CATHODE CURRENT SHARING APPARATUS AND METHOD THEREFOR
The invention relates to a cathode current sharing apparatus and method, more particularly, to cathode current control for Thruster with Anode Layer (TAL), Stationary Plasma Thrusters (SPT) or ion thrusters, which are typically used in spacecraft to change attitude and/or altitude. Present space satellites utilize thrusters to provide attitude and/or altitude control. The traditional method is to use chemical thrusters such as hydrazine thrusters combined with momentum wheels or magnetic torquers. Systems using electrothermal thrusters such as resitojets or arcjets are now common due to their specific impulse, i.e. fuel utilization. The use of Hall current and ion thrusters is even more attractive due to their even better specific impulse. The disadvantage of the Hall current and ion thruster systems is their complexity. Each thruster requires a plurality of supplies to power the thruster and its cathode(s). These thrusters are normally powered from separate isolated supplies.
A significant reduction in system complexity can be realized if the multiple thrusters are operated from a common discharge supply. In this method, the anode from each operating thruster is connected to the discharge supply (positive) and the cathodes connect to the discharge supply return (negative). The parallel architecture can also improve system reliability because it can allow sharing of cathodes between different thrusters. One significant problem with the parallel architecture with multiple cathodes is that the current sharing between the various cathodes is inherently unstable. There is a strong tendency for the cathode current to become significantly imbalanced. This imbalance can become so severe that only one cathode is supplying electrons.
Thus, there is a need to control or limit the cathode currents in thruster applications where the cathodes are not electrically isolated from each other.
While the problem of cathode control is disclosed in the following prior are systems, these systems are inadequate because none of them permits an efficient sharing of cathode current between a plurality of thrusters.
U.S. Patent Number 4,594,630 (Rabinowitz et al.) discloses emission controlled current limiter for use in electric power transmission and distribution. The apparatus controls the current either thermionically, by cold cathode emission, photoemission or with plasma devices. U.S. Patent Number 4,733,530 (Beattie et al.) discloses an emission current control system for multiple hollow cathode devices. Current sensors determine the current drawn by
each cathode from a power supply. The current sensor output signals are averaged, and this value is applied to a controller.
U.S. Patent Number 4,887,005 (Rough et al.) discloses multiple electrode plasma reaction power distribution system. A multiple electrode plasma reactor power circuit utilizes a power splitting device to deliver power to a plurality of powered electrodes. Balanced plasmas are created between powered electrodes and grounded electrodes.
Hall current and ion thrusters for space propulsion use separate cathodes to provide a source of electrons. If more than one cathode is operating at a time in a system where the cathodes are electrically common, there is a potential for non-uniform current sharing between the cathodes.
If the current imbalance between multiple cathodes becomes significant enough, the higher stressed cathode will suffer a reduction in operational life due to the higher temperature. There is a strong possibility of a run-away condition in which the more effective cathode provides all of the electron current to a thruster and the other cathode provides no current to a thruster. The unstable condition exists because the ability of the cathodes to emit electrons is a function of temperature. The temperature of the cathode increases with increasing current flow. This condition provides a situation of positive feedback that tends to prevent stable current balancing between cathodes that are electrically common.
There is a need for a cathode sharing system that allows common cathode connections while eliminating the drawbacks associated with unstable current balancing.
One embodiment of the invention is that the system has a controller and feedback loop to measure the cathode current and alter the relative electron flow from the cathodes by changing the cathode bias voltages. In this manner it is possible to adjust the current split between cathodes to any desired ratio within the operational limits of the cathodes. Another embodiment of the invention uses a passive resistive feedback to bias the cathodes to provide a balancing mechanism for cathode current flow. The resistive feedback method is simple but is more limited in the amount of control that is possible. The present invention can be applied to any number of cathodes connected to a common power bus.
In a simple system there may be two Hall current thrusters which are operated from a common anode power source. In such a system, each thruster is operated at the same power level and each Hall current thruster has one operating cathode. The present invention provides a method to ensure that the cathodes share current equally. The anode current flow is controlled in the conventional way by adjusting propellant flow rate. The proposed cathode biasing method is used to ensure that the cathode current flow is balanced.
