Recent electric propulsion development activities for NASA science missions

The primary source of electric propulsion development throughout NASA is implemented by the In-Space Propulsion Technology Project at the NASA MSFC under the management of the Science Mission Directorate. The Solar Electric Propulsion technology area's objective is to develop near and mid-term SEP technology to enhance or enable mission capture while minimizing risk and cost to the end user. Major activities include developing NASA s Evolutionary Xenon Thruster (NEXT), implementing a Standard Architecture, and developing a long life High Voltage Hall Accelerator (HiVHAC). Lower level investments include advanced feed system development, advanced cathode testing and xenon recovery testing. Progress on current investments and future plans are discussed.

The NASA's evolutionary xenon thruster (NEXT) ion propulsion system has been in advanced technology development under the NASA in-space propulsion technology project. The highest fidelity hardware planned has now been completed by the government/industry team, including: a flight prototype model (PM) thruster, an engineering model (EM) power processing unit, EM propellant management assemblies, a breadboard gimbal, and control unit simulators. Subsystem and system level technology validation testing is in progress. To achieve the objective Technology Readiness Level 6, environmental testing is being conducted to qualification levels in ground facilities simulating the space environment. Additional tests have been conducted to characterize the performance range and life capability of the NEXT thruster. This paper presents the status and results of technology validation testing accomplished to date, the validated subsystem and system capabilities, and the plans for completion of this phase of NEXT development. The next round of competed planetary science mission announcements of opportunity, and directed mission decisions, are anticipated to occur in 2008 and 2009. Progress to date, and the success of on-going technology validation, indicate that the NEXT ion propulsion system will be a primary candidate for mission consideration in these upcoming opportunities.

As a critical part of NASA's Evolutionary Xenon Thruster (NEXT) test validation process, a single string integration test was performed on the NEXT ion propulsion system. The objectives of this test were to verify that an integrated system of major NEXT ion propulsion system elements meets project requirements, to demonstrate that the integrated system is functional across the entire power processor and xenon propellant management system input ranges, and to demonstrate to potential users that the NEXT propulsion system is ready for transition to flight. Propulsion system elements included in this system integration test were an engineering model ion thruster, an engineering model propellant management system, an engineering model power processor unit, and a digital control interface unit simulator that acted as a test console. Project requirements that were verified during this system integration test included individual element requirements ; integrated system requirements, and fault handling. This paper will present the results of these tests, which include: integrated ion propulsion system demonstrations of performance, functionality and fault handling; a thruster re-performance acceptance test to establish baseline performance: a risk-reduction PMS-thruster integration test: and propellant management system calibration checks.

The NASA s Evolutionary Xenon Thruster (NEXT) project is developing an advanced ion propulsion system for future NASA missions for solar system exploration. An engineering model (EM) power processing unit (PPU) for the NEXT project was designed and fabricated by L-3 Communications under contract with NASA Glenn Research Center (GRC). This modular PPU is capable of processing up from 0.5 to 7.0 kW of output power for the NEXT ion thruster. Its design includes many significant improvements for better performance over the state-of-the-art PPU. The most significant difference is the beam supply which is comprised of six modules and capable of very efficient operation through a wide voltage range because of innovative features like dual controls, module addressing, and a high current mode. The low voltage power supplies are based on elements of the previously validated NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) PPU. The highly modular construction of the PPU resulted in improved manufacturability, simpler scalability, and lower cost. This paper describes the design of the EM PPU and the results of the bench-top performance tests.

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

*† NASA’s Evolutionary Xenon Thruster (NEXT) project is developing next generation ion propulsion technologies to provide future NASA science missions with enhanced mission performance benefit at a low total development cost. The objective of the NEXT project is to advance next generation ion propulsion technology by producing engineering model and prototype model system components, validating these through qualification-level and integrated system testing, and ensuring preparedness for transitioning to flight system development. This paper describes the NEXT ion propulsion system development status, characteristics and performance. A review of mission analyses results conducted to date using the NEXT system is also provided.

