductor losses for specified coldplate temperature CPT - Coldplate temperature in degrees C SLI_ Semiconductor losses for 100 ° C coldplate temperature Transformers and inductors contain a core that is utilized to conduct magnetic flux. As with any element, losses occur during operation; however, the losses in a core decline with temperature. Using test data generated by the Univer- ! 93 sity of Pittsburgh while under contract to NASA LeRC, an algorithm relating core losses to temperature was developed (Ref. A-5). For the algorithm devel- opment a single core material, supermalloy, was used. Supermalloy is widely used for high frequency, high power applications because it exhibits low core losses and has a high thermal conductivity. Since this is consistent with proposed NEP vehicle PMAD requirements, it was considered to be a good mate- rial for modelling purposes. The algorithm developed from this data is shown below. CL=(I.]+O.OOI*CPT)*CLI_ where: CL - Core losses for specified coldplate temperature CPT - Coldplate temperature in degrees C CLI_ - Core losses for 100 ° C coldplate temperature The final device that required an algorithm relating losses to temperature is a capacitor. For this process, the characteristics of a ceramic capacitor were selected (Ref. A-6). Ceramic capacitors are utilized in several compo- nents for the SSF electrical power system due to their low mass and high reli- ability. They can also be used in both dc and ac applications and they are suitable for relatively high radiation, high temperature applications. Be- cause these characteristics are desirable in a NEP vehicle PMAD application, it is presumed that ceramic capacitors will be utilized in many components. The algorithm developed from the normalized ceramic capacitor data is shown below. CPL=(O.26+O.OO741*CPT)*CPLI0o where: CPL - Capacitor losses for specified coldplate temperature CPT - Coldplate temperature in degrees C CPLI_ - Capacitor losses for 100° C coldplate temperature Figure 20 compares the normalized efficiencies of these four elements at temp- eratures ranging from 60 to 200 ° C. Again it is stressed that these algor- ithms are for representative devices only, and the characteristics of certain devices may vary considerably from this generic data. The algorithm results will be general in nature and the algorithms themselves should only be used to determine efficiency-temperature trends and not specific values. The next step in producing efficiency-temperature algorithms for complete com- ponents is to determine the losses that are attributable to the various devic- es. For this process, the loss breakdowns of representative components, such as the SSF main inverter units, were used. The loss allocations presented in Table 28 were generated from this effort. The temperature-resistance proper- ties are the same for the internal component conductors and the transformer and inductor windings because these elements are all fabricated from copper. However, the losses shown in Table 28 were broken out separately for clarity. 94 L_. |! ! a 0 ,,_I x n UJ IJ_ LIJ (o_)sossO"lpoz!lem.ml_I 95 _4P Table 28 Component Loss A11ocati ons Component Stage Inverter Copper Conductor Losses (%) Switch or Diode Losses(%) 10 ii n| 7O Copper Winding Losses (%) i 0 10 Transformer 0 0 60 Rectifier 20 80 0 Filter 10 0 40 RBI/RPC 50 0 Magnetic Core Losses (%) Capacitor Losses (%) rr ir 5 40 0 o o 2o 0 30 Relay Contact Losses (%) 0 o o 5o Utilizing the loss allocation percentages shown in Table 28 and their associ- ated device algorithms, algorithms were developed for the component stages. These algorithms determine the change in component efficiency as a function temperature. They were generated by multiplying the loss percentages and the coefficients in the device algorithms together. The algorithms for the in- verter, transformer, rectifier, filter, and RBI/RPC stages are shown below. Inverter: CSET=I-(I-CSE)*(o.sg3+o.oo4os*cPT) Transformer: TSET=I-(I-TSE)*(O.Bg+O.OOII*CPT) Rectifier: RSET=I-(I-RSE)*(O.526+O.OO475*CPT) Filter: FSET=I-(I-FSE)*(O.82+O.OOI8*CPT) RBI/RPC: RBET=I-(I-RBE)*(O.675+O.OO325*CPT) where: CSET - Chopper stage efficiency at the coldplate temperature (%) CSE Chopper stage efficiency at 100° C (%) CPT - Coldplate temperature in degrees C TSET - Transformer stage efficiency at the coldplate temperature (%) TSE - Transformer stage efficiency at 100° C (%) RSET - Rectifier stage efficiency at the coldplate temperature (%) RSE - Rectifier stage efficiency at 100° C (%) FSET - Filter stage efficiency at the coldplate temperature (%) FSE - Filter stage efficiency at 100° C (%) RBET - RBI/RPC efficiency at the coldplate temperature (%) RBE - RBI/RPC efficiency at 100° C (%) These temperature corrected efficiencies were incorporated into the component models and used to adjust the calculated end-to-end efficiency of the complete component. This efficiency determines the total component power losses, and affects the calculated size of the associated electronics radiator. Finally, because these corrected efficiencies interact, it caused minor adjustments in the masses of the component stages. 96 APPENDIX B End-to-End PMAD Model Also includes Temporary Driver Module, Common Block Module, and Print Output Module 97 = SUBROUTINE PMAD C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C PMAD SYSTEM DESIGN CODE Revised: 4/27/1992 tcn Author: Ken Metcalf, (818) 586-3976 Inputs: TOP LEVEL: AOF Alternator Operating Frequency (kHz) APC Available PMAD Channels CPT Electronics Coldplate Temperature (C) CRTD Electronics Coldplate to Radiator Temperature Delta (C) KRA Variable to Select Counter Rotating Alternators IDPPU Type of PPU (lffiion w/o transformer; 2=ion w/transformer; 3ffimpd PPU) NAC Number of Alternators per PMAD Channel NTC Number of Thrusters per PMAD Channel PMADPO PMAD System Power Output (kWe) PPUVI Power Processing Unit Input Voltage (Vrms) RPC Required PMAD Channels RST Electronics Radiator Sink Temperature (K) ALL PPU: PPAM Power Processing Unit Available Modules PPRM Power Processing Unit Required Modules IFE Power Processing Unit Input Filter Efficiency (frac) RF Ripple Factor (frac) PPU 1 & PPU2: BOV DOV AOV NOV ATE ARE AFE BRE BFE DRE DFE NFE NRE PPU 1: DTE NTE PPU2: BTE DT1E DT2E NT1E NT2E PPU3: PPOV Beam Supply Output Voltage (Vdc) Discharge Supply Output Voltage (Vdc) Accelerator Supply Output Voltage (Vdc) Neutralizer Supply Output Voltage (Vdc) Accelerator Power Supply Transformer Efficiency (frac) Accelerator Power Supply Rectifier Efficiency (frac) Accelerator Power Supply Filter Efficiency (frac) Beam Power Supply Rectifier Efficiency (frac) Beam Power Supply Filter Efficiency (frac) Discharge Power Supply Rectifier Efficiency (frac) Discharge Power Supply Filter Efficiency (frac) Neutralizer Power Supply Filter Efficiency (frae) Neutralizer Power Supply Rectifier Efficiency (frac) Discharge Power Supply Transformer Efficiency (frac) Neutralizer Power Supply Transformer Efficiency (frac) Beam Power Supply Transformer Efficiency (fract) Discharge Power Supply Transformer #1 Efficiency (fract) Discharge Power Supply Transformer//2 Efficiency (fraet) Neutralizer Power Supply Transformer #1 Efficiency (frac) Neutralizer Power Supply Transformer//2 Efficiency (frac) Power Processing Unit Output Voltage Level (Vrms) 98 C "rE Transformer Efficiency (frac) C RE Rectifier Efficiency (frac) C OFE Output Filter Efficiency (frac) C TRANSMISSION LINE: C TLE (= 0.98) Transmission Line Efficiency C TLL (= 150.) Transmission Line Length, m C ATC (= 1.) Available Transmission Circuits C RTC (= 1.) Required Transmission Circuits C NOB (= 7.) Number of Buodles C LPF (= .9) Load Power Factor C AC SWITCHGEAR: C RBE RBI Unit Efficiency at 100 C (fraction) C SWAM Switchgear Available Modules C SWRM Switchgear Required Modules C PHASE LOCK TRANSFORMER: C PTAM Phase Lock Transformer Available Modules C PTPP Phase Lock Transformer Power Percentage (fraction) C PTRM Phase Lock Transformer Required Modules C TSE Transformer Stage Efficiency at 100 C (%) C ALTERNATOR SPEED REGULATOR: C SRAM Speed Regulator Available Modules C SRRM Speed Regulator Required Modules C NSS Number of Shunt Switch Elements C SRF Shunt Redundancy Factor (frac) C PWMF Pulse-Width-Modulation Frequency (kHz) c BCE Bus Conductor Efficiency at 100 C (frac) C SSE Shunt Switch Efficiency at 100 C (frac) C EFE EMI Filter Efficiency at 100 C (frac) C PARASITIC LOAD RADIATOR: C APM Available Parasitic Load Radiator Modules C RPM Required Parasitic Load Radiator Modules C PWOT PLR Wire Operating Teml_ramre (K) C WRTD Wire to Radiating Surface Temperature Delta OK) C PST Parasitic Load Radiator Sink Temperature OK) C CCD Carbon-Carbon Density (g/cm3) ND Nichrome V Density (g/era3) NR Nicrome V Resistivity (ohms-cm2/meter) NRTC Nicrome V Resistivity Temperature Coefficient (/C) C C C C C C C C C C C C C C C= C C C C Outputs: EEPE TERA TERM TPCM TPM TPSM TTLM End-to-End PMAD System Efficiency (%) Total Electronics Radiator Area (m2) Total Electronics Radiator Mass (kg) Total Power Conditioning Component Mass (kg) Total PMAD System Mass (kg) Total PMAD System Specific Mass (kg/kWe) Total Transmission Line Mass (kg) INCLUDE "COMMONS.FOR" IDPPU SHOULD BE 1, 2, OR 3. SET TO 3 OTHERWISE 99 CC C C IF (IDPPU .NE. 1 .AND. IDPPU .NE. 2 .AND. IDPPU .NE. 3) IDPPU=3 CHECK FOR VALIDITY OF NO. OF PMAD CHANNELS REQUIRED IF (RPC .GT. APC) THEN RPC-- APC WRITE (6,99001) RPC 99001 FORMAT (llX,'* WARNING! INPUT INVALID RPC IN PMAD. ', & ' SET RPC = APC = ', F3.00 ENDIF C C C CHECK FOR VALID NO. OF ALTERNATOR (EVEN NAC IS REQUIRED IF KRA= 1) NACHAF=NAC/2. IF (KRA.EQ. 1 .AND. NAC.GT. 2.