The cathode current flow can be balanced and thereby balance stresses on the cathodes. The natural tendency for the cathodes to become imbalanced is solved by the present invention. This is accomplished without requiring that the cathodes be electrically isolated. The ability to have common anode power supplies allow a fault tolerant system design that is less complex and therefore less expensive than multiple anode power supply designs.
Figure 1 shows a cathode current control device.
Figure 2 shows a cathode bias supply circuit.
Figure 3 shows the cycle of transistors in the control circuitry.
Figure 4 shows a cathode bias control circuit. Figure 5 shows a feedback resistor embodiment that provides cathode balancing.
Figure 6 shows a configuration in which the cathode bias voltage supply is provided actively.
Figure 7 show a configuration implementing the present control method.
Figure 8 shows control circuitry of the cathode current sharing system. A method and apparatus (system) to control cathode current from a cathode to a thruster of a spacecraft are disclosed. This system is useful where there is a direct current (dc) connection between different operating cathodes. The system is illustrated with the thruster with anode layer (TAL) thruster example but is not limited to TAL thrusters. The system biases the cathode relative to the common return to change the relative current in the cathodes. The biasing will change the electric fields and therefore alter the relative electron flux from the cathodes. The operation is shown in the attached diagrams.
Figure 1 shows a thruster system 10 with a thruster 12. This diagram is a simplified cross sectional view of one thruster 12 and two operational cathode current sources 114 and 115. The concept is illustrated with TAL (Thruster with Anode Layer) Hall current thruster but is equally applicable to SPT (Stationary Plasma Thruster) Hall current thruster. It is also applicable to the neutralizer cathodes in an ion thruster system. The thruster 12 has an anode 136 with an inner circular anode ring 135 and an outer anode ring 137. Cathode current sources 114 and 115 provide cathode current 138, 139 to allow operation of the thruster 12. There are two parts to each of these cathode currents 138, 139. Cathode current 138 has components 138A and 138B and cathode current 139 has components 139A and 139B. Cathode current components 139A and 138A provide electrons to an electron cloud 134 that is held above the anode 136 by the Hall current forces. This cloud of electrons 134 provides an acceleration potential for the ions (typically xenon (Xe)) that are expelled from the anode 136 of the thruster 12 to produce thrust.
The electrons from this cloud 134 eventually fall through the Hall current field and initiate ionization of the thrust propellant 148 in the discharge chamber of the thruster 12.
The second major component of the cathode currents 138 and 139 is electron currents 138B and 139B respectively that are provided to neutralize the ions that are expelled from the thruster 12. This current component is shown as 138A and 139A in Figure 1.
The cathode current sources 114 and 115 are coupled to bias voltage sources 142 and 143 at the positive terminal. The negative terminal of voltage bias sources 142, 143 is coupled to the body of the thruster 12. Cathode current sources 114 and 115 have similar components. For discussion purposes, only cathode current source 114 will be described in detail. Cathode current source 114 has a cathode heater 116 with a heater power source 120 to heat an electron source 150, until the electrons reach a temperature sufficient to sustain the discharge of electrons from the cathode current source 114. The cathode current source 114 is self-heating after a cathode emitter 112 reaches a temperature of approximately 850 degrees Celsius. Above the self-heating, the cathode heater 116 is no longer needed. Once electrons have been separated from the cathode emitter 112, the electrons flow to the anode electron cloud 134 via current path 138A or to join the ions that are expelled from the thruster via current path 138B. A keeper 110 is used to initiate electron current 138 during startup.
Cathode current 138A flows from the emitter 112 of the cathode current source 114 to the thruster 12. The cathode current 138 is transferred through a plasma (not shown) or ion flux that surrounds the cathodes and thruster 12. The thruster 12 has a single anode 136. An anode power source 140 connects to the anode 136 to provide power from a power bus (not shown). The electron emitters surface 112, 113 are typically a low work a function metal such a lanthinum hexaboride or barium oxide. A propulsion medium 148 that is easily ionized such as xenon or argon is used to aid the emission of electrons at lower temperatures. In some cases materials such as mercury vapor have also been used. There is also a north pole magnet 129 at the center of the anode and a south pole magnet 132 at the perimeter of the anode. These magnetic poles 129 and 132 create a magnetic field that suspends the electrons from the cathode current 138A and 139A such that the electrons do not attract to the positive potential of the anode metal 136. The magnetic Hall force causes the electrons to circulate in an orbit and causes an electric field between the anode 136 and the suspended electrons. The suspended electrons form a virtual acceleration grid to accelerate electrons from the anode 136 creating thrust. The potential of the electron cloud 134 is near zero (2 to 25 volts) while the ions are generated at a much higher
potential which may be near the applied anode voltage which is often at 300 volts or higher. This large electric potential gradient causes an acceleration force to act on the ions.