Since 2001, the In-Space Propulsion Technology (ISPT) program has been developing and delivering in-space propulsion technologies that will enable or enhance NASA robotic science missions. These in-space propulsion technologies are applicable, and potentially enabling, for future NASA flagship and sample return missions currently being considered. They have a broad applicability to future competed mission solicitations. The high-temperature Advanced Material Bipropellant Rocket (AMBR) engine, providing higher performance for lower cost, was completed in 2009. Two other ISPT technologies are nearing completion of their technology development phase: 1) NASA's Evolutionary Xenon Thruster (NEXT) ion propulsion system, a 0.6-7 kW throttle-able gridded ion system; and 2) Aerocapture technology development with investments in a family of thermal protection system (TPS) materials and structures; guidance, navigation, and control (GN&C) models of blunt-body rigid aeroshells; aerothermal effect models; and atmospheric models for Earth, Titan, Mars and Venus. This paper provides status of the technology development, applicability, and availability of in-space propulsion technologies that have recently completed their technology development and will be ready for infusion into NASA's Discovery, New Frontiers, SMD Flagship, or technology demonstration missions.

*† ‡ § ¶ The objectives of the NASA’s Evolutionary Xenon Thruster (NEXT) program are to develop a next generation ion propulsion system to Technology Readiness Level 6 and to transfer the NASA technology to industry partners to facilitate the manufacturing of future flight systems. A primary focus of the program is to minimize first user cost of the system through a flexible system design approach, manufacturing process development, and element and system validation. The NEXT program has made significant progress towards these goals in the last 18 months. With the fabrication and qualification-level testing of engineering and prototype model hardware, a substantial level of technical and production readiness has been demonstrated. This paper describes the development and validation status of each of five system elements, summarizes performance and interface characteristics for each element, and details Aerojet’s readiness to manufacture the flight system.

NASA’s Glenn Research Center (GRC) is leading the development of NASA’s Evolutionary Xenon Thruster (NEXT) system. The central feature of the NEXT system is an electric propulsion thruster that inherits the knowledge gained through the NSTAR thruster that successfully propelled the Deep Space 1 to asteroid Braille and comet Borrelly, while significantly increasing the thruster power level and making improvements in performance parameters associated with NSTAR. The thruster under development has a 40 cm beam diameter, twice the effective area of the Deep-Space 1 thruster. It incorporates mechanical features and operating conditions to maximize the design heritage established by the flight NSTAR 30 cm thruster, while incorporating new technology where warranted to extend the power and throughput capability. To date three engineering-model thrusters have been manufactured at NASA GRC, and performance, wear, vibration, and integration testing of these thrusters is underway.

An axisymmetric ion-optics model is applied to NASA's Evolutionary Xenon Thruster (NEXT) ion engine.The model is used to simulate the performance of the entire thruster by modeling several apertures at varying radii on the thruster face and integrating the results.The integrated results are compared to experimentally measured data for the NEXT thruster, showing good agreement in most areas.The primary area of discrepancy is in the accelerator grid current, although erosion results suggest that the measured current is unaccountably high.The model is also used to estimate the life of the thruster before the onset of electron backstreaming.Three separate methods are applied, and each predicts thruster failure after approximately 40,000 hours of operation or 845 kg of xenon throughput.

Current NSTAR (planned for the Discovery Mission: Dawn) and NASA's Evolutionary Xenon Thruster based propulsion systems were compared for a comet surface sample return mission to Tempe1 1. Mission and systems analyses were conducted over a range of array power for each propulsion system with an array of 12 kW EOL at 1 AU chosen for a baseline. Engine configurations investigated for NSTAR included 4 operational engines with 1 spare and 5 operational engines with 1 spare. The NEXT configuration investigated included 2 operational engines plus 1 spare, with performance estimated for high thrust and high Isp throttling modes. Figures of merit for this comparison include Solar Electric Propulsion dry mass, average engine throughput, and net non-propulsion payload returned to Earth flyby.