*NACHAF) THEN NAC = NAC + 1. WRITE (6,99002) NAC 99002 FORMAT (/IX,'* WARNING! INVALID INPUT NAC IN PMAD. ', & ' SET NO. OF ALTERNATORS = ', F3.0/) ENDIF C C C C C C C C C C ************* POWER PROCESSING UNIT (PPU) design (PPU input voltage, PPIV, is specified for ionpu2 & mpdppu. PPIV is calculated for ionpul--PPU w/o transformer ) Power Processing Unit Input Power Ocwe) & Voltage (Vrms) PPIP = PMADPO/RPC/NTC IF (IDPPU.NE. 1) PPIV=PPUVI IF ( IDPPU.EQ. 1 ) CALL IONPU1 IF ( IDPPU.EQ.2 ) CALL IONPU2 IF ( IDPPU.EQ.3 ) CALL MPDPPU ******** PPU-to-Switchgcar TRANSMISSION LINE deaign PSTLOP = PPIP PSTLOV = PPIV TLOP = PSTLOP TLOV = PSTLOV TLL = PSTLL TLE = PSTLE ATC = PSATC RTC = PSRTC N OB = PSN OB LPF = PSLPF CALL LWTRLN PSTLM = CM PSTI_=TLIP PSTIJV =TLIV PSCJOR = CJOR 100 PSCJST = CJST PSTLCT=TLCT PSTLE=TLE PSPF = PF C C ******************* SWITCHGEAR design ********************** C C Switchgear Unit Numbers of Input and Output RBIs C NIRB = NAC NORB -- NTC C C Output RBI Output Power (kwe) & Voltage (Vrms) C ORBOP=PSTLIP ORBOV = PSTLIV CALL ACSWGR C C C SWIBIP = IRBIP SWIBIV = IRBIV SWXBIP = XRBIP SWXBIV = XRBIV ****** Switchgear-to-Switchgear TRANSMISSION LINE design SSTLOP= SWXBIP SSTLOV = SWXBIV TLOP= SSTLOP TLOV = SSTLOV TLL = SSTLL TLE = SSTLE ATC = SSATC RTC = SSRTC NOB = SSNOB LPF = SSLPF CALL LWTRLN C C C SSTLM = CM SSTLIP = TLIP SSTLIV = TLIV SSCJOR = CJOR SSCJST = CJST SSTLCT = TLCT SSTLE = TLE SS PF -- PF ****** Altemator-to-Switchgear TRANSMISSION LINE design SATLOP = SWIBIP SATLOV = SWIBIV TLOP = SATLOP I01 TLOV = SATLOV TLL -- SATLL TLE=SATLE ATC = SAATC RTC = SARTC NOB = SANOB LPF = SALPF CALL LW'IRI.N C C C C C C SATLM = CM SATLIP= TLIP SATLIV = TLIV SAC/OR = C/OR SAC/ST = CJST SATLCT--TLCT SATLE=TLE SAPF--PF ALTERNATOR OUTPUT power (kwe) & voltage (Vrms) APO=SATLIP AVO = SATLIV ***************** PHASE LOCK TRANSFORMER design IF OKRA .EQ. I) THEN CALL TRNFMR C C C C C C BYPASS TRANSFORMER IF COUNTER ROTATING ALTERNATORS IS NOT SELETED ELSE PTRA=0. PTM=0. PTRAM--0. ENDIF ************** ALTERNATOR SPEED REGULATOR design ************** CALL SPDREG C C C SRSPO = SPO SRSVO-- SVO ********* Shunt regulator to PLR TRANSMISSION LINE design ********* (Known input power & voltage. Calculate output power & Voltage) C C C SPTLIP = SRSPO SPTLIV = SRSVO ISP=0 ASSUME INITIAL VALUES FOR SPTLOP & SPTLOV 102 IF (SPTLE .EQ. 0.) $PTLE = 0.85 170 SPTLOP = SPTLIP*SPTLE SPTLOV = SPTLIV*SPTLE TLOP = SPTLOP TLOV = SPTLOV TLL= SPTLL TLE= SP'IZE ATC = SPATC RTC=SPRTC NOB = SPNOB LPF = SPLPF CALL L_,"rRLN C C C ADJUST SPTLE UNTIL DELTAT CONVERGED WITHIN .001% DELTAT= SPTLE-TIE IF (ABS(DELTAT) .GT. 1.E-5) THEN ISP=ISP+ 1 IF (ISP .LE. 50) THEN SPTLE--TLE GOTO 170 ENDIF WRITE (*,*) ' WARNING IN PMAD! SPTLE ITERATIONS EXCEED 50' ENDIF SPTI_=TLIP SPTLIV = TLIV sP'rLM = CM SPOOR = OOR SPCJST = CJST SFII.L-'T = qq.L'T SPTI_=TLE SPPF-- PF SPTLOP= TLOP SPTLOV = TLOV C C C C C ************** PARASITIC LOAD RADIATOR design ************** C C PLR Power Dissipation Level (kWe) & Input Voltage Level (Vrms) C PPD = SPTLOP PW = SPTLOV C C PLR No. of Resistive Circuits & Resistive Circuit Redundancy Fact C NRC=NSS RCRF=SRF SIZE & WEIGH THE PLR 103 CALL ACPLR ****************************** SUMMARY C C C PMAD SYSTEM END-TO-END EFFICIENCY EEPE = PPE*PSTLE*SWE*SATLE C C PMAD SYSTEM ELECTRONICS RADIATOR AREA, M**2 C TERA=APC*(NTC*PPRA + SWRA + NAC/2.*PTRA + NAC*SRRA) C C PMAD SYSTEM TOTAL POWER CONDITIONING COMPONENT MASS, KG C TPCM=APC*(NTC*PPM + SWM + NAC/2.*PTM + NAC*(SRM+TPLRM)) C C PMAD SYSTEM TOTAL TRANSMISSION LINE MASS, KG C T]"LM=APC*(NTC*PSTLM + SSTLM + NAC*(SATLM+SFFLM)) C C PMAD SYSTEM ELECTRONICS RADIATOR MASS, KG C TERM=APC*(NTC*PPRAM + SWRAM + NAC/2.*_ + NAC*SRRAM) C C TOTAL PMAD SYSTEM MASS, KG C TPM=TPCM + 'ITLM + TERM C C TOTAL PMAD SYSTEM SPECIFIC MASS, KG/KWE C TPSM = TPM/(RPC*NTC*PPOP) C C RETURN END 104 =L = il = | C C C C C C C C C C C C C C C C C C C C C C PROGRAM MAIN DRIVER FOR KEN METCALF'S PMAD SY_M OR COMPONENT MODELS IDCOMP = 0: IDCOMP - I: IDCOMP = 2: IDCOMP = 3: IDCOMP = 4: IDCOMP = 5: IDCOMP = 6: IDCOMP = 7: IDCOMP = 8: End-to-End NEP PMAD System Model Ion Thruster PPU Model (w/o Beam Supply Transformer) Ion Thruster PPU Model (with Beam Supply Transformer) MPD Thruster Power Processing Unit (PPU) Model Transmission Line Model AC Switehgear Unit Model Phase Lock Transformer Model Alternator Speed Regulator Model AC Parasitic Load Radiator Model Revised: 5/05/1992 jam INCLUDE "COMMONS.FOR" LOGICAL DEBUG CHARACTER*12 FILIN CHARACTER*12 FILOUT, FILDMP CHARACTER*4 CHARS(18), BLANK NAMELIST/COMTYP/IDCOMP, IDEBUG NAMELIST/INPUTS/CPT , CRTD , RST , AOF, 1 PPIV, PPOV, PPIP, PPAM, PPRM, BOV, DOV, AOV, NOV, RF, 2 IFE, BRE, BFE, DTE, DRE, DFE, ATE, ARE, AFE, NTE, NRE, NFE, 3 BTE, DT1E, DT2E, NT1E, NT2E, TE, RE, OFE, 4 TLOP , TLOV , TLL , ATC , RTC , NOB , LPF , TLE, 5 NIRB, NORB, ORBOP, ORBOV, RBE, SWAM, SWRM, 6 APO, AVO, PTAM, PTPP, PTRM, TSE, 7 SRAM, SRRM, NSS, SRF, PWMF, BCE, SSE, EFE, 8 PPD , PIV , APM , RPM , PWOT , WRTD , PST , & NRC , RCRF , NR , NRTC , ND , CCD NAMELIST/INPMAD/CPT , CRTD , RST , AOF, o PMADPO, PPUVI, APC, RPC, NAC, NTC, KRA, IDPPU, 1 PPOV, PPAM, PPRM, BOV, DOV, AOV, NOV, RF, 2 WE, BRE, BFE, DTE, DRE, DFE, ATE, ARE, AFE, NTE, NRE, NFE, 3 BTE, DTiE, DT2E, NT1E, NT2E, TE, RE, OFE, 4 PSTLL, PSATC, PSRTC, PSNOB, PSLPF, PSTLE, b SSTLL, SSATC, SSRTC, SSNOB, SSLPF, SSTLE, e SATLL, SAATC, SARTC, SANOB, SALPF, SATLE, d SPTLL, SPATC, SPRTC, SPNOB, SPLPF, SPTLE, 5 RILE, SWAM, SWRM, 6 PTAM, PTPP, PTRM, TSE, 7 SRAM, SRRM, NSS, SRF, PWMF, BCE, SSE, EFE, 8 APM, RPM, PWOT, WRTD, PST, NrR, NRTC, ND, CCD DATA BLANK/' '/ 105 DATA IDCOMP/1/, IDEBUG/1/ C C C****** read inputs from a data file ******* C CALL SYSTEM ("CLS") CALL SYSTEM ("DIR/W *.*") 100 WRITE (*,*) 'Name of local input data file? READ (%99001) FILIN C C PRINT MAIN HEADER TO SCREEN C CALL SYSTEM ("CLS") WRITE (*, I000) 1000FORMAT(' iT , , , 2 ' 3 ' II I I I PMAD Component' 4 '& Systems Model [ I ]II '/ 5 ' II I I I RockwenInternaC 6 'ional Corporation IIIII '/ 7 'lllll Rocketdyne' 8 'Division Iltll */ 9 ' II I I I Ken Metcalf, ' o '(818) 586-3976 IIIII '/ 1 '11111 Revised:' 2 '05May92 [ I [ [I '/ 3 '1111 _ 4 ' 5 I I I II _/ ill 5 '111 I 5 7 '11 _ WRITE (*, 1002) 1002 FORMAT (' it 2 ' C C C Open Files for Input, output, and dump(debug purpose) data i ......... OPEN (10,FILE = FILIN,FORM = 'FORMATrED',STATUS = 'OLD',ERR = 200) REWIND 10 JP = index(FILIN,'.') IF (JP .EQ. 0) JP = index('FILIN,' ') IF (JP .GT. 9) JP = 9 FILOUT(I:JP-1) = FILIN(I:JP-1) FILOUT(JP:JP + 3) ='.out' OPEN (13,FILE= FILOUT) REWIND 13 FILDMP(1 :_P-1) = FILIN(1 :]P-l) FILDMP(J-P:J]'+3) = 'Amp' OPEN (UNIT = 11,FILE = FILDMP) REWIND 11 GOTO 300 200 WRITE (*,*) 'ERROR IN OPENING FILE OR FILE NOT EXIST', FILIN WRITE (*,*) ' TYPE 1 TO CONTINUE AND 0 TO END.' II'/ III" Ill ') w 7//) 106 READ (*,*) KONT IF ( KONT.EQ.0 ) GOTO 400 GOTO 100 300 READ (10,320) (CHARS(I)J= 1,18) 320 FORMAT (18A4) IF (CHARS(I).EQ.'NAME') GO TO 350 IF (CHARS(1).EQ.'STOP' .OR. CHARS(1).EQ.'stop') GOTO 370 IF (CHARS(1).EQ.BLANK) GO TO 300 350 READ (IO,COMTYP) iv (IDCOMP.NE.0) READ (10JNPUTS) IF (IDCOMP.EQ.0) READ (10,INPMAD) IF ( IDCOMP.EQ.0 ) CALL PMAD iv ( IDCOMP.EQ. 1 ) CALL IF ( IDCOMP.EQ.2 ) CALL IF ( IDCOMP.EQ.3 ) CALL IF ( IDCOMP.EQ.4 ) CALL IF ( IDCOMP.EQ.5 ) CALL IF ( IDCOMP.EQ.6 ) CALL IF ( IDCOMP.EQ.7 ) CALL IONPU 1 IONPU2 MPDPPU LWTRL_ ACSWGR TRNFMR SPDREG IF ( IDCOMP.EQ.8 ) CALL ACPLR C C C C C C C C Output TO SCREEN & FILE ID#13 CALL PRINTO (IDCOMP) Parameter Dump To File 11 DEBUG = .FALSE. IF ( IDEBUG.NE.0 ) DEBUG = .TRUE. IV ( DEBUG ) THEN WRITE (I1,99004) WRITE (II,COMTYP) WRITE (I1,INPUTS) WRITE (11,INPMAD) ENDIF GOTO 300 370 CONTINUE CLOSE (10) C OPTION TO RUN ANOTHER CASEC C C C C WRITE (*,*) ' TYPE 1 TO CONTINUE AND 0 TO END.' READ (*,*) KONT IF ( KONT.NE.0 ) GOTO 100 400 WRITE (*,99002) FILOUT IF (DEBUG) WRITE (*,99003) FILDMP CLOSE (II) CLOSE (13) 99001 FORMAT (A12) 99002 FORMAT (/IX,' Output File: ',A12/) 107 99003 FORMAT (/1X,'Debug Input Print: ',A12/) 99004 FORMAT (//lX, 'INPUT NAMELIST:') END C @@@_b@@@@@@@@O@@@@@@@@@@@@@@@@llt4tt#@*@@@@@'l*@@@@_@@@@@@@@_O@@*@O*@_@_l'*_* BLOCKDATA PUINIT C C 4/16/92 C Default Values C C C C C C C C C C C C C C C C C C C C C C C C INCLUDE "COMMONS.FOR" Default Values for PMAD system DATA PM,M)PO/30000./,PPUVI/5000./, APC,RPC/2*3./, NAC/2./, NTC/4./, & KRA/1/, IDPPU/1 / & PSATC/1./,PSRTC/1./,PSTLL/10./,PSLPF/.9/,PSNOB/7./,PSTLE/.85/, & SSATC/1./,SSRTC/1 ./,SSTLL/5./,SSLPF/.9/,SSNOB/7./,SSTLE/.85/, & SAATC/1./,SARTC/1./,SATLL/150./,SALPF/.9/,SANOB/7./,SATLE/.85/, & SPATC/48./,SPRTC/40./,SPTLLIlO./,SPLPF/.9/,SPNOB/1./,SPTLE/.85/ Primary User Input Parameters for power processing units DATA CPT/100./, CRTD/16.67/, RST/247.67/, AOF/0.8/ DATA PPIP/2500./, PPAM/1./, PPRM/1./, BOV/1800./, DOV/30./, & AOV/500./, NOV/20./, RF/0.05t DATA PPIV/5000./, PPOV/300./ Secondary Primary Input Parameters for PPU DATA IFE/0.995/, BRE/0.98/, BFE/0.995/, DTF_J0.99/, & DRE/0.9725/, DFE/0.992/, ATE/0.99/, ARE/0.98/, & AFE/0.995/, NTE/0.99/, NRE/0.955/, NFE/0.99/ DATA BTE/0.99I , DTIE , DT2E/2*0.99/, N-TIE , NT2E/2*0.99/ DATA TE/0.99/ , REI0.98/ , OFF_,/0.995/ Default Inputs for Transmission Line Module DATA TLOP/5000./, TLOV/1367./, ATC,RTC/2*I./, TLE/.9800/ DATA TLL/i50./, LPF/.9/, NOB/7./ User Input Parameters for AC Switehgear Unit ..... DATA NIRBI2.1, NORB/4./, ORBOP/2500./, ORBOV/5000./ DATA RBE/0.9985/, SWAM/1./, SWRM/1./ User Input Parameters for Phase Lock Transformer DATA APO,AVO/2*5000./, PTPP/0.02/, PTAM/1./, PTRM/I./, TSE/0.99/ User Input Parameters for alternator Speed Regulator model DATA SRAMII./, SRRM/1./, NSSI40,/, SRF/1.2/ DATA PWMF/20./, BCE/0.9965/, SSF_J0.9945/, EFE/0.9993/ User Input Parameters for AC Parasitic Load Radiator Model 108 CDATA PPDI5000./, PIVI5000.1,APMII.I, RPMII./, & PWOT/1255./, WRTDII00./, PST/247.67/ DATA NRC/40./, RCRF/I.2/, NR/I.0806E-02/, NRTC/0.00011/, & ND/8.4296/, CCD/1.66/ END F 109 C COMMONS.FOR C 4/14/92 C REAL NSS REAL NOB, LPF REAL IRBIP, IRBIV, IRBM, IRBOP, IRBOV, NIRB, NORB REAL ND , NR, NRC , NRTC REAL IFE , NFE , NOV, NRE , NTE , NT1E , NT2E REAL NAC, NTC COMMON/INALL / CPT, CRTD, RST, AOF COMMON/PMADI/PMADPO, PPUVI, &PC, RPC, NAC, NTC, KRA, IDPPU COMMON/PMADO/EEPE, TERA, TPCM, TILM, TERM, TPM, TPSM C C COMMON/PPUIN/PPIP, PPAM, PPRM, RF, IFE COMMON/PPUI12/BOV, DOV, AOV, NOV, ATE, ARE, AFE, BRE, BFE, 2 DRE, DFE, NRE, NFE COMMON/PPUI1/ DTE ,NTE COMMON/PPUI2/ BTE , DT1E , DT2E , NT1E , N'r2E COMMON/PPU 123/PPIV COMMON/PPUI3/PPOV, TE, RE, OFE COMMON/PPUOUT/PPM, PPSM, PPMR, PPSMR, PPE, PPBE, PPOP, & PPRAM, PPRA, PPCACV, PPCACH, PPCACW, PPCACL COMMON/TRANIO/TLOP, TLOV, TLL, ATC, RTC, NOB, LPF, o CM, TLIP, TLIV , CIOR, CAST, TLCT, TLE, PF COMMON/TRANSI.I 1 PSTLOP PSTLOV, PSTLL, PSATC, PSRTC, PSNOB, PSLPF, & PSTLM PSTLIP, PSTLIV, PSCAOR, PSCAST, PSTLCT, PSTLE, PSPF, 2 SSTLOP. SSTLOV, SSTLL, SSATC, SSRTC, SSNOB, SSI.PF, & SSTLM SSTLIP, SSTLIV, SSCAOR, SSCAST, SSTLCT, SSTLE, SSPF, 3 SATLOP SATLOV, SATLL, SAATC, SARTC, SANOB, SALPF, & SATLM SATLIP, SATLIV, SACAOR, SACAST, SATLCT, SATLE, SAPF, 4 SPTLOP SPTLOV, SPTLL, SPATC, SPRTC, SPNOB, SPLPF, & SPTLM SPTLIP, SPTLIV, SPCAOR, SPCAST, SPTLCT, SPTLE, SPPF COMMON/ACSWIO/NIRB, NORB, ORBOP, ORBOV, RBE, SWAM, SWRM, o IRBIP, IRBIV, IRBM, IRBOP, IRBOV, ORBM, & XRBIP, XRBIV, XRBM, XRBOP, XRBOV, o SWM, SWSM, SWMR, SWSMR, SWE & , SWRAM, SWRA, SWCACV, SWCACH, SWCACW, SWCACL COMMON/']RNREG/APO, AVO COMMON/TRNFIO/PTAM, PTPP, PTRM, TSE, o PTM, PTSM, PTMR, PTSMR, PTE & , PTRAM, PTRA, PTCACV, PTCACH, PTCACW, PTCACL COMMON/SREGIO/SRAM, SRRM, NSS, SRF, PW/vlF, BCE, SSE, EFE, o SPO, SVO, SRM, SRSM, SRMR, SRSMR, FSE & , SRRAM, SRRA, SRCACV, SRCACH, SRCACW, SRCACL COMMON/RADIO / PPD, PIV, APM, RPM, PWOT, WRTD, PST, i NR, NRTC, ND, CCD, i NRC, RCRF, o TPLRA, TPLRM , TPLRSM 110 i L i li I _ C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C SUBROUTINE PRINTO (IDCO_ --j--- PRINT OUTPUT FOR KEN METCALF'S PMAD system & component MODELS TO SCREEN ID#6 & FILE ID#13 IDCOMP = 0: IDCOMP = I: IDCOMP = l: IDCOMP = 2: IDCOMP = 3: IDCOMP = 4: IDCOMP = 5: IDCOMP = 6: IDCOMP = 7: IDCOMP = 8: End-to-End NEP PMAD System Model Ion Thruster PPU