The thruster 12 is coupled to a bias voltage source 142 that controls how much cathode current 138 is generated by cathode electron source 114. There may also be a second bias voltage source 143, which is coupled to thruster 12. The bias voltage source 143 is coupled to cathode current source 115, which produces cathode current 139. The greater the magnitude of the positive bias of the voltage bias source 142, the fewer electrons will be emitted from the cathode electron source 114, and hence a reduction in cathode current 138 will result. Since the total cathode current must be equal to the anode current 140, this means that the electrons from cathode current source 115 will increase correspondingly. The positive discharge current goes to anode current source 140 and the negative discharge current goes to body return 144.
The bias voltage source 142, 143 may maintain a bias voltage of zero while the cathode current is below a predetermined maximum level. This maximum level is a function of the ratio of thrusters to cathodes. In the example with one thruster and two cathode current sources, the cathode current in each cathode current source would be controlled to be one-half the anode current. This maintains equal magnitude between the cathode current sources. The total anode current equals the total cathode current. Some design systems in which the present invention could be used would have a maximum cathode current of one ampere, while other applications would have a higher threshold. The natural tendency is for the relative cathode current to increase with increasing cathode temperature and decrease with decreasing temperature. Since the cathode temperature increases with increasing temperature an unstable situation exists. Adjustment of bias voltage sources 142 and 143 provide a mechanism to counteract this inherent instability.
The greater the cathode current 138, the higher the temperature of the cathode 112. The bias voltage sources 142 and 143 maintain a balance in cathode current between a plurality of cathode current sources 114, 115 and thus maintains an equilibrium condition with the desired current distribution between the cathodes 112 and 113. One possible implementation of the bias circuitry is shown in Figure 2.
Current flows from the anode current source 140 to the cathode 114 and returns through the bias voltage source 142 to a body return 144. Body return 144 is connected to the thruster 12.
The anode current source 140 produces anode current. The total anode current is equal in magnitude to the total cathode current.
Power in the body return 144 may be transferred to another power source for uses in the thruster system 10 other than propulsion.
Figure 2 illustrates that bias voltage supply 142 or 143 can be a circuit 20 that is coupled to the cathode 112, via circuit input 212 and the thruster body return 144. Possible voltage ranges for the positive voltage bias supply are from about 0 to +30 volts with a more preferred range of about 0 to 10 volts. A negative bias voltage of substantially similar magnitude may also be effective.
Bias voltage control circuit 20 has input terminals 212 and 144. Terminal 212 is coupled to the positive terminal of the bias voltage supply connection and terminal 144 is the body return, which is a negative terminal of the bias voltage supply connection.
The bias voltage control circuit 20 also has two output terminals 210 and 214. Terminal 210 is a positive output terminal coupled to a positive terminal of a power receiving location such as a conventional satellite power bus (satellite power bus is not shown but is known to those skilled in the art).
Terminal 214 is coupled to a negative terminal of a power receiving location, such as the negative terminal of the satellite power bus. Power receiving locations may be, for example, the input power source to the Hall current system, or the anode power source. Possible magnitudes of this power are from about 15 to about 175 volts. The input from the cathode 212 is coupled to a MOSFET transistor Q2 234 that is coupled to a control unit 250. The control unit 250 also received as input, a voltage signal from shunt resister 244. Controller 250 drives transistor Ql 230 and transistor Q2 234. Controller 250 controls the bias voltage of the bias voltage source 142. Thus, the controller 250 determines the cathode current sharing of the thruster system 10 by controlling when the voltage bias voltage to a cathode current source 114, 115. There are multiple ways to control the bias voltage source 142 with controller 250, Figure 4 is an example of one such method.