Current NSTAR (planned for the Discovery Mission: Dawn) and NASA's Evolutionary Xenon Thruster based propulsion systems were compared for a comet surface sample return mission to Tempe1 1. Mission and systems analyses were conducted over a range of array power for each propulsion system with an array of 12 kW EOL at 1 AU chosen for a baseline. Engine configurations investigated for NSTAR included 4 operational engines with 1 spare and 5 operational engines with 1 spare. The NEXT configuration investigated included 2 operational engines plus 1 spare, with performance estimated for high thrust and high Isp throttling modes. Figures of merit for this comparison include Solar Electric Propulsion dry mass, average engine throughput, and net non-propulsion payload returned to Earth flyby.

The High Voltage Hall Accelerator (HiVHAc) propulsion system consists of a thruster,power processing unit (PPU), and propellant feed system. An engineering model PPU was developed by Colorado Power Electronics, Inc. funded by NASA's Small Business Innovative Research Program. This PPU uses an innovative 3-phase resonant converter to deliver 4 kW of discharge power over a wide range of input and output voltage conditions.The PPU includes a digital control interface unit that automatically controls the PPU and a xenon flow control module (XFCM). It interfaces with a control computer to receive high level commands and relay telemetry through a MIL-STD-1553B interface. The EM PPU was thoroughly tested at GRC for functionality and performance at temperature extremes and demonstrated total efficiencies a high as 95 percent. It was integrated with the HiVHAc thruster and the XFCM to demonstrate closed-loop control of discharge current with anode flow. Initiation of the main discharge and power throttling were also successfully demonstrated and discharge oscillations were characterized.

A 0.5-2.3 kW xenon ion propulsion system is presently being developed under the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) program. This propulsion system includes a 30 cm diameter xenon ion thruster, a Digital Control Interface Unit, a xenon feed system, and a power processing unit (PPU). The PPU consists of the power supply assemblies which operate the thruster neutralizer, main discharge chamber, and ion optics. Also included are recycle logic and a digital microcontroller. The neutralizer and discharge power supplies employ a dual use configuration which combines the functions of two power supplies into one, significantly simplifying the PPU. Further simplification was realized by implementing a single thruster control loop which regulates the beam current via the discharge current. Continuous throttling is possible over a 0.5-2.3 kW output power range. All three power supplies have been fabricated and tested with resistive loads, and have been combined into a single breadboard unit with the recycle logic and microcontroller. All line and load regulation test results show the power supplies to be within the NSTAR flight PPU specified power output of 1.98 kW. The overall efficiency of the PPU, calculated as the combined efficiencies of the power supplies and controller, at 2.3 kW delivered to resistive loads was 0.90. The component was 6.16 kg. Integration testing of the neutralizer and discharge power supplies with a functional model thruster revealed no issues with discharge ignition or steady state operation.

The Microsatellite Electric Propulsion System (MEPS) program has been originated by the increasing need to provide a low cost and low power Electric Propulsion System (EPS) for small satellites (<300Kg). The propulsion system of MEPS consists of three main parts, the Thruster Units (TUs) composed of a Hall Effect Thruster (Rafael's CAM-200 or SITAEL's HT100) and a Cathode (Rafael's Heaterless Hollow Cathode RHHC), the Propellant Management and Tank Assembly (PMA/PTA) which performs the regulation of xenon mass flow rate from the tank to the TU inlet, and the Power Processing Unit (PPU) which provides the necessary power to drive the TUs and the PMA/PTA and implements the system control logic. The objective of this paper is to present the development status of MEPS PPU highlighting the design optimizations and simplifications that have been performed. Particular emphasis is aimed at the most indicative improvements and how all modifications contributed to the PPU budget in terms of number of components, mass, size and cost, without affecting system efficiency, performance and reliability. Aggregated results for PPU budget are thoroughly illustrated, by taking into account the overall optimizations and simplifications. The results are very promising and point to a reduction on overall number of components, mass, area and cost in the range of 15% - 33%, all very significant especially in space market.