Model (w/o Beam Supply Transformer) Ion Thruster PPU Model (w/oBeam Supply Transformer) Ion Thruster PPU Model (with Beam Supply Transformer) MPD Thruster Power Processing Unit (PPU) Model Transndssion Line Model AC Switchgear Unit Model Phase Lock Transformer Model Alternator Speed Regulator Model AC Parasitic Load Radiator Model Revised: 17 Apr 92 (JAM) INCLUDE "COMMONS.FOR" CHARACTER* 1 PAGF CHARA_*20 PPUTYP(3) LOGICAL OFILE DATA ISCRN/6/, IFILO/13/ DATA IPRT/0/ DATA PPUTYP/'Ion w/o Transformer', 'Ion w/Transformer ', & ' MPD '/ PAGF = CHAR(12) PAGF = '1' 1PRT = IPRT + 1 IF (IPRT .GT. 1) WRITE (13,99049) PAGF OUTPUT TO SCREEN(IU=6) THEN TO FILE #13 OFILE = .FALSE. IU=13 DO 200 IU=6,13,7 IF (IU.EQ. 13) OFILE = .TRUE. WRr_ (IU,0O050) WRITE (IU,99051) IF (IDCOMP.EQ.0 )WRITE (IU,99000) IF ( IDCOMP.EQ.1 ) WRITE (IU,99001) IF ( IDCOMP.EQ.2 ) WRITE (IU,99002) IF ( IDCOMP.EQ.3 ) WRITE (1"U,99003) IF ( IDCOMP.EQ.4 ) WRITE (1-0,99004) IF (IDCOMP.EQ.5) WRITE: (111,99005) IF ( IDCOMP.EQ.6 ) WRITE (IU,99006) IF ( IDCOMP.EQ.7 ) WRITE (IU,99007) IF ( IDCOMP.EQ.8 )WRITE (IU,99008) 111 CC C C C C WRITE (R1,99052) OU'I_UTS FOR End-to-End NEP PMAD System Model & IF (IDCOMP .EQ. 0) THEN IF (IDPPU.NE. 1) WRITE (IU,99059) PPUVI WRITE (1U,99060) PMADPO, AOF, APC, RPC, NAC, NTC, KRA, PPUTYP(IDPPU) WRITE 0U,99019) CPT, CRTD, RST WRITE (IU,99075) TERA,TERM,TPCM,TI'I.aM,TPM,TPSM,EEPE*100. WR/TE (RL_205D IF (OFILE) WRITE (13,99049) PAGF WRITE (IU,99050 WRITE (]U,99007) wRrrE 0u,9905 D WRITE (IU,99017) SRAM, SRRM, APO, AVO, NSS, SRF*I00., & PWMF, BCE*100., SSE*100., EFE*100. WRITE (IU,99027) SRM, SRSM, SRMR, SRSMR, FSE*100. WRITE (IU,99030) SRRAM, SRRA, SRCACV, SRCACH, SRCACW, SRCACL WRITE (IU,99037) SPO, SVO WRITE 0U,99051) WRITE (IU,99073) WRITE (IU,O00SD WRITE (IU,99074) 4 SPTLOP, SP'IT,OV, SPTLL, SPATC, SPRTC, SPNOB, SPLPF, & SPTLIP,StrI'I.JV, SPTLM, SPCJOR,SPCJST,S/r[T,Cr, SPTLE*100.,SPPF WRITE (IU,99051) i o IF (OFILE) WRITE (13,99049) PAGF wRrrE (IU,9905D WRITE (IU,9900S) WRITE (IU,9905D WRITE (IU,99018) PPD, PIV, APM, RPM, PWOT, WRTD, PSI', NRC, RCRF*100., NR, NRTC, ND, CCD, TPLRA, TPLRM, TPLRSM WRITE (IU,9905 D IF (KRA.EQ. 1) THEN WRITE (IU,990_) WRITE 0U,9905D WRITE (IU,99016) PTAM,PTRM,APO,AVO,PTPP*100.,TSE*100. WRITE (IU,99026) PTM, PTSM, PTMR, PTSMR, PTE*100. WRITE (IU,99030) PTRAM,PTRA,PTCACV,PTCACH,PTCACW,PTCACL WRrI'E (IU,99051) ENDIF IF (OFILE)WRITE WroTE 01.1,99051) WRITE (IU,99072) WRITE fru,goo50 WRITE (113,99074) ,SATLIP, SATLIV, wRrrE (tO,00051) WRITE (IU,99071) WRITE (IU,9905 D (13,99049) PAGF SATLOP,SATLOV, SATLL,SAATC, SARTC, SANOB,SALPF SATLM, SACJOR,SACJST, SATLCT,SATLE* 100., SAPF 112 !! m il = = l | i C C C C C 2 WRITE 0U,99074) SSTLOP,SSTLOV,SSTLL, SSATC,SSRTC,SSNOB,SSLPF ,SSTLIP,SSTLIV, SSTLM, SSCJOR,SSCJST,SSTLCT,SSTLE*100.,SSPF WRrTE t_,99050 IF (OF1LE) WRITE (13,99049) PAGF WRITE (IU,99051) WRrrE 0-0,99005) wRrr'E 0u,99051) WRITE (II3,99015) SWAM,SWRM,NIRB,NORB,RBE*100.,ORBOP, ORBOV WRITE (IU,99035) XRBIP, XRBIV WRITE 0U,99025) SWM, SWSM, SWMR, SWSMR, SWE*100. WRITE (IU,99030) SWRAM,SWRA,SWCACV,SWCACH,SWCACW,SWCACL wRrrE 0U,99051) WrUTE frO,99070) WRITE (r0,9905 0 WRITE 0U,99074) PSTLOP,PSTLOV,PSTLL, PSATC,PSRTC,PSNOB,PSLPF ,PSTLIP,PSTLIV, PSTLM, PSCJOR,PSCJST,PSTLCT,PSTLE*100.,PSPF WRITE (ro,_051) & & & & & IF (OFILE) WRITE (13,99049) PAGF WRrr'E 0-0,99051) IF (IDPPU.EQ.I) WRITE 0I3,99001) IF (IDPPU.EQ.2) WRITE (IU,99002) IF 0DPPU.EQ.3 ) WRITE 0"I3,99003) WRITE (1U,99051) WRITE (IU,99061) PPAM, PPRM, IFE*100., RF*100. IF 0DPPU.EQ.3) THEN WRITE 0U,99065) TE*100.,RE*100.,OFE*100., PPIP,PPIV,PPOV, PPOP ELSE WRITE (1'U',99062) BOV,DOV,AOV,NOV, ARE* 100. ,AFE* 100. ,ATE* 100., BRE* 100. ,BFE* 100. ENDIF IF (I'DPPU.EQ. 1) WRITE (IU,99063) DRE*100.,DFE*100.,DTE*I00., NRE*100. ,NFE*I00.,NTE*100.,PPIP,PPIV,PPOP IF (IDPPU.EQ.2) WRITE (IU,99064) BTE*100., DRE* 100.,DFE* 100.,DTI E* 100.,DT2E* I00., NRE*100. ,NFE*100.,NT1E*100.,NT2E*100., PPIP, PP1V,PPOP WRITE 0U,99020) PPM, PPSM, PPMR, PPSMR, PPE*100. IF (IDPPU.NE.3) WRITE 0"U,99021) PPBE*100. WRITE (IU,99030) PPRAM, PPRA, PPCACV, PPCACH, PPCACW, PPCACL ENDIF OUTPUTS FOR Ion POWER PROCESSING UNIT w/o Beam Supply Transformer IF (IDCOMP .EQ. 1) THEN WRITE 0-0,99009) AOF, PPIP WRITE (IU,99061) PPAM, PPRM, IFE*100., RF*I00. WRITE 013,99062) BOV,DOV,AOV,NOV, & ARE* 100.,AFE* 100.,ATE* 100., BRE*100.,BFE*I00. WRITE (1U,99063) DRE*100.,DFE*100.,DTE*100. & ,NRE*100.,NFE*100.,NTE*100., PPIP, PPIV,PPOP WRITE (1"U,99019) CPT, CRTD, RST WRITE 0U,99020) PPM, PPSM, PPMR, PPSMR, PPE*100. 113 C C C C C C C C C C C C C C C WRITE 0-U,99021) PPBE*100. WRITE (11.1,99030) PPRAM, PPRA, PPCACV, PPCACH, PPCACW, PPCACL ENDIF OUTPUTS FOR Ion POWER PROCESSING UNIT with Beam Supply Transformer IF (IDCOMP .EQ. 2) THEN WRITE (IU,99029)PPIV WRITE (IU,99009)AOF, PPIP WRITE (IU,99061) PPAM, PPRM, IFE*I00., RF*100. WRITE (IU,99062) BOV,DOV,AOV,NOV, & ARE*100., AFE* 100. ,ATE* 100., BRE*100. ,BFE* 100. WRITE (IU,99064) BTE*100., & DRE*100.,DFE*100.,DT1E*100.,DT2E*100., & NRE* 100. ,NFE*100. ,NT1 E* 100. ,NT2E* 100., PPIP, PPIV, PPOP WRITE (IU,99019) CPT, CRTD, RST WRITE 0U,99020) PPM, PPSM, PPMR, PPSMR, PPE*100. WRITE (IU,99021) PPBE*I00. WRITE (IU,99030) PPRAM, PPRA, PPCACV, PPCACH, PPCACW, PPCACL ENDIF OUTPUTS FOR MPD POWER PROCESSING UNIT IF ( IDCOMP.EQ.3 ) THEN WRITE (IU,99029) PPIV WRITE (IU,99009) AOF, PPIP WRITE (IU,99061) PPAM, PPRM, IFE*100., RF*100. WRITE 0U,99065) TE*100.,RE*100.,OFE*100.,PPIP, PPIV,PPOV,PPOp WRITE (IU,99019) CPT, CRTD, RST WRITE (IU,99020) PPM, PPSM, PPMR, PPSMR, PPE*100. WRITE (IU,99030) PPRAM, PPRA, PPCACV, PPCACH, PPCACW, PPCACL ENDIF PRINT OUTPUTS FOR Transmission Line Model IF (IDCOMP .EQ. 4) THEN WRITE (IU,99014) AOF WRITE (IU,99074) TLOP,TLOV,TLL,ATC,RTC,NOB,LPF, o TLIP, TLIV , CM, CJOR , CIST, TLCT, TLE*100. , PF ENDIF PRINT OUTPUTS FOR AC SWITCHGEAR UNIT IF (IDCOIVIP .EQ. 5) THEN WRITE (IU,99015) SWAM,SWRM,NIRB,NORB,RBE*100.,ORBOP, ORBOV WRITE (IU,99019) Cl:q', CRTD, RST WRITE (IU,99025) SWM, SWSM, SWMR, SWSMR, SWE*100. WRITE (IU,99030) SWRAM, SWRA, SWCACV, SWCACH, SWCACW, SWCACL ENDIF PRINT OUTPUTS FOR Phase Lock Transformer Model IF ODCOMP .EQ. 6) THEN WRITE (IU,99014) AOF WRITE (IU,99016) PTAM, PTRM, APO, AVO, PTPP*100., TSE*100. 114 _i i C C C C C C C C C WRITE 0U,99019) CPT, CRTD, RST WRITE (IU,99026) PTM, PTSM, PTMR, PTSMR, PTE*100. WRITE (1"U,99030) PTRAM, PTRA, PTCACV, PTCACH, PTCACW, PTCACL ENDIF PRINT OUTPUTS FOR Alternator Speed Regulator Model IF (IDCOMP .EQ. 7) THEN WRITE (IU,99017) SRAM, SRRM, APO, AVO, NSS, SRF*100., & PWMF, BCE*100., SSE*100., EFE*100. WRITE (1U,99019) CPT, CRTD, RST WRITE 0TI,99027) SRM, SRSM, SRMR, SRSMR, FSE*100. WRITE (IU,99030) SRRAM, SRRA, SRCACV, SRCACH, SRCACW, SRCACL ENDIF PRINT OUTPUTS FOR AC Parasitic Load Radiator Model IF (IDCOMP .EQ. 8) THEN WRITE 0U,99018) PPD, PIV , APM, RPM, PWOT, WRTD, PSI", i NRC , RCRF*100. , NR, N-RTC , hiD, CCD , o TPLRA, TPLRM, TPLRSM ENDIF PRINT OUTPUTS FOR ALL INDIVIDUAL MODELS WRITE 011,99051) C200 CONTINUE RETURN C C 99049 FORMAT (A1) 99050 FORMAT (1H 1) 99O51 FORMAT ( 99052 FORMAT ( &7X,'* *'I &7X,'* Rockwell International Corporation *'/ &7X,'* Rocketdyne Division *'/ &7X,'* Revised: 17 Apr 92 *'/ 99000 FORMAT ( &7X,'* An End-to-End NEP PMAD System *'/ &TX,'* (Radiator Designed for LEO) *') 99001 FORMAT ( &7X,'* Ion Thruster Power Processing Unit (PPU) *'/ &7X,'* (w/o Beam Supply Transformer) *'/ &TX,'* (Radiator Designed for LEO) *') 99002 FORMAT ( &7X,'* Ion Thruster Power Processing Unit (PPU) *'/ &7X,'* (with Beam Supply Transformer) *'/ &'IX, '* (Radiator Designed for LEO) *') 99003 FORMAT ( &7X,'* MPD Thruster Power Processing Unit OaPU) *'/ &7X,'* (Radiator Designed for LEO) *') 115 99004 FORMAT ( &7X,'* Transmission Line Design *') 99O70 FORMAT( &7X,'* PPU-to-Switchgear TRANSMISSION LINE 99071 FORMAT( &7X,'* Switchgear-to-Switchgear TRANSMISSION LINE 99072 FORMAT( &7X,'* Alternator-to-Switchgear TRANSMISSION LINE 99073 FORMAT( &7X,'* Shunt-Regulator-to-PLR TRANSMISSION LINE 99005 FORMAT ( &7X,'* AC Switchgear Unit *'/ &7X,'* (Radiator Designed for LEO) *') 99006 FORMAT ( &7X,'* Phase Lock Transformer *'/ &TX,'* (Radiator Designed for LEO) *') 99007 FORMAT ( &7X,'* Alternator Speed Regulator *'/ &7X,'* (Radiator Designed for LEO) *') 99008 FORMAT ( &TX,'* AC Parasitic Load Radiator (PLR) *'/ &7X,'* (Radiator Designed for LEO) *') 99059 FORMAT ( &7X,'Power Processing Unit Input Voltage ....... ',F9.2,' Vrms') 99060 FORMAT ( &7X,'PMAD System Power Output ................... ',F9.3,' kwe'/ &7X,'Alternator Operating Frequency ............ ',F9.3,' kHz'/ &7X,'Available PMAD Channels .................. ',F9.0/ &7X,'Required PMAD Channels ................... ',F9.0/ &7X,'Number of Alternators per PMAD Channel ..... ',Fg.0/ &7X,'Number of Thrusters per PMAD Channel ....... ',Fg.0/ &7X,'Counter Rotating Alternators Flag7 (1 _Yes) ',I9/ &7X,'Type of Power Processing Unit? ............ ',A20) 99061 FORMAT (/ &7X,'PPU Available Modules ..................... ',F9.0/ &7X,'PPU Required Modules ...................... ',F9.0/ &7X,'PPU Input Filter Efficiency ................ ',F9.2,' %'/ &7X,'Ripple Factor ............................. ',F9.2,' _') 99062 FORMAT ( &7X,'Beam Supply Output Voltage ................ ',F9.2,' Vdc'/ &7X,'Discharge Supply Output Voltage ........... ',F9.2,' Vdc'/ &7X,'Accelerator Supply Output Voltage ......... ',F9.2,' Vdc'/ &7X,'Neutralizer Supply Output Voltage ......... ',F9.2,' Vdc'/ &7X,'Accelerator Power Supply Rectifier Effi ..... ',F9.2,' _'/ &7X,'Accelerator Power Supply Filter Efficiency . ',F9.2,' %'/ &7X,'Accelerator Power Supply Transformer Effi... ',F9.2,' % '/ &7X,'Beam Power Supply Rectifier Efficiency ... ',F9.2,' %'/ &7X,'Beam Power Supply Filter Efficiency ....... ',F9.2,' %') 99O63 FORMAT ( &7X,'Discharge Power Supply Rectifier Efficiency ',F9.2,' %'/ &7X,'Discharge Power Supply Filter Efficiency ... ',F9.2,' %'/ &7X,'Discharge Power Supply Transformer Effi ..... ',F9.2,' %'/ &7X,'Neutralizer Power Supply Rectifier Effl ..... ',F9.2,' %'/ &7X,'Neutralizer Power Supply Filter Efficiency ',F9.2,' %'/ &7X,'Neutralizer Power Supply Transformer Effi... ',F9.2,' %'/ ,,) *') *') *') 116 &7X,'PPU Input Power Level ..................... ',F9.3,' kwe'// &7X, 'PPU Input Voltage Level ................... ',F9.2,' Vrms'/ &7X,'PPU Output Power Level .................... ",F9.3,' kwe'/) 99O64 FORMAT ( &7X,'Beam Power Supply Transformer Efficiency ... ',F9.2,' %'/ &7X,'Discharge Power Supply Rectifier Effi ....... ',F9.2,' _ '/ &7X,'Discharge Power Supply Filter Efficiency ... ',F9.2,' %'/ &7X,'Discharge Power Supply Transformer #1 Effi.. ',F9.2,' %'/ &7X,'Discharge Power Supply Transformer #2 Effi.. ',F9.2,' %'/ &TX,'Neutralizer Power Supply Rectifier Effi ..... ',F9.2,' %'/ &7X,'Neutralizer Power Supply Filter Efficiency. ',F9.2,' %'/ &7X,'Neutralizer Power Supply Transformer #1 Effi ',F9.2,' %V &TX,'Neutralizer Power Supply Transformer #2 Effi ',F9.2,' %'/ &7X,'PPU Input Power Level ..................... ',F9.3,' kwe'/ &7X,'PPU Input Voltage Level ................... ',F9.2,' Vrms'// &7X,'PPU Output Power Level .................... ',F9.3,' kwe'/) 99O65 FORMAT ( &7X,'Transformer Efficiency .................... ',F9.2,' %'/ &7X,'Rectifier Efficiency ...................... ',F9.2,' %'/ &7X,'Output Filter Efficiency .................. ',F9.2,' _'/ &7X,'PPU Input Power Level ..................... ',F9.3,' kwe'/ &7X,'PPU Input Voltage Level ................... ',F9.2,' Vrms'/ &7X,'PPU Output Voltage Level .................. ',F9.2,' Vrms'// &7X,'PPU Output Power Level .................... ',F9.3,' kwe'/) 99074 FORMAT ( &7X,'Transmission Line Output Power Level ....... ',F9.3,' kWe'/ &7X,'Transmission Line Output Voltage ........... ',F9.2,' Vrms'/ &7X,'Transmission Line Length ................... ',F9.2,' m'/ &7X,'Available Transmission Circuits ........... ',F9.0/ &7X,'Required Transmission Circuits ............ ',F9.0/ &7X 'Number of Bundles ......................... ',F9.0/ &7X 'Load Power Factor .......................... ',F9.2// &7X 'Transmission Line Input Power .............. ',F9.3,' kWe'/ &7X 'Transmission Line Input Voltage ............ ',F9.2,' Vrms'// &7X 'Transmission Line Mass ..................... ',F9.3,' kg'/ &7X 'Cable Jacket Outer Radius ................. ',F9.4,' cm'/ &TX 'Cable Jacket Surface Temperature ........... ',F9.2,' K'/ &7X 'Transmission Line Conductor Temperature .... ',F9.2,' deg C'/ &7X 'Transmission Line Efficiency ............... ',F9.2,' %'/ &7X 'Circuit Power Factor ...................... ',F9.4/) 99O75 FORMAT ( &7X 'Total Electronics Radiator Area ........... ',F9.4,' m2'/ &TX &TX &7X &TX &7X &TX 'Total Electronics Radiator Mass ........... ',F9.3,' kg'/ 'Total Power Conditioning Component Mass . ',F9.3,' kg'/ 'Total Transmission Line Mass .............. ',F9.3,' kg'/ 'Total PMAD System Mass .................... ',F9.3,' kg'/ 'Total PMAD System Specific Mass ........... ',F9.4,' kg/kWe'/ 'End-to-End PMAD System Efficiency ........ ',F9.2,' 9_'/) 99029 FORMAT ( &TX,'Power Processing Unit Input Voltage Level .. ',F9.2,' Vrms') 99009 FORMAT ( &7X,'Power Processing Unit Available Modules .... ',F9.0/ &TX,'Power Processing Unit Required Modules .... ',F9.0/ &TX,'Alternator Operating Frequency ............ ',F9.3,' kHz'/ 117 &TX,'PPU Input Power Output Level .............. ',F9.3,' kwe'/ &TX,'Ripple Factor ............................. ',F9.2,' %') 99010 FORMAT ( &TX,'Beam Supply Output Voltage ................ ',F9.2,' Vdc'/ &TX,'Discharge Supply Output Voltage ........... ',F9.2,' Vdc'/ &TX,'Accelerator Supply Output Voltage ......... ',F9.2,' Vdc'/ &7X,'Neutralizer Supply Output Voltage ......... ',F9.2,' Vdc') 99011 FORMAT ( &TX,'PPU Input Filter Efficiency ................ ',F9.2,' %'/ &7X,'Beam Power Supply Rectifier Efficiency ... ',F9.2,' %'/ &7X,'Beam Power Supply Filter Efficiency ....... ',F9.2,' % '/ &TX,'Discharge Power Supply Transformer Effi ... ',F9.2,' %'/ &TX,'Discharge Power Supply Rectifier Efficiency ',F9.2,' %'/ &7X,'Discharge Power Supply Filter Efficiency ... ',F9.2,' %'/ &TX,'Accelerator Power Supply Transformer Effi... ',F9.2,' %'/ &TX,'Accelerator Power Supply Rectifier Effi ..... ',F9.2,' %'/ &TX,'Accelerator Power Supply Filter Efficiency ',F9.2,' %'/ &TX,'Neutralizer Power Supply Transformer Effi... ',F9.2,' %'/ &TX,'Neutralizer Power Supply Rectifier Effi ..... ',F9.2,' %'/ &TX,'Neutralizer Power Supply Filter Efficiency ',F9.2,' %') 99014 FORMAT ( &TX,'Alternator Operating Frequency ............ ',F9.3,' kHz') 99015 FORMAT (/ &TX,'Switchgear Available Modules .............. ',F9.0/ &TX,'Switchgear Required Modules ............... ',F9.0/ &7X,'Number of Input Remote Bus Isolators (RBIs) ',F9.0/ &7X,'Number of Output RBIs ...................... ',F9.0/ &7X,'RBI Unit Efficiency at 100 deg C .......... ',F9.2,' % '/ &TX,'Output RBIs Output Power Level ............ ',F9.3,' love'/ &7X,'output RBIs Output Voltage Level .......... ',F9.2,' Vrms') 99035 FORMAT (/ &7X,'Switchgear Cross Tie RBI Input Power ....... ',F9.3,' kWe'/ &7X,'Switchgear Cross Tie RBI Input Voltage ..... ',F9.2,' Vrms') 99018 FORMAT (/ &7X,'PLR Power Dissipation Level .............. ",F9.3,' k'we'/ &7X,'Parasitic Load Radiator Input Voltage Level ',F9.2,' Vrms'/ &7X,'Available Parasitic Lead Radiator Modules .. ',F9.0/ &7X,'Required Parasitic Load Radiator Modules .. ',F9.0/ &7X,'PLR Wire Operating Temperature ............ ',F9.2,' K'/ &7X,'Wire to Radiating Surface Temperature Delta ',F9.2,' K'/ &7X,'Parasitic Load Radiator Sink Temperature .. ',F9.2,' K'/ &7X,'Required No. of Nichrome V Circuits ...... ',F9.2/ &7X,'Resistive Circuit Redundancy Factor ....... ',F9.2,' %'/ &7X,'Nichrome V Resistivity ................... ',E9.4, & ' ohm-cm2/m'/ &7X,'Nichrome V Resistivity Temp Coefficient .... ',E9.4,'/deg C'/ &7X,'Nichrome V Density ....................... ',F9.4,' g/cm3'/ &7X,'Carbon-Carbon Density ..................... ',F9.4,' g/era3'// &7X,'Total Parasitic Load Radiator Surface Area ',F9.4,' m2'/ &7X,'Total Parasitic Load Radiator Mass ........ ',F9.3,' kg'/ &TX,'Total Parasitic Load Radiator Specific Mass ',F9.4,' kg/kw'/) 99019 FORMAT ( &7X,'Coldplate Temperature ..................... ',F9.2,' deg C'/ &7X,'Coldplate to Radiator Temperature Delta .... ',F9.2,' deg C'/ &TX,'Radiator Sink Temperature ................. ',F9.2,' K'/) 118 ! i i i I 99020 FORMAT ( &TX,'PPU Mass w/o Radiator ..................... ',F9.3,' kg'/ &7X,'PPU Specific Mass w/o Radiator ........... ',F9.4,' kg/kw'/ &7X,'PPU Mass with Radiator .................... ',F9.3,' kg'/ &TX,'PPU Specific Mass with Radiator ........... ',F9.4,' kg/kw'/ &7X,'PPU Efficiency ............................ ',F9.2,' %') 99O21 FORMAT ( &7X,'PPU Beam Supply Efficiency Measure ......... ',F9.2,' %') 99O25 FORMAT (/ &7X,'Switchgear Unit Mass w/o Radiator ........ ',F9.3,' kg'/ &7X,'Specific Mass w/o Radiator ................ ',F9.4,' kg/kw'/ &7X,'Switchgear Unit Mass with Radiator ........ ',F9.3,' kg'/ &7X,'Specific Mass with Radiator ................ ',F9.4,' kg/kw'/ &7X,'Switchgear Unit Efficiency ................ ',F9.2,' _') 99O16 FORMAT (/ &7X,'Phase Lock Transformer Available Modules ... ',F9.0/ &7X,'Phase Lock Transformer Required Modules .... ',F9.0/ &TX,'Altemator Power Output ................... ',F9.3,' kwe'/ &7X,'Altemator Voltage Output ................. ',F9.2,' Vrms'/ &7X,'Phase Lock Transformer Power Percentage .... ',F9.2,' %'/ &7X,'Transformer Stage Efficiency at 100 deg C ',F9.2,' %') 99026 FORMAT (/ &7X,'Phase Lock Transformer Mass w/o Radiator ',F9.3,' kg'/ &7X,'Transformer Specific Mass w/o Radiator ... ',F9.4,' kg/kw'/ &7X,'Phase Lock Transformer Mass with Radiator .. ',F9.3,' kg'/ &7X,'Transformer Specific Mass with Radiator ... ',F9.4,' kg/kw'/ &7X,'Total Transformer Efficiency .............. ',F9.2,' %') 99017 FORMAT (/ &7X,'Speed Regulator Available Modules ......... ',F9.0/ &7X,'Speed Regulator Required Modules .......... ',F9.0/ &7X,'Alternator Power Output ................... ',F9.3,' kwe'/ &7X,'Altemator Voltage Output ................. ',F9.2,' Vrms'/ &7X,'Number of Shunt Switch Elements ........... ',F9.2/ &7X,'Shunt Redundancy Factor ................... ',F9.2,' % '/ &TX,'Pulse-Width-Modulation Frequency .......... ',F9.3,' kHz'/ &7X,'Bus Conductor Efficiency at 100 C ......... ',F9.2,' %'/ &7X,'Shunt Switch Efficiency at 100 C .......... ',F9.2,' %'/ &TX,'EMI Filter Efficiency at 100 C ............ ',F9.2,' _') 99027 FORMAT (/ &7X,'Speed Regulator Mass w/o Radiator ......... ',F9.3,' kg'/ &7X,'Regulator Specific Mass w/o Radiator ...... ',F9.4,' kg/lcw'/ &7X,'Speed Regulator Mass with Radiator ......... ',F9.3,' kg'/ &7X,'Regulator Specific Mass with Radiator ...... ',F9.4,' kg/kw'/ &7X,'Fully Shunted Efficiency .................. ',F9.2,' _') 99037 FORMAT ( &7X,'Shunt Power Output ........................ ',F9.3,' kwe'/ &TX,'Shunt Voltage Output ...................... ',F9.2,' Vrms'/) 99030 FORMAT (/ &7X,'Radiator Mass .............................. ',F9.3,' kg'/ &7X,'Radiator Area .............................. ',F9.4,' m2'/ &7X,' Complete Assembly Component Volume ......... ',F9.6,' m3'/ &TX,'Complete Assembly Component Height ......... ',F9.2,' m'/ &TX,'Complete Assembly Component Width .......... ',F9.2,' m'/ &7X,'Complete Assembly Component Length ......... ',F9.2,' m'/) END 119 APPENDIX C Ion Power Processing Unit w/o Beam Power Supply Transformer Model 120 == !i I ! i = 7 = g Z = i = SUBROUTINE IONPU 1 REAL IFET , IFM , NCCM , NFET , NFM , NOP, NRET, NRM, NTET, NTM REAL IFE , NFE , NOV , NRE , NTE COMMON/INALL / CPT , CRTD , RST, AOF COMMON/PPUIN/PPIP, PPAM, PPRM, RF, IFE COMMON/PPUI12/BOV, DOV, AOV, NOV, ATE, ARE, AFE, BRE, BFE, 2 DRE, DFE, NRE, NFE COMMON/PPUII/ DTE ,NTE COMMON/PPU123/PPIV COMMON/PPUOUT/PPM, PPSM, PPMR, PPSMR, PPE, PPBE, PPOP & , RAM, RA, CACV , CACH , CACW, CACL C C C C C C C C C Ion Power Processing Unit Model - w/o Beam Power Supply Transformer - Radiator Equations Set for LEO (400 km orbit) - Last Revised: 13 April 92 ten - Author: Ken Metealf, (818) 586-3976 C C Inputs: C PPIP C PPAM C PPRM C BOV C DOV C AOV C NOV C AOF C RF C CPT C CRTD C RST C IFE C ATE C ARE C AFE C BRE C BFE C DTE C DRE C DFE C NTE C NRE C NFE C C Outputs: C PPIV C PPOP C PPM C PPMR C PPSM .......... III_iiI_ _ Power Processing Unit Input Power Level (kWe) Power Processing Unit Available Modules Power Processing Unit Required Modules Beam Supply Output Voltage (Vdc) Discharge Supply Output Voltage (Vde) Accelerator Supply Output Voltage (Vde) Neutralizer Supply Output Voltage (Vde) Alternator Operating Frequency (kHz) Ripple Factor (frac) Coldplate Temperature (deg C) Coldplate to Radiator Temperature Delta (deg (2) Radiator Sink Temperature (deg Kelvin) Power Processing Unit Input Filter Efficiency (frae) Accelerator Power Supply Transformer Efficiency (frac) Accelerator Power Supply Rectifier Efficiency (frae) Accelerator Power Supply Filter Efficiency (frac) Beam Power Supply Rectifier Efficiency (frac) Beam Power Supply Filter Efficiency (frac) Discharge Power Supply Transformer Efficiency (frac) Discharge Power Supply Rectifier Efficiency (frac) Discharge Power Supply Filter Efficiency (frac) Neutralizer Power Supply Transformer Efficiency (frae) Neutralizer Power Supply Rectifier Efficiency (frac) Neutralizer Power Supply Filter Efficiency (frac) Power Processing Unit Input Voltage Level (Vrms) Power Processing Unit Total Output Power (kwe) Power Processing Unit Mass w/o Radiator (kg) Power Processing Unit Mass with Radiator (kg) Power Processing Unit Specific Mass w/o Radiator (kg/kw) 121 C PPSMR C PPE C PPBE C RAM C RA C CACV C CACH C CACW C CACL C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C Power Processing Unit Specific Mass with Radiator (kg/kw) Power Processing Unit Efficiency (frac) Power Processing Unit Beam Supply Effi Measure (frac) Radiator MASS (KG) Radiator Area (m2) Complete Assembly Component Volume (m3) Complete Assembly Component Height (m) Complete Assembly Component Width (m) Complete Assembly Component Length (m) Primary User input Parameters for Ion Power Processing Unit w/o Transformer PPIP --- 2500. PPAM -- 1. PPRM = 1. BOV = 1800. DOV = 30. AOV = 500. NOV = 20. AOF = 0.8 RF = 0.05 CPT = 100. CRTD = 16.67 RST = 247.67 Secondary Primary User input Parameters for Ion Power Processing Unit w/o Transformer ***RECOMMENDED DEFAULT VALUES*** C C C IFE = 0.995 BRE = 0.98 BFE - 0.995 DTE = 0.99 DRE - 0.9725 DFE = 0.992 ATE -= 0.99 ARE = 0.98 AFE -- 0.995 NTE = 0.99 NRE = 0.955 NFE = 0.99 _ZmmmD__mm MAKE SURE REQUIRED MODULES < = AVAILABLE MODULES IF (PPRM .GT. PPAM) PPRM=PPAM Power Supply Stage Efficiency Calculations at Coldplate Temp IFET = 1. - (1.