Figure 3 shows the duty cycle of transistor Q2 230 at line 310 and the duty cycle of transistor Q2 234 at line 330. In the case where cathode current 138 is lower than the desired value, the "on" time of both Ql 230 and Q2 234 of Figure 2 is increased. If the cathode current 138 exceeds a desired magnitude then the "on" time of the Ql and Q2 (230 and 234) is decreased to allow the cathode voltage to increase. A typical desired result is to have the cathode current match the anode current for each thruster in the system or in a one thruster, two cathode system, for the total cathode current to equal the total anode current.
Alternatively, rather than utilizing pulsed width modulation, a resonant-type power converter with resonant control circuitry could be used. Typical elements for such a circuit are similar to those found in Figure 2 with the addition of resonant energy transfer elements such as capacitors and inductors as known by those skilled in the art.
Referring back to Figure 2, this causes the controller 250 to pulse width modulate transistors Ql 230 and Q2 234 thereby regulating the cathode voltage to the commanded voltage. When Q2 234 turns OFF, current from inductor 254 drives the primary of transformer 224. This causes power to be transferred to the input power bus 210 through the transformer 224 and diode 220. When Ql 230 is OFF, the voltage on the transformer 224 can reverse polarity to allow reset of the transformer core. The OFF duty cycle of the power switches can vary to approximately 50%. At the full 50% off duty cycle, the maximum possible bias voltage is injected.
Figure 4 shows circuitry of controller 250. The control circuitry performs the limiting function in the example, such that, if the cathode current exceeds a predetermined limit the control circuitry will cause the power circuitry in Figure 2 to bias the cathode positive, which causes a decrease in cathode current in one cathode current source and an increase in cathode current in the other cathode current source. The control circuitry 40 is used as an integrated circuit controller 418. An example is an industry standard 1825 type that is operated in the pulsed width modulated (PWM) control mode instead of a current mode control mode. In this mode of operation the transistors Ql 230 and Q2 234 have duty cycles that are the same and change slowly from cycle to cycle compared to the fast cycle by cycle response of the current control mode. The CMOS inverters 401, 402 and driver transistors 403, 404, 405, and 406 invert the controller outputs. If a controller with inverted output polarity was used, these additional drive parts could be deleted. The control circuitry could be designed to control equal cathode current instead of simply limiting the cathode current.
Figure 5 shows one possible method of providing feedback resistance. Feedback circuitry may include ballast resistors 560 and 580 to provide a feedback path for cathode balancing. This configuration can provide stable parallel operation of cathode electron sources 514, 515. The configuration illustrated shows two thrusters, 52 and 54 and two cathode current sources 515 and 514. The thruster anode current 530 is set by the propellant flow rate to the thrusters 52, 54. The following describes an example of one specific embodiment; however, the magnitudes could be changed to meet the requirements of a different application. In the case of two 4kW thrusters operating at 300 volts, the anode currents for each thruster can be approximately 13.3 Amperes. The total cathode current that must be supplied is the sum of each cathode current and therefore can range in magnitude from approximately 26 Amperes. An example of the above is a follows: if it is assumed that 0.5 ohms is chosen for ballast resistors 580 and 560 and each cathode current is 13.3 Amperes and the cathodes are perfectly balanced, then each cathode will be elevated above the common return by multiplying (13.3 Amperes)(0.5 ohms) or 6.65 volts. If the thrusters and cathodes are not perfectly balanced but have a slight voltage difference of two volts in
cathode voltage then the equilibrium condition is 5.5 volts on one cathode and 7.5 volts on the other cathode. While this is not perfect sharing, it would be expected to be a workable solution for simple systems. In the example the electron current supplied from one cathode would be about 11 Amperes and the electron current from the other cathode would be about 15 Amperes. This is a 15% imbalance from the average. This approach has the disadvantage of significant power dissipation in the resistors. In the case of the above example the lower current cathode bias resistor will have about 63.80 Watts of dissipation and the higher current resistor will have about 117.04 Watts of dissipation. A larger voltage drop in the resistors will cause better balancing but at the expense of more power dissipation. The method has a limited control range in balancing cathodes since a large voltage drop and consequently high power dissipation in ballasting resistors 560 and 580 is not normally desirable.
The resistor balance circuitry will always have some imbalance current. For example, if the current in cathode 512 increases, the voltage of cathode 512 will also increase and the voltage on cathode 513 will decrease because of the lower current. This will tend to increase the electron emissions from cathode 513 and decrease the electron emissions from cathode 512. This forms a balancing mechanism or feedback that tends to balance by making the resistor voltage drops different.