-IFE)*(0'82+0.0018"C_ BRET --- 1. - (I.=BRE)*(0.526+0.00475.cPT) BFET = 1. - (1.-BFE)*(0.82+0.0018*CPT) 122 2C C C C C C C C C C C C C C C C C C C C C C C C C C C DTET DRET DFET ATET ARET AFET NTET NRET NFET =1. = 1. |. -- |. ---- 1. - (1 .-DTE)*(0.89+0.0011*CPT) - (1 .-DRE)*(O.526 +0.00475"CPT) - (1.-DFE)*(0.82 + 0.0018*CPT) - (1.-ATE)*(0.89+0.0011*CPT) - (1 .-ARE)*(0.526 + 0.00475"CPT) - (1 .-AFE)*(0.82 +0.0018*CPT) = I. - (1.-NTE)*(0.89+O.O011*CPT) = 1. - (1.-NRE)*(0.526+0.00475*CPT) = 1. - (1.-NFE)*(0.82+O.0018*CPT) Power Processing Unit Input Voltage Calculation PPIV = BOV/BFET/BRET/1.35flFET Power Processing Unit Control and Monitoring Power Demand EquN CMP = PPAM*79.4*(PPIP/PPRM)**0.i .... Power Processing Unit Efficiency Equations PPE = ((PPIP*IFET-CMP/1000.) & *(0.9629*BRET*BFET + 0.036*DTET*DRET*DFET + & 0.001 .ATET*ARET*AFET + 0.0001 *NTET*NRET*NFET))/PPIP PPBE = 0.9629*PPE PPSE = ((PPIP*IFET) & .(0.9629.BRET*BFET + 0.036 *DTET*DRET*DFET + 0.001 *ATET*ARET* & AFET+0.0001 *NTET*NRET*NFET))/PPIP Power Processing Unit Power Division Equations BOP = PPIP*0.9629*PPE DOP = PPIP*0.036*PPE AOP = PPIP*0.001*PPE NOP = PPIP*0.0001*PPE Power Processing Unit Total Output Power Calculation PPOP = BOP + DOP + AOP + NOP RATIO RATMOD = PPAM/PPRM Power Processing Unit Input Ac Filter Mass Equation IFM = 0.0105*((1.-0.995)/(1.-IFE))*RATMOD*(PPIP*IFZF) & *(ppIP*IFET/PPRM)**(-0.03) *(AOF/20.) **(-0.6) OF AVAILABLE PPU MODULES/REQUIRED PPU MODULES Beam Power Supply Mass Equations BRM = 0.175*((EXP(0.006/(I.-BRE)))/1.35)*RATMOD*(BOP/BFET) & *(BOP/PPRM/BFET) **(-0.04)*(BOV/BFET/(BOV/BFET-2.)) & **7*EXP(BOV/BFET/40000.) BFM = 2.3*(1./(RF/0.01)**0.5)*((I.-0.995)/(1.-BFE)) & *RATMOD*BOP*(BOV**(-0.7) + 0.0015)*(6.7/AOF) 123 C C C C C C C C C C C C C C C C C C Discharge Power Supply Mass Equations DTM = 2.5*((EXP(0.003/(1.-DTE)))/1.35)*RATMOD*(DOP/DFET/DRE_ & *((DOP/PPRM/DFET/DRET) **(-0.25) *EXP(PPIV *IFE_/2000_.) & *EXP(DOV/1.35/DFET/DRET/200000.)*AOF**(-O.47) + (AOF/300.) & **1.4) DRM = 0.175*((EXP(0.006/(1.-DRE)))/1.35)*RATMOD*(DOP/DFET) & *(DOP/PPRM/DFET)**(-0.04) *(DOV/DFET/(DOV/DFET-2.)) & **7*EXP(DOV/DFET/40000.) DFM = 2.3*(1./(RF/0.01)**0.5)*((1.-0.995)/(1.-DFE)) & *RATMOD*DOP*(DOV**(-0.7) +0.0015)*(6.7/AOF) Accelerator Power Supply Mass Equations ArM --2.5 *( (EXP(O. OO3/(1. -ATE) ))/1.3 5)*RA TM OD*( A O P /AFET /ARET) & *((AOP/PPRM/AFET/ARE_**(-0.25) *EXP(PPIV*IFET/200000.) & *EXP(AOV/1.35/AFET/ARET/200000.) *AOF**(-0.47) + (AOF/300.) & **1.4) ARM = 0.175*((EXP(0.006/(I.-ARE)))/1.35)*RATMOD*(AOP/AFET) & *(AOP/PPRM/AFET) **(-0.04) *(AOV/AFET/(AOV/AFET-2.)) & *'7 *EXP(AOV/AFET/40000.) AFM = 2.3*(1./(RF/0.01)**0.5)*((1.-0.995)/(1.-AFE)) & *RATMOD*AOP*(AOV**(-0.7) + 0.0015)*(6.7/AOF) Neutralizer Power Supply Mass Equations NTM = 2.5*((EXP(0.003/(1.-NTE)))/1.35)*RATMOD*(NOP/NFET/NRE'I) & *((NOp/pPRM/NFET/NRET)**(-0.25) *EXP(PPIV *IFET/200000.) & *EXP(NOV/1.35/NFET/NRET/200000.)*AOF**(-0.47) + (AOF/300.) & **1.4) NRM -- 0.175*((EXP(0.006/(1 .-NRE)))/1.35)*RATMOD*(NOP/NFET) & *(NOP/PPRM/NFET) **(-0.04)*(NOV/NFET/(NOV/NFET-2.)) & *'7 *EXP(NOV/NFET/40000.) NFM-- 2.3*(1./(RF/0.01)**0.5)*((1.-0.995)/(1.-NFE)) & *RATMOD*NOP*(NOV**(-0.7) +0.0015)*(6.7/AOF) Power Processing Unit Conductor and Connector Equations FCONV = 0.**0.5/2.)*0.028 BCCM = RATMOD*(FCONV*((BOP*1000,)/BOV) & + FCONV*(((BOP* 1000.)/BFET/BRET/IFET)/PPIV)) DCCM = RATMOD*(FCONV*((DOP*1000.)/DOV) & + FCONV*(((DOP* 1000.)/DFET/DRET/DTET/IFET)/PPIV)) ACCM = RATMOD*(FCONV*((AOP*1000.)/AOV) & + FCONV*(((AOP* 1000.)/AFET/ARET/ATET/IFET)/PPIV)) NCCM = RATMOD*(FCONV*((NOP*1000.)/NOV) & + FCONV*(((NOP* 1000.)/NFET/NRET/NTET/IFEI)/PPIV)) Power Processing Unit Control and Monitoring Mass Equation CMM = PPAM*(2. +2.5*(PPIP/PPRM)**0.3+0.75*(PPIP/PPRM)**0.3) Power Processing Unit Electronics Mass Equation 124 C C C C C C C C C C C C C C C C C C C C C PPEM = IFM + BRM + BFM+ DTM + DRM + DFM + ATM + _+ AFM + NTM + & NRM + NFM + BCCM + DCCM + ACCM + NCCM + CMM Power Processing Unit Volume and Dimension Eqns (Single Module) SMCV = (PPEM/PPAM)/(0.342*1000.) SMCH = 0.7*SMCV**0.3333 SMCW = 1. l*SMCV**0.3333 SMCL -- 1.3*SMCV**0.3333 Power Processing Unit Vol & Dimension Eqns (Complete Assembly) CACV = PPEM/(0.342*1000.) CACH _ SMCH CACW -- PPAM*SMCW CACL ffi SMCL Power Processing Unit Enclosure Equations SMCPEM = 44.26*SMCV**0.6666 + 10.25*(SMCL*SMCW) CACPEM = PPAM*SMCPEM Power Processing Unit Radiator Equations RA = RATMOD*(1.48E+ 10*(PPIP-PPIP*PPE)/((CPT-CRTD+273.)**4-RST**4)) RAM = 3.418"RA Power Processing Unit Mass Summary Equations PPM = PPEM + CACPEM PPMR ffi PPEM + CACPEM + RAM PPSM -- PPM/PPOP PPSMR = PPMR/PPOP Print PPU Masses, Specific Masses, Efficiencies, Radiator Area, Assembly Vol & Dimensions PPM , PPSM , PPMR, PPSMR, PPE, PPBE, RA, CACV , CACH , & CACW, CACL RETURN END i| 125 APPENDIX D Ion Power Processing Unit with Beam Power Supply Transformer Model 126 == =- SUBROUTINE IONPU2 REAL IFET , IFM , NCCM , NFET , NFM , NIV , NOP , NRET , NRM , & NT1ET, N-TIM, IqT2ET, NT2M REAL IFE , NFE , NOV , NRE , NT1E , NT2E COMMON/INALL / CPT , CRTD , RST, AOF COMMON/PPUIN/PPIP, PPAM, PPRM, RF, IFE COMMON/PPUI12/BOV, DOV, AOV, NOV, ATE, ARE, AVE, BRE, BFE, 2 DRE, DFE, NRE, NFE COMMON/PPUI2/ BTE, DT1E, DT2E, NT1E, NT2E COMMON/PPU123/PPIV COMMON/PPUOUT/PPM, PPSM, PPMR, PPSMR, PPE, PPBE, PPOP, & RAM, RA, CACV, CACH, CACW, CACL Ion Power Processing Unit Model - with Beam Power Supply Transformer - Radiator Equations Set for LEO (400 km orbit) - Last Revised: 13 April 92 tcn - Author: Ken Metcalf, (818) 586-3976 C C C C C C C C C C C Inputs: C PPIV C PPIP C PPAM C PPRM C BOV C DOV C AOV C NOV C AOF C RF C CPT C CRTD C RST C IFE C ATE C ARE C AFE C BTE C BRE C BFE C DT1E C DT2E C DRE C DFE C NT1E C NT2E C NRE C NFE C C Outputs: Power Processing Unit Input Voltage Level (Vrms) Power Processing Unit Input Power Level (kWe) Power Processing Unit Available Modules Power Processing Unit Required Modules Beam Supply Output Voltage (Vdc) Discharge Supply Output Voltage (Vdc) Accelerator Supply Output Voltage (Vdc) Neutralizer Supply Output Voltage (Vdc) Alternator Operating Frequency (kHz) Ripple Factor (frac) Coldplate Temperature (deg C) Coldplate to Radiator Temperature Delta (deg C) Radiator Sink Temperature (deg Kelvin) Power Processing Unit Input Filter Efficiency (fract) Accelerator Power Supply Transformer Efficiency (fract) Accelerator Power Supply Rectifier Efficiency (fract) Accelerator Power Supply Filter Efficiency (fract) Beam Power Supply Transformer Efficiency (fract) Beam Power Supply Rectifier Efficiency (fract) Beam Power Supply Filter Efficiency (fract) Discharge Power Supply Transformer #1 Efficiency (fract) Discharge Power Supply Transformer #2 Efficiency (fract) Discharge Power Supply Rectifier Efficiency (fract) Discharge Power Supply Filter Efficiency (fract) Neutralizer Power Supply Transformer #i Efficiency (frac) Neutralizer Power Supply Transformer #2 Efficiency (frac) Neutralizer Power Supply Rectifier Efficiency (fract) Neutralizer Power Supply Filter Efficiency (fract) 127 C PPOP C PPM C PPMR C PPSM C PPSMR C PPE C PPBE C RAM C RA C CACV C CACH C CACW C CACL C Power Processing Unit Total Output Power (kwe) Power Processing Unit Mass w/o Radiator (kg) Power Processing Unit Mass with Radiator (kg) Power Processing Unit Specific Mass w/o Radiator (kg/kw) Power Processing Unit Specific Mass with Radiator (kg/kw) Power Processing Unit Efficiency (fract) Power Processing Unit Beam Supply Effi Measure (fract) Radiator MASS (KG) Radiator Area (m2) Complete Assembly Component Volume (m3) Complete Assembly Component Height (m) Complete Assembly Component Width (m) Complete Assembly Component Length (m) C C Primary User Input Parameters for Ion PPU with Transformer C PPIP = 2500 C PPIV = 5000 C PPAM = 1 C PPRM = 1 C BOV -- 1800 C DOV = 30 C AOV ffi 500 C NOV = 20 C AOF = 0.8 C RF -- 0.05 C CPT -- I00 C CRTD = 16.67 C RST ffi 247.67 C Secondary Primary User Input Parameters for Ion PPU w/Transformer C *** Recommended Default Values *** C IFE = 0.995 C BTE -- 0.99 C BRE ffi 0.98 C BFE = 0.995 C DTIE = 0.99 C DT2E = 0.99 C DRE = 0.9725 C DFE -- 0.992 C ATE = 0.99 C ARE =0.98 C AFE = 0.995 C NT1E = 0.99 C NT2E = 0.99 C NrRE = 0.955 C NFE = 0.99 C Power Supply Stage Efficiency Calculations at Coldplate Temp C IFET = I. - (1.-IFE)*(0.82+0.0018*CPT) BTET ffi I. - (1.-BTE)*(0.89+0.0011*CPT) BRET = 1. - (1.-BRE)*(0.526+0.00475*CPT) BFET = 1. - (I.-BFE)*(0.82+0.0018*CPT) DT1ET = 1. - (1.-DT1E)*(0.89+0.0011*CPT) DT2ET = 1. - (1.-DT2E)*(0.89+0.0011*CPT) 128 ! l = i i i ! ! = z C C C C C C C C C C C C C C C C C C C C C C C C C DRET = I.- (I.-DRE)*(0.526+0._D0475*CPT) DFET = I.- (I.-DFE)*(0.82+0.0018*CPT) ATET = I.-(I.-ATE)*(0.89+0.0011*CPT) ARET = I.- (I.-ARE)*(0.526+0.00475*CPT) AFET = I.- (I.-AFE)*(0.82+0.0018*CPT) NTIET = I.- (I.-NTIE)*(0.89+0.0011*CPT) NT2ET = 1. - (1.-NT2E)*(0.89+0.0011*CPT) NRET = 1. - (1.-NRE)*(0.526+0.00475*CPT) NFET = 1. - (1.-NFE)*(0.82+0.0018*CPT) PPU Control and Monitoring Power Demand Equation CMP = PPAM*79.4*(PPIP/PPRM)**0.1 Power Processing Unit Efficiency Equations EFFTRM = 0.9629*BTET*BRET*BFET + 0.0360*DT1ET*DT2ET*DRET*DFET + & 0.0010*ATET*ARET*_ + 0.0001*NT1ET*NT2ET*NRET*NFET PPE = ((PPIP*IFET-CMP/1000.)*EFFTRM)/PPIP PPSE = ((PPIP*IFE_*EFFFRM)/PPIP PPBE = 0.9629*PPE Power Processing Unit Power Division Equations BOP = PP1P*0.9629*PPE DOP = PPIP*0.036*PPE AOP = PPIP*0.001*PPE NOP = PPIP*O.OOOI*PPE Power Processing Unit Total Output Power Calculation PPOP = BOP + DOP + AOP + NOP Discharge & Neutralizer Power Supply Intermediate Voltage Calcs DIV = (PPIV*IFET)/(((PPIV*IFET)/(DOV/1.35/DFET/DRET))**0.5) NIV = (PPIV*IFET)/(((PPIV*IFET)/(NOV/1.35/NFET/NRET))**0.5) RATIO OF AVAILABLE PPU MODULES/REQUIRED PPU MODULES RATMOD = PPAM/PPRM Power Processing Unit Input Ac Filter Mass Equation IFM = 0.0105*((I.-0.995)/(I.-IFE))*RATMOD*('PPIP*IFET) & *(PPIP*IFET/PPRM) **(-0.03) *(AOF/20.)**(-0.6) Beam Power Supply Mass Equations BTM - 2.5*((EXP(0.003/(1.-BTE)))/1.35)*RATMOD*(BOP/BFET/BRET) & *((BOP/PPRM/BFET/BRZr)**(-O. 25) *EXP(PPIV *IFET/200000.) & *EXP(BOV/1.35/BFET/BRET/200000.)*A OF**(-O. 47) + (AOF/300.) & *'1.4) BRM = 0.175*((EXP(0.006/(1.-BRE)))/1.35)*RATMOD*(BOP/BFET) & *(BOP/PPRM/BFET) **(-0.04)*('BOV/BFET/(BOV/BFET-2.)) 129 C C C C C C C C C C C C & **7*EXP(BOV/BFET/400_.) BFM = 2.3*(1./(RF/0.01)**0.5)*((1.-0.995)/(1.-BFE)) & *RATMOD*BOP*(BOV**(-0.7) + 0.0015)*(6.7/AOF) Discharge Power Supply Mass Equations DT1M = 2.5*((EXP(0.003/(1.-DT1E)))/1.35) & *RATMOD*(DOP/DFETfDRET/DT2ET) & *((DOP/PPRM/DFET/DRET/DT2ET)**(-0.25) & *EXP(PPIV*IFET/2000_.)*EXP(DIV/200000.) *AOF**(-0.47) & + (AOF/300.)**l.4) DT2M = 2.5*((EXP(0.003/(1.-DT2E)))/1.35)*RATMOD*(DOP/DFET/DRET) & *((DOPfPPRM/DFET/DRET)**(-0.25) *EXP(DIV/200000.) & *EXP(DOV/1.35/DFET/DRET/200000.)*AOF**(-0.47) + (AOF/300.) & *'1.4) DRM = 0.175*((EXP(0.006/(1.-DRE)))/1.35)*RATMOD*(DOP/DFET) & *(DOPfPPRM/DFET) **(-0.04) *(DOV/DFET/(DOV/DFET-2.)) & **7*EXP(DOV/DFET/40000.) DFM -- 2.3*(1./(RF/0.01)**0.5)*((1.-0.995)/(1.-DFE)) & *RATMOD*DOP*(DOV**(-0.7) + 0.0015)*(6.7/AOF) Accelerator Power Supply Mass Equations A TM ffi2. 5*( (EXP( O.OO3/(1. -ATE) )) /1. 35) *RA TM O D*( A O P /AFET /AREI) & *((AOP/PPRM/AFET/ARET)**(-O.25)*EXP(PPIV*IFETI200000.) & *EXP(AOV/1.35/AFET/ARETI200(O)O.)*AOF**(-O.47)+(AOFI300.) & **1.4) ARM = 0.175*((EXP(0.006/(1.-ARE)))/1.35)*RATMOD*(AOP/AFET) & *(AOP/PPRM/AFET)**(-0.04)*(AOV/AFET/(AOV/AFET-2.)) & *'7 *EXP(AOV/AFET/40000.) AFM = 2.3*(1./(RF/0.01)**0.5)*((1.-0.995)/(I.-AFE)) & *RATMOD*AOP*(AOV**(-0.7) + 0.0015)*(6.7/AOF) Neutralizer Power Supply Mass Equations NTIM = 2.5*((EXP(0.003/(I.-NTIE)))/I.35) & *RATMOD*(NOP/NFET/NRETfN'V2ET) & *((NOP/PPRM/NFET/NRET/NT2ET)**(-0.25) & *EXP(PPIV *IFET/200000.) *EXP(NIV/200000.)*AOF**(-0.47) & + (AOF/300.)**1.4) NT2M = 2.5*((EXP(0.003/(1.-NT2E)))/1.35)*RATMOD*(NOP/NFET/NRET) & *((NOPfPPRM/NFET/NRET) **(-0.25)*EXP(NIV/200000.) & *EXP(NOV/1.35/NFET/NRET/200000.)*AOF**(-0.47) + (AOF/300.) & *'1.4) NRM = 0.175*((EXP(0.006/(1.-NRE)))/1.35)*RATMOD*(NOP/NFET) & *(NOP/PPRMfNFET) **(-0.04)*(NOV/NFET/(NOV/NFET-2.)) & *'7 *EXP(NOV/NFET/40000.) NFIVI -- 2.3*(1./(RF/0.01)**0.5)*((1.-O.995)/(1.-NFE)) & *RATMOD*NOP*(NOV**(-0.7) +0.0015)*(6.7/AOF) Power Processing Unit Conductor and Connector Equations FCONV = (3.**0.5/2)*0.028 BCCM = RATMOD*(FCONV*((BOP*1000.)/BOV) & + FCONV*(((BOP* 1000.)/BFET/BRET/BTET/IFET)/PPIV)) 130 C C C C C C DCCM = RATMOD*(FCONV*((DOP*1000.)/DOV) & + FCONV*(((DOP* 1000.)/DFET/DRET/DT2ET/DT1ET/IFET)/PPIV)) ACCM = RATMOD*(FCONV*((AOP*1000.)/AOV) & + FCONV *(((AOP* 1000.)/AFET/ARET/ATET/IFET)/PPIV)) NCCM = RATMOD*(FCONV*((NOP*1000.)/NOV) & + FCONV*(((NOP* 1000.)/NFET/NRET/NT2ET/NT 1ETfIFET)/PPIV)) Power Processing Unit Control and Monitoring Mass Equation CMM = PPAM*(2.+2.5*0aPIP/PPRM)**0.3+0.75*(PPIP/PPRM) **0"3) Power Processing Unit Electronics Mass Equation C C C C C C C C C PPEM = IFM + BTM 4 BRM + BFM + DT1M + DT2M + DRM + DFM + ATM + & ARM + AFM + NT1M + NT2M + NRM + NFM + BCCM + DCCM + ACCM + & NCCM + CMM PPU Volume and Dimension Equations (Single Module) SMCV = (PPEM/PPAM)/(0.342*1000.) SMCH = 0.7*SMCV**0.3333 SMCW = 1.1*SMCV**0.3333 SMCL = 1.3*SMCV**0.3333 PPU Volume and Dimension Equations (Complete Assembly) CACV -- PPEM/(0.342*I000.) CACH = SMCH CACW -- PPAM*SMCW CACL = SMCL Power Processing Unit Enclosure Equations SMCPEM = 44.26*SMCV**0.6666 + 10.25*(SMCL*SMCVO CACPEM -- PPAM*SMCPEM = C - C Power Processing Unit Radiator Equations C i RA = RATMOD*(1.48E+ 10*(PpIp-ppIP*PPE)/((CPT-C'RTD+273.)**4-RST**4))RAM = 3.418"RA i C -_ C Power Processing Unit Mass Summary Equations _z 1 ! i = IR C C C C C PPM = PPEM + CACPEM PPMR = PPEM + CACPEM + RAM PPSM -- PPMfPPOP PPSMR = PPMR/PPOP Print PPU Masses, Specific Masses, Efficiencies, Radiator Area, Assembly Volume and Dimensions PRINT PPM, PPSM, PPMR, PPSMR, PPE, PPBE, RA, CACV , & CACH , CACW , CACL RETURN END 131 APPENDIX E MPD Power Processing Unit Model 132 SUBROUTINE MPDPPU REAL IFET, IFM REAL IFE COMMON/INALL / CPT, CRTD, RST, AOF COMMON/PPUIN/PPIP, PPAM, PPRM, RF, IFE COMMON/PPU123/PPIV COMMON/PPUI3/PPOV, TE, RE, OFE COMMON/PPUOUT/PPM, PPSM, PPMR, PPSMR, PPE, PPBE, PPOP, & RAM, RA , CACV , CACH , CACW , CACL C C C C C C C C MPD Power Processing Unit Model - Radiator Equations Set for LEO (400 km orbit) - Last Revised: 13 April 92 ten - Author: Ken Metealf, (818) 586-3976 C C Inputs: C PPIV C PPOV C PPIP C PPAM C PPRM C AOF C RF C CPT C CRTD C RST C WE C TE C RE C OFE C C Outputs: C PPOP C PPM C PPMR C PPSM C PPSMR C PPE C RAM C RA C CACV C CACH C CACW C CACL C C_._ C C C C Power Processing Unit Input Voltage Level (Vrms) Power Processing Unit Output Voltage Level (Vrms) Power Processing Unit Input Power Level (kWe) Power Processing Unit Available Modules Power Processing Unit Required Modules Alternator Operating Frequency (kHz) Ripple Factor (frac) Coldplate Temperature (deg <2) Col@late to Radiator Temperature Delta (deg C) Radiator Sink Temperature (deg Kelvin) Power Processing Unit Input Filter Efficiency (frac) Transformer Efficiency (frac) Rectifier Efficiency (frac) Output Filter Efficiency (frac) Power Processing Unit Total Output Power (kwe) Power Processing Unit Mass w/o Radiator (kg) Power Processing Unit Mass with Radiator (kg) Power Processing Unit Specific Mass w/o Radiator (kg/lcw) Power Processing Unit Specific Mass with Radiator (kg/kw) Power Processing Unit Efficiency (frac) Radiator MASS (KG) Radiator Area (m2) Complete Assembly Component Volume (m3) Complete Assembly Component Height (m) Complete Assembly Component Width (m) Complete Assembly Component Length (m) Primary User Input Parameters for MPD Power Processing Unit PPIP = 2500 PPIV = 5000 133 C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C PPOV = 300 PPAM = 1 PPRM = 1 AOF = 0.8 RF = 0.05 CPT = 100 CRTD = 16.67 RST = 247.67 Secondary Primary User Input Parameters for MPD PPU *** Recommended Default Values *** IFE = 0.995 TE = 0,99 RE = 0.98 OFE --- O 995 Power Supply Stage Efficiency Calculations at Coldplate Temp IFET -= 1. - (1.-IFE)*(0.82+0.0018*CPT) TET = 1. - (1.-TE)*(0.89+0.0011*cP'r) RET - 1. - (1.-RE)*(0.526+0.00475*CPT) OFET = 1. - (1.-OFE)*(0.82+0.0018*CPT) Power Processing Unit Control and Monitoring Power Demand Equn CMP = PPAM*79.4*(PPIP/PPRM)**0.1 Power Processing Unit Efficiency Equations PPE = ((PP1P*IFET-CMP/1000.)*(TET*RET*OFF_)/PPIP PPSE = IFET*TET*RET*OFET Power Processing Unit Output Power Calculation PPOP = PPIP*PPE RATIO OF AVAILABLE PPU MOD.ULF__/REQUIRED PPU MODULES RATMOD = (PPAM/PPRbl) Power Processing Unit Power Stages Mass Equations IFM = 0.0105*((1.-0.995)/(1.-IFE))*RATMOD*(PPIP*IFET) & *(PPIP*IFET/PPRM)**(-O.03)*(AOF/20.)**(-0.6) TM = 2.5*((EXP(0.003/(1.-TE)))/I.35)*RATMOD*(PPOP/OFET/RET) & ,((ppop/ppRM/OFET/RET)**(-0.25) *EXP(PPIV*IFET/200000.) & *EXP(PPOV/1.35/OFET/RET/200000.) *AOF**(-0.47) + (AOF/300.) & **1.4) RM --- 0.175*((EXP(0.006/(1.-RE)))/1.35)*RATMOD*(PPOP/OFET) & *(ppop/PPRM/OFET) **(-0.04)*(PPOV/OFET/(PPOV/OFET-2.)) & *'7 *EXP(PPOV/OFET/40000.) OFM -- 2.3*(1/(RF/0.01)**0.5)*((1.-0.995)/(1.-OFE)) & *RATMOD*PPOP*(PPOV**(-0.7) +0.0015)*(6.7/AOF) Power Processing Unit Conductor and Connector Equation 134 FCONV = (3.**0.5/2.)*0.028 CCM = RATMOD*(FCONV*((PPOP*1000.)/PPOV)+FCONV*((PPIP*1000.)/PPIV)) C C Power Processing Unit Control and Monitoring Mass Equation C CMM = PPAM*(2. + 2.5*(PpIP/PPRM)**0.3+0.75*(PPIP/PPRM)**0.3) C C Power Processing Unit Electronics Mass Equation C PPEM = IFM + TM + RM + OFM + CCM + CMM C C Power Processing Unit Vol & Dimension Equations (Single Module) C SMCV = (PPEM/PPAM)/(0.342*1000.) SMCH = 0.7*SMCV**0.3333 SMCW = 1.1*SMCV**0.3333 SMCL = 1.3*SMCV**0.3333 C C Power Processing Unit Vol & Dimension Eqns (Complete Assembly) C CACV = PPEM/(0.342*1000.) CACH = SMCH CACW = PPAM*SMCW CACL = SMCL C C Power Processing Unit Enclosure Equations C SMCPEM = 44.26*SMCV**0.6666 + 10.25*(SMCL*SMCVO CACPEM = PPAM*SMCPEM C C Power Processing Unit Radiator Equations C RA = RATMOD*(1.48E+ 10*(PpIp-pPIP*PPE)/((CPT-CRTD+273)**4-RST**4)) RAM = 3.418"RA C C Power Processing Unit Mass Summary Equations C PPM = PPEM + CACPEM PPMR = PPEM + CACPEM + RAM PPSM = PPM/PPOP PPSMR = PPMR/PPOP C Print PPU Masses, Specific Masses, Efficiency, C Radiator Area, Assembly Volume and Dimensions C Print PPM, PPSM, PPMR, PPSMR, PPE, RA, CACV, eACH, CACW, CACL RETURN END 135 APPENDIX F AC Switchgear Unit Model _ 136 SUBROUTINE ACSWGR REAL IRBIP, IRBIV, IRBM, IRBOP, IRBOV, NIRB, NORB COMMON/ACSWIO/NIRB, NORB, ORBOP, ORBOV, RBE, SWAM, SWRM, o IRBIP, IRBIV, IRBM, IRBOP, IRBOV, ORBM, & XRBIP, XRBIV, XRBM, XRBOP, XRBOV, & SWM, SWSM, SWMR, SWSMR, SWE & ,RAM, RA, CACV, CACH, CACW, CACL COMMON/INALL/ CPT, CRTD, RST, AOF AC Switchgear Unit Model - Radiator Equations Set for LEO (400 Ion orbit) - Last Revised: 13 April 92 tcn Ken Metcalf, (818) 586-3976 Assumptions: 1) All output remote bus isolators (RBIs) will have the same rating; consequently, a single power level, ORBOP, is specified. 2) All output RBIs will operate at the same voltage; consequently, a single voltage level, ORBOV, is specified. 3) The efficiency of the switchgear bus is 99.9% C C= C C C C C C C - Author: C C C C C C C C C C Inputs: C NIR Number of Input RBIs C NORB Number of Output RBIs C ORBOP Output RBI Output Power Level (kWe) C ORBOV Output RBI Output Voltage Level (Vrms) C RBE C SWAM C SWRM C CPT C CRTD C RST C C Outputs: C XRBIP C XRBIV C XRBOP C XRBOV C XRBM C IRBIP C IRBIV C IRBM C IRBOP C IRBOV C ORBM C SWM C SWIVlR C SWSM C SWSMR RBI Unit Efficiency at 100 C (fraction) Switchgear Available Modules Switchgear Required Modules ColdplateTemperature (deg(2) ColdplatetoRadiatorTemperature Delta (deg C) Radiator Sink Temperature (deg Kelvin) Cross Tie RBI Input Power Level (kWe) Cross Tie RBI Input Voltage Level (Vrms) Cross Tie RBI Output Power Level (kWe) Cross Tie RBI Output Voltage Level (Vrms) CROSS TIE RBI Mass (KG) Input RBI Input Power Level (kWe) Input RBI Input Voltage Level (Vrms) Mass of one Input RBI (kg) Input RBI Output Power Level (kWe) Input RBI Output Voltage Level (Vrms) Mass of one Output RBI (kg) Switchgear Unit Mass w/o Radiator 0cg) Switchgear Unit Mass with Radiator (kg) Switchgear Unit Specific Mass w/o Radiator (kg/kwe) Switchgear Unit Specific Mass with Radiator (kg/kwe) 137 C SWE C RA C RAM C CACV C CACH C CACW C CACL C Switchgear Unit Efficiency (fraction) Radiator Area (nO.) Radiator MASS (KG) Complete Assembly Component Volume (m3) Complete Assembly Component Height (m) Complete Assembly Component Width (m) Complete Assembly Component Length (m) C C User Input Parameters for AC Switchgear Unit C NIRB = 2. C NORB = 4. C ORBOP -- 2500. C ORBOV - 5000. C RBE = 0.9985. C SWAM = I. C SWRM-- I. C cFr-- I00. c CRTD = 16.67 C RST = 247.67 C C C C BE SURE THAT required modules < = available modules IF (SWRM .GT. SWAM ) SWRM=SWAM C C RBI Efficiency Correction at Col@late Temperature C RBET -- 1. - (1.-RBE)*(0.675+0.00325*CPT) C C Switchgear Unit Bus Power Calculation C SWBP = (NORB*ORBOP)/RBET C C Switchgear Unit Control and Monitoring Power Demand Equation C CMP = SWAM*79.4*(SWBP/SWRM)**0.1 C C COMBINED RBI & BUS SECTION EFFICIENCY C (The efficiency of the switchgear bus is assumed to be 99.9%) C RBSE = RBET*0.999*RBET C C Switchgear Unit Efficiency Calculations C SWE -- (NORB*ORBOP)/(((NORB*ORBOP)FRBET/0.999+CMP/1000.)/RBET) C C Switchgear Unit RBI Power Calculations C IRBOP = (SWBP/0.999+CMP/1000.)/NIRB XP,.BOP = (SWBP/0.999+CMP/1000.) IRBIP = IRBOP/RBET XRBIP = XRBOP/RBET C 138 C C Switchgear Unit Voltage Calculations SWBV = ORBOV/RBET IRBOV = SWBV/0.999 XRBOV = IRBOV IRBIV = ORBOV/RBSE XRBIV ffi IRBIV C C RBI Unit Mass Calculations C ORBM = 0.135*((EX'P(0.0008/(1.-RBE)))/1.7)*(SWAM/SWRM) & *ORBOP*(ORBOP/SWRM)**(- 0.15)*(ORBOV/200.)**0.05 IRBM = 0.135*((EXP(0.0008/(1.-RBE)))/1.7)*(SWAM/SWRM) & *IRBOP*(IRBOP/SWRM)**(- 0.15)*(IRBOV/200.)**0.05 XRBM ffi 0.135*((EXP(0.0008/(1.-RBE)))/1.7)*(SWAM/SWRM) & *XRBOP*(XRBOP/SWRM)**(- 0.15)*(XRBOV/200.)**0.05 C C Switchgear Unit Conductor and Connector MASS Calculation C CCM = (SWAM/SWRM)*((3.**0.5/2.)*0.056*(SWBP*1000.)/SWBV) C C Switchgear Unit Control and Monitoring Mass Calculation C CMM = SWAM*(2. +2.5*(SWBP/SWRM)**0.3 +0.75*(SWBP/SWRM)**0.3) C C Switchgear Unit Electronics Mass Calculation C SWEM = (NIRB*IRBM) + (NORB*ORBM) + XRBM + CCM + CMM C C Single Module Switchgear Unit Volume and Dimension Calculations C SMCV = (SWEM/SWAM)/(0.342*1000.) SMCH = 0.7*SMCV**0.3333 SMCW = 1.1*SMCV**0.3333 SMCL = 1.3*SMCV**0.3333 C C Complete Assembly Switchgear Unit Volume & Dimension Calculations C CACV = SWEM/(0.342*1000.) CACH = SMCH CACW = SWAM*SMCW CACL = SMCL C C Switchgear Unit Enclosure Calculations C SMCPEM = 4.4.26*SMCV**0.6666 + 10.25*(SMCL*SMCW) CACPEM = SWAM*SMCPEM C C Switchgear Unit Radiator Calculations C RA = (SWAM/SWRM) & *(1.48E+ 10*((NIRB*IRBIP)-(NORB*ORBOP))/((CPT-CRTD + 273.) & **4-RST**4)) RAM -- 3.418"RA C 139 C C C C C Ac Switchgear Unit Mass Summary Calculations SWM = SWEM + CACPEM SWSM = SWM/(NORB*ORBOP) SWMR = SWEM + CACPEM + RAM SWSMR = SWMR/(NORB*ORBOP) Print Swltchgear Masses, Specific Masses, Efficiency, Radiator Area, Assembly Volume and Dimensions PRINT SWM, SWSM, $WMR, $WSMR, SWE, RA, CACV, CACH, CACW, CACL RETURN END 140 APPENDIX G Phase Lock Transformer Model 141 SUBROUTINE TRNFMR COMMON/INALL ! CPT, CRTD, RST, AOF COMMON/TRNREG/APO, AVO COMMON/TRNFIO/PTAM, PTPP, FIRM, TSE, o PTM, PTSM, PTMR, PTSMR, PTE & , RAM, RA , CACV , CACH , CACW , CACL C C C C C C C Phase Lock Transformer Model - Radiator Equations Set for LEO (400 km orbit) - Last Revised: 13 April 92 tcn C - Author: Ken Metc_tlf, (818) 586-3976 C C C C C C C C C C C C C C C C C C C C Inputs: AOF APO AVO CPT CRTD PTAM PTPP FIRM RST TSE Alternator Operating Frequency (kHz) Alternator Power Output (kWe) Alternator Voltage Output (Vrms) Coldplate Temperature (deg C) Coldplate to Radiator Temperature Delta (deg C) Phase Lock Transformer Available Modules Phase Lock Transformer Power Percentage (fraction) Phase Lock Transformer Required Modules Radiator Sink Temperature (deg Kelvin) Transformer Stage Efficiency at 100 C (%) C C C C C C Outputs: Phase Lock Transformer Mass w/o Radiator (kg) PTSM Phase Lock Transformer Specific Mass w/o Radiator (kg/kWe) PTMR Phase Lock Transformer Mass with Radiator (kg) PTSMR Phase Lock Transformer Specific Mass w/Radiator (kg/kWe) PTE Phase Lock Transformer Efficiency (fraction) RAM Radiator MASS (KG) RA Radiator Area (m2) CACV Complete Assembly Component Volume (m3) CACH Complete Assembly Component Height (m) CACW Complete Assembly Component Width (m) CACL Complete Assembly Component Length (In) C C User Input Parameters for Phase Lock Transformer C APO=50O0 C AVO=50O0 C PTPP=0.02 C PTAM= 1 C PTRM-- 1 C AOF=0.8 C TSE=0.99 C CPT= 100 C CRTD= 16.67 C RST=247.67 142 C C C C BE SURE THAT required modules < = available modules IF (IYrRM .GT. PTAM ) PTRM=PTAM C C Phase Lock Transformer Power Output Calculation C PTPO = FTPP*APO C C Phase Lock Transformer Control & Monitoring Power Demand Calc C CMP = PTAM*47.6*(FITO/PTRM)**0.1 C C Phase Lock Transformer Efficiency Calculations C TSET = 1. - (1.-TSE)*(0.89+0.0011*CPT) FTE = PTPO/(lYrPO/TSET+CMPlI000.) C C Transformer Stage Mass Calculation C TSM --- 2.5*((EXP(0.003/(1.-TSE)))/1.35)*(PTAM/FI'RM) & *PTPO*((PTPO/PTRM)**(-0.25)*EXP(AVO/100000.)*AOF**(-0.47) & + (AOF/300.)**1.4) C C Phase Lock Transformer Conductor and Connector Mass Calculation C CCM - (PTAM/PTRM)*((3.**0.5/2.)*0.056*(PTPO*1000.)/AVO) C C Phase Lock Transformer Control and Monitoring Mass Calculation C CMM = PTAM*(2.+0.83*fFFPO/FI'RM)**0.3+0.25*fFFPO/FIRM)**0.3) C C Phase Lock Transformer Electronics Mass Calculation C PTEM = TSM + CCM + CMM C C Phase Lock Transformer Single Module Volume & Dimension Calc C SMCV = (PTEM/PTAM)/(0.342*1000.) SMCH = 0.7*SMCV**0.3333 SMCW = 1.1*SMCV**0.3333 SMCL = 1.3*SMCV**0.3333 C C Phase Lock Transformer Complete Assembly Volume & Dimension Calc C CACV = PTEM/(0.342*1000.) CACH = SMCH CACW = PTAM*SMCW CACL = SMCL C C Phase Lock Transformer Enclosure Calculations C SMCPEM = 44.26*SMCV**0.6666 + 10.25*(SMCL*SMCW) CACPEM = PTAM*SMCPEM 143 C C C C C C C C C Phase Lock Transformer Radiator Calculations RA = (lYl'AM/FIRM)*(1.48E+ 10*(PTPO/PTE-PTPO)) & /((CPT-CRTD + 273.)**4-RST**4) RAM = 3.418"RA Phase Lock Transformer Mass Summary Calculations PTM = PTEM + CACPEM PTSM = PTM/PTPO PTMR = PTEM + CACPEM + RAM PTSMR = PTM_./PTPO Print Phase Lock Transformer Masses, Specific Masses, Efficiency, Radiator Area, Assembly Volume and Dimensions Print PTM, PTSM, PTMR, PTSMR, PTE, RA, CACV, CACI-I, CACW, CACL RETURN END 144 APPENDIX H Speed Regulator Model 145 SUBROUTINE SPDREG REAL NSS COMMON/INALL / CPT, CRTI), RST, AOF COMMON/TRNRF__/APO, AVO COMMON/SREGIO/SRAM, SRRM, NSS, SRF, PWMF, BCE, SSE, EFE, o SPO, SVO, SRM, SRSM, SRMR, SRSMR, FSE & , RAM, RA, CACV , CACH, CACW , CACL C C C C C C C C _Z_E_mmmm_g Alternator Speed Regulator Model - Radiator Equations Set for LEO (400 km orbit) - Last Revised: 13 April 92 - Author: Ken Met_f, (818) 586-3976 C C C C C C C C C c C C C C C C C C C C C C Inputs: APO AVO SRAM SRRM NSS SRF Alternator Power Output (kWe) Alternator Voltage Output (Vrms) Speed Regulator Available Modules Speed Regulator Required Modules Number of Shunt Switch Elements Shunt Redundancy Factor (frac) PWIVlF BCE SSE EFE CPT CRTD RST Pulse-Width-Modulation Frequency ff,Hz) Bus Conductor Efficiency at 100 C (frac) Shunt Switch Efficiency at 100 C (frac) EMI Filter Efficiency at 100 C (frac) Coldplate Temperature (deg C) Coldplate to Radiator Temperature Delta (deg C) Radiator Sink Temperature (deg Kelvin) Outputs: SPO SVO SRM SRSM SRMR C C C C C C C C C C--.m C C C C C C Shunt Power Output (kWe) Shunt Voltage Output (Vrms) Speed Regulator Mass w/o Radiator (kg) Speed Regulator Specific Mass w/o Radiator (kg/kWe) Speed Regulator Mass with Radiator (kg) SRSMR Speed Regulator Specific Mass w/Radiator (kg/kWe) FSE Fully Shunted Efficiency (fraction) RAM Radiator MASS (KG) RA Radiator Area (m2) CACV Complete Assembly Component Volume (m3) CACH Complete Assembly Component Height (In) CACW Complete Assembly Component Width (m) CACL Complete Assembly Component Length (m) gg Primary User Input Parameters for Speed Regulator APO = 5000 AVO = 5000 SRAM = 1 SRRM = 1 146 C C C C C C C C C C C C C C C CPT = 100 CRTD = 16.67 RST = 247.67 Secondary User Input Parameters for Speed Regulator *** Recommended Default Values *** NSS = 40 SRF= 1.2 PWMF= 20 BCE = 0.9965 SSE = 0.9945 EFE = 0.9993 BE SURE THAT required modules < = available modules IF (SRRM .GT. SRAM ) SRRM=SRAM C C Speed Regulator Control and Monitoring Power Demand Calculation C CMP = SRAM*79.4*(APO/SRRM)**0. I C C BUS CONDUCTOR EFFICIENCY AT COLDPLATE TEMP C BCET = 1. - (1.-BCE)*(0.75+0.0025*CPT) C C EMI FILTER EFFICIENCY AT COLDPLATE TEMP C EFET = 1. - (1.-EFE)*(0.g2+0.0018*CPT) C C SHUNT SWITCH EFFICIENCY AT COLDPLATE TEMP C SSET = 1. - (1.-SSE)*(0.526+0.00475*CPT) C C FULLY SHUNTED EFFICIENCY C FSE = ((APO-CMP/1000)*BCET*EFEW*SSET)/APO C C COMBINED BUS, FILTER, AND SHUNT Efficiency C BFSE = BCET*EFET*SSET C C Speed Regulator Shunt Output Calculations C SPO = APO*FSE SVO = AVO*BFSE C C Bus and Connector Mass Calculation C BCM = (SRAM/SRRM)*((1.-O.9965)/(1.-BCE)) & *SRF*((3**0.5/2.)*0.056*(APO* 1000.)/AVO) C C EMI Filter Mass Calculation C EFM = 0.0105*((1.-0.9993)/(1.-EFE))*(SRAM/SRRM)*SRF*(SPO/SSET) & *(SPO/SRRM/NSS/SSET)**(-0.03)*(PWMF/20.)**(-0.6) 147 C C C C C C C C C C C C C C C C C C C C C C C C C C C Shunt Switch Mass Calculation SSM = 0.15*((EXP(0.001/(I.-SSE)))/I.2)*(SRAM/SRRM) & *SRF*SPO*(SPO/SRRM/NSS)**(-0.04)*(SVO/(SVO-2.)) & **7*EXP(SVO/40000.) Speed Regulator Control and Monitoring Mass Calculation CMM = SRAM*(2. +2.5*(APO/SRRM)**0.3+0.75*(APO/SRRM)**0.3) Speed Regulator Electronics Mass Calculation SREM = BCM+ EFM + SSM + CMM Speed Regulator Single Module Volume and Dimension Calculations SMCV = (SREM/SRAM)/(0.342*1000.) SMCH = 0.7*SMCV**0.3333 SMCW = 1. l*SMCV**0.3333 SMCL = 1.3*SMCV**0.3333 Speed Regulator Complete Assembly Volume & Dimension Calculations CACV = SREM/(0.342*1000.) CACH = SMCH CACW = SRAM*SMCW CACL = SMCL Speed Regulator EnclosureCalculations SMCPEM = 44.26*SMCV**0.6666 + 10.25*(SMCL*SMCW) CACPEM = SRAM*SMCPEM Speed Regulator Radiator Calculations RA = (SRAM/SRRM)*(1.48E+ 10*(APO-FSE*APO)) & /((CPT-CRTD + 273.)**4-RST**4) RAM = 3.418"RA Speed Regulator Mass Summary Calculations SRM = SREM + CACPEM SRSM = SRM/SPO SRMR = SREM + CACPEM + RAM SRSMR = SRMPJSPO Print Shunt Regulator Masses, Specific Masses, Efficiency, Radiator Area, Assembly Volume and Dimensions Print SRM, SRSM, SRMR, SRSMR, FSE, RA, CACV, CACH, CACW, CACL RETURN END 148 APPENDIX I Parasitic Load Radiator Model 149 SUBROUTINE ACPLR REAL ND, NR, NRC, NRTC COMMON/RADIO / PPD, PIV, APM, RPM, PWOT, WRTD, PSI", i NR, NRTC, ND, CCD, i IRRC, RCRF, o TPLRA, TPLRM, TPLRSM AC Parasitic Load Radiator Model - Radiator Equations Set for LEO (400 km orbit) - Last Revised: 14 April 92 - Author: Ken Metcalf, (818) 586-3976 C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C Assumptions: 1) Nichrome V wire mass includes 50% extra mass for bonding & insulating materials 2) Radiator plates are 2-.5 mm fiat & corrugated C-C plates 3) Radiator frame, braces & strucmrai supports are lmm thick CC 4) Radiation efficiency = 0.873 5) Radiator surface emissivity = 0.90 Inputs: PPD PLR Power Dissipation Level (kWe) PIV PLR Input Voltage Level (Vrms) AIM Available Parasitic Load Radiator Modules RPM Required Parasitic Load Radiator Modules PWOT PLR Wire Operating Temperature (K) WRTD Wire to Radiating Surface Temperature Delta (K) PST CCD ND NR N-RC RCRF NRTC Parasitic Load Radiator Sink Temperature (K) Carbon-Carbon Density (g/cm3) Nichrome V Density (g/cm3) Nicrome V Resistivity (ohms-cm2/meter) Number of Resistive Circuits Resistive Circuit Redundancy Factor (FRACT) Nicrome V Resistivity Temperature Coefficient (/C)C C C C C C C Outputs: TPLRA TPLRM TPLRSM Total Parasitic Load Radiator Surface Area (m2) Total Parasitic Load Radiator Mass 0cg) Total Parasitic Load Radiator Specific Mass (kg/kWe) C C Primary User Input P_Lmmeters for Parasitic Load Radiator C PPD = 500O C PIV = 50OO C APM= 1 C RPM= I C PWOT = 1255 C WRTD = I00 C PST = 247.67 150 C C C C C C C C C C C C C C C C C C C C C C C C Secondary User Input Parameters for Parasitic Load Radiator *** Recommended Default Values *** NRC =40 RCRF = 1.2 NR = 1.0806E-02 NRTC -- 0.00011 ND = 8.4296 CCD -- 1.66 C C C C C C C C BE SURE THAT required modules < = available modules IF (RPM .GT. APM ) RPM = APM Parasitic Load Radiator Circuit Calculations CC ffi (PPD*1000.)/RPM/NRC/3./PIV CER ffi PIV/CC Parasitic Load Radiator Resistive Wire Calculations RWXA = CC**1.4/10500. RWL = (CER*RWXA)/(NR*(1. +NRTC*(PWOT-273.-20.))) Single Module Parasitic Load Radiator Plate & Frame Area Calc SMPA ffi 2.*RCRF*(1.48E+10*PPD/RPM)/((PWOT-WRTD)**4-PST**4) SMFA = 4.*(SMPA**0.5*I.002)*(SMPA**0.5*0.02) Single Module Parasitic Load Radiator Mass Calculations SMWM = 1.5*3.*RCRF*NRC*((RWL*100.)*RWXA)*(ND/1000.) RHOCC = CCD/1000. SMPM = 2.15*SMPA*10000.*0.05*RHOCC SMFM = (SMFA*10000.*0.1)*RHOCC + & 2.*(SMFA/4.*2.**0.5* 10000.*0.1)*RHOCC SMSM = (SMFA/2.*10000.*O. i5)*RI-IOCC + (SMFA*I. 12"10000.*0.15)*RHOCC Single Module Parasitic Load Radiator Mass Summary Calculation SMPLRM = SMWM + SMPM + SMFM + SMSM Total Parasitic Load Radiator Mass Calculations TPLRA = APM*SMPA TPLRM = APM*SMPLRM TPLRSM -- TPLRM/PPD Print Parasitic Load Radiator Area, Mass, Specific Mass Print TPLRA, TPLRM, TPLRSM RETURN END 151 APPENDIX J Litz Wire Transmission Line Model 152 LC C C C C C C n c c c c c c c c c c c c c c c c c c c c c c c c c C C C C C C C C C C C C C C SUBROUTINE LWTRI2q REAL IDS, IDSF, IMD, ITC, KF, KPF REAL LRP, LXP, LWR, LWIT, LWIM REAL NOB, LPF COMMON/INALL / CPT, CRTD, RST, AOF COMMON flRANIO/TLOP, TLOV, TLL, ATC, RTC, NOB, LPF, & CM, TLIP , TLIV , CIOR , CIST , TLLTF , TLE , PF DATA MAXIT/1000/, TOLTLE/0.01/ Transmission Line Module 3 Phase, Aluminum Conductor Insulated Litz Wire Radiation Cooled Cable Jacket (LEO, 400 km) Last Revised: 27 April 92 tcn Author: Ken Metcalf, (818) 718 - 3391 User Input Parameters Par Default Name Value Parameter Description TLOP TLOV i/o TLE TLL AOF ATC RTC NOB LPF 5000. Transmission Line Output Power Level, kWe 1367. Transmission Line Output Voltage, Vrms .9800 Initial Transmission Line Efficiency (0 if unknown) 150. Transmission Line Length, m .8 Alternator Operating Frequency, kHz 1. Available Transmission Circuits 1. Required Transmission Circuits 7. Number of Bundles .9 Load Power Factor Outputs: CM Transmission Line Mass, kg TLIP Transmission Line Input Power, kWe TLIV Transmission Line Input Voltage, Vrms CJOR Cable Jacket Outer Radius, cm CJST Cable Jacket Surface Temperature, deg C TLCT Conductor Temperature, deg C i/o TLE Transmission Line Efficiency, frac PF Circuit Power Factor, frac Notes: TLOP and TLOV obtained from PPU or Switchgear model AOF obtained from Power conversion Submodule (CR-191134 or CR-191135) ATC must be equal to or greater than RTC NOB must be 1., 7. or 17. Combinations of high power (> 5 MWe), lower voltage (< 2000 Vrms), and higher frequency (> 1 KHz) may cause divergence errors. 153 CC C C C C C C C C C C C C C N= 3.1415926536 C C C C C C C C C C C C C C C C C C C C C C C Typically a circuit power factor of 0.8 or less indicates unstable operation and pending divergence errors. The following steps are suggested to correct these problems: 1) Select a higher operating voltage if possible; 2) Utilize a larger value for the number of bundles (NOB), for example, 7 instead of 1, or 17 instead of 7; 3) Reduce transmission line length if practical; 4) Reduce the power level or break a single line into parallel lines using the ATC and RTC values. In general, it should be noted that transmission line divergence errors may indicate the selected values are not actually practical or they will result in a complex or undesirable transmission line design. BE SURE THAT RTC < = ATC IF (RTC .GT. ATC )RTC= ATC BE SURE THAT NOB= I,7, OR 17. SET NOB=7 OTHERWISE IF (NOB .NE. 1. .AND. NOB .NE. 7. .AND. NOB .NE. 17.) NOB=7. Calculate an initial TLE CALTLE= 1. - TLL/150.*5000./TLOV*O.01 IF (TLE .LT. CALTLE) TLE=CALTLE Aluminum Resistivity, Temperature, and Density Constants AVR = 0.028264 ARTC ffi 0.00403 AMD = 2.703 Insulation Density, DielectriC Strength, Safety Factor Constants IMD = 1.42 IDS = 7OOO. 1DSF = 10. Litz Wire Strand Radius (Value suitable for 60 Hz to 5 kHz) LWR ffi 0.016 Cable Jacket Temperature CABS = 0.4 CEM = 0.9 CEVF = 0.8 ALBD = 0.3 CABI = 0.9 and Conductor Temperature Calculation Constants Calculation Constants Suitable for LEO (400 kin) 154 CC C C C C C I00 C C C C C C C C C C C C QSOL = 1372. QEIR = 237. SBC = 5.67E-08 ITC = 0.300 Calculate Transmission Line Output Parameters TLCI" = 150. PF ffi LPF I=0 ********* RETURN HERE FOR TLCT and/or TLE Calculations Aluminum Volume Resistivity at Temperature AVRT = (AVR_'(1. +0.00403*(TLCT-20.)))/1000000. X-factor XF = 2.*PI*LWR*((2.*AOF*I000.)/(AVRT*100.*1000000000.))**0.5 K-factor IF ( XF.LT.2. ) THEN KF = XF*0.03908 + 1. ELSE KF -- XF*0.35233163 + 0.37349673 ENDIF Aluminum Volume Resistivity at Temperature and Frequency AVRF = KF*AVRT Transmission Line Power Losses C C C C C C 20O C C C C C C C C C TLPL --- TLOP/TLE - TLOP J=0 ********* RETURN HERE FOR Power Factor PF Calculation Loop ******* Conductor Current Level CCUR = ((TLOP*1000.)/RTC/NOB)/(3.**0.5*TLOV*PF) Conductor Resistance CRES = (((TLPL/3.)*1000.)/RTC/NOB)/CCUR**2 Conductor Radius CRAD -- (((AVRF*'IZL,)/(PI*CR_))**0.5)*100. Litz Wire Insulation Thickness LWIT = TLOV/(IDS/0.00254) 155 C C C Equivalent Litz Wire Insulation Thickness ELWT = ((CRAD**2/LWR**2)*(LWR+LWIT)**2)**0.5- CRAD C C Conductor Insulation Thickness C CIT = 0DSF*TLOV)/(IDS/0.00254) C C Conductor Insulation Outer Radius C ClOR -- CRAD + ELWT + CIT C C Geometric Mean Distance C GMD ffi 2.*CIOR C C K'-factor C IF ( XF.LT.2. ) KPF = 1./EXP(XF/40.) IF ( XF.GE.2..AND. XF.LT.10. ) KPF = EXP((1.7-XI_/6.) IF ( XF.GE. 10. ) KPF = EXP(2.116/XF) - 0.985 C C Conductor Reactance C CREA = ((2.*ALOG(GMD/CRAD)+KPF*(I./2.))*0.000000001) & *(2.*PI*AOF* 1000.)*(TLL* 100.) C C Load Resistance per Phase C LRP = ((TLOP*!000.)/RTC/3.)/(NOB*CCUR)**2 C C Load Reactance per Phase C LXP = TAN(ACOS(LPF))*LRP C C Circuit Resistance per Phase C CRP = LRP + (CRF_/RTC/NOB) C C Circuit Reactance per Phase C CXP = LXP + CREA/RTC/NOB C C Circuit Power Factor C PFOLD = PF PF = COS(ATAN(CXP/CRP)) IF ( ABS(PF-PFOLD).GT.0.001 ) THEN IF ( J.GT.MAXIT ) THEN WRITE (*,99001) PF, PFOLD ELSE J=J+l GOTO 200 ENDIF 156 C C C C C C C C C C C C C C C C C C C C C C C C C C ENDIF Bundle Jacket Thickness BJT = (IDSF*TLOV)/(IDS/O.O0254) Bundle Jacket Outer Radius BJOR = CIOR*(1.+2./3.**0.5) + BJT Cable Jacket Thickness CJT = (IDSF*TL_V)/(IDS/0.00254) Cable Jacket Outer Radius IF ( NOB.EQ. 1. ) THEN CJOR = BJOR ELSEIF ( NOB.EQ.7. ) THEN CJOR = 3.*BJOR + CAT ELSE CJOR = 5.*BJOR + CJT ENDIF Exterior Cable Heating Effects ECHE = (CABS*QSOL) + (ALBD*QSOL*CABS*CEVF) + (CABI*QEIR) Cable Jacket Surface Temperature CJST -- ((ECHE*(2, *CJOR]I O3.*'IT,L) + (TLPL* 1030.)) & /(SBC*CEM w2.*PI*CJOR/100.*TLL)) **0.25 Conductor Temperature TOLD = TLL'W TI.ZTT = (TLPL*1000.) & *(ALOG(CIOR/(NOB* *0.5"3.**0.5 *C'RAD))/(2. *PI *ITC *TLL)) & + CJST - 273. I=I+l IF ( I.LE.MAXrr ) THEN IF ( ABS(TLCT-TOLD).GT.0.1 ) GOTO 103 IF ( TLCT.GE.203. ) THEN TIE = ((1.-TLE)*TOLTLE) + TLE GOTO 103 ENDIF ELSE WRrlE (*,99002) MAXIT, TLCT, TLE ENDIF Conductor Mass COM = ATC*3.*NOB*PI*CRAD**2*(TLL*103.)*(AMD/1000.) Litz Wire Insulation Mass 157 C LWIM ffi ATC*3.*NOB*PI*((CRAD+ELWT)**2-CRAD**2)*(TLL*100.) & *(IMD/1000.) C C Conductor Insulation Mass C CIM = ATC*3. *NOB*PI*((CRAD + ELWT+ CIT)**2-(CRAD + ELWT)**2)*(TLL* 100.) & *(IMD/IO00.) C C Bundle Jacket Mass C RIM = ATC*NOB*PI*(BJOR**2-(BJOR-BJT)**2)*(TI_*100.)*(IMD/1000.) C C Cable Jacket Mass C CJM = ATC*PI*(CJOR**2-(CJOR-C3T)**2)*(TLL*100.)*(IMD/1000.) C C Cable Mass C CM = COM + LWIM + CIM + BJM + CJM C C Transmission Line Input Power C TLIP = TLOP/TLE C C Transmission Line Input Voltage C TLIV -- TI_V/TLE C REFLrRN 99001 FORMAT (IX,Tailed to conv in lwtrin, PFf',F9.4,' PFOLD=',F9.4) 99002 FORMAT (IX,'WARNING! Exceeds',15,'iters in lwtrln. TLCT --',F9.2, & ' TLE =',F9.4) END 158 Report Documentation Page I 2. Governmant,,_-es3_e-No. 3. R_c_p_ent'$ Cat=,og NO. 4. _de and Su_e Power Conditioning System Modelling for Nuclear Electric Propulsion 5. Repen Dam November .1993 6. _mg Organ_on Cc_e Rocketdyne Division Rockwell International 7. Xumor(s) Kenneth J. Metcalf 9. Performing Organization N,ime and Addrm_ Rocketdyne Division Rockwell International Corporation 6633 Canoga Avenue Park, CA 91303 I_ S_nso_g _ency Nim. _d _drmm National Aeronautics and Space Administration Lewis Research Center 21000 Brookpark Road Cleveland, OH 44135 8. _,n;'O_s_uon Re_ No. None 10. Work Umt No. 11. _ or Grant No. NAS3-25808 13. Type of Rel_ort aFrO Psriocl Covere¢l J] Contractor Report Final I . Sponsonng Agunc-/CA_al 16. _" NASA LeRC is currently developing a Fortran based model of a complete nuclear electric propulsion (NEP) vehicle that would be used for piloted and cargo mis- sions to the Moon or Mars. The proposed vehicle design will use either a Brayton or K-Rankine power conversion cycle to drive a turbine coupled with a rotary alternator. Two thruster types are also being studied, ion and magnetoplasmady- namic (MPD). In support of this NEP model, Rocketdyne developed a power manage- ment and distribution (PMAD) subroutine that provides parametric outputs for selected alternator operating voltages and frequencies, thruster types, system power levels, and electronics coldRlate temperatures. The end-to-end PMAD model described in this report is based on the direct use of _he alternator voltage and frequency for transmitting power to either ion or MPD thrusters. This low,frequency transmission approach was compared with dc and high frequency ac designs, and determine, to have the lowest mass, highest efficiency, highest reliability and lowest development costs. While its power quality is not as good as that provided by a high ifrequency system, It was considered adequate for both ion and MPD engine applications. The low frequency architecture will be used as the reference in future NEP PMAD studies. i 17. Key Wo_s _ugges._ _ Aue_l)) _ 1¢ OL_n]_Jt_n Smmmem Nuclear Electric Porulsion, Power I Unclassified Unlimited Management and Distribution, Subroutines Subject Category 44 % uric I ass1 T1 eo unc I assl tl eo I_SA FORM tCZe _ m *For sale by bhe National Technical Information Service. Springfield. Vifginm 22161

NEP mission sensitivities

Abstract

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