The passive resistor balance method could also make the resistors adjustable in value by switching in different value resistor or using rheostats. This approach can provide better matching of currents in the cathodes, but requires the addition of control circuitry to change the resistance values.
The voltage of each cathode 512, 513 is elevated above the return or common bus 570, which is typically less than 10 volts. The voltage of a cathode is determined by the total cathode current in each cathode 547 and 546 and the balancing resistances 560 and 580. In the case of cathode 514 for example, the cathode current is the total of all electron currents emitted from the emitter surface 512. There are multiple possible current paths for cathode electron current 546. Electrons can flow to thruster 54 as shown by current path 546A. Electrons are also emitted to the plume 575 to neutralize the beam of ions 576 emitted from thruster 54, as illustrated by line 577 A. In addition, there are electron current paths 539 that extend to the other thruster 52 and electrons 577B that neutralize a beam of ions 573,574 emitted from thruster 52. It is these electrons that cause the potential sharing problem between the cathodes 512, 513.
Beam ion current 573, 574, (discharged from thruster 52) and 575, 576 (discharged from thruster 54) are positive currents that are discharged from the thruster. These are typically about
cathode current 546. These attracted electrons form electron currents 577A and B, 578A and B. These electron current 577, 578 maintain charge neutrality.
Figure 6 shows a two thruster configuration in which the cathode bias voltage is provided actively. Each cathode current source 614, 615 has an associated cathode bias source 696, 692 respectively. This illustration shows a pair of stationary plasma type thrusters (SPT) 62 and 64. This configuration is equally applicable to a thruster with anode layer (TAL) type thruster. In this illustration, the cathode bias voltage sources 692, 696 are shown as a voltage source symbol. In practice this voltage source 692, 696 would likely be a power converter that can be used to adjust the voltage at the associated cathodes (i.e., voltage source 692 with cathode 613 and voltage source 696 with cathode 612). Referring back to Figure 2, shows that Figure 2 is one example of such a power converter.
For descriptive purposes, only operation of cathode source 615 will be described in detail. Cathode current source 614 operates in a similar fashion to cathode current source 615. The anode current 630 for each thruster 62, 64 respectively is controlled by the flow rate a gaseous material such as xenon gas 648, 649. The total anode current from both thrusters together is determined by the voltage and power level. For example if the two thrusters are operating at 4kW each at 300 volts from anode supply voltage 690 the total anode current 630 would be 26.67 Amperes and therefore, the sum of the total cathode currents 638 and 647 is also 26.67 Amperes. The anode current 630 in each thruster is controlled by the gas flow but where the electrons come from is not controlled.
Electrons may be supplied from either cathode and the natural tendency is for one cathode to supply all of the electron current and the other one to supply none of the current.
Figures 7 and 8 show one possible configuration to implement control of bias voltage of the embodiments shown in Figures 2, 3 and 4, using analog circuitry. A power converter transfers energy from an anode supply back to an input.
Figure 7 shows a system 70 with two anodes 722 and 723 and two cathodes 712 and 713. The two anodes 722 and 723 are operated from a common discharge supply voltage 750. There are anode current sensors 710 and 711 that measure the anode currents and produce a voltage that is proportional to current. There is an anode current path 705. In this embodiment the transfer function is 0.1 volts output per ampere of anode current. With this scale factor, a 4kW thruster operating at 300 volts will have 13.3 amperes of anode current. The voltage signal corresponding to current would be then 1.33 volts. Each cathode 712, 713 has a bias power converter 720, 721 in series with it and the common return 740. The power converters 720, 721 have a control input voltage or voltage command (VCMD1 770, and VCMD2 780) to output a voltage transfer
function. A power converter that illustrates this function is shown in Figures 2 and 3. (The control circuitry would be modified slightly to implement the voltage controlled voltage source function.) This voltage command is provided by command voltage circuit 80A and 80B that is shown in more detail as 80 in Figure 8. An example of the voltage transfer function is 2 volts of output per 1 volt of input. (One volt of voltage command 770 produces two volts of power converter output from power converter 720.) Voltage command inputs 770, 780 to the power converters 720, 721 are the output of the voltage comparison performed by circuitry as shown in Figure 8. The above example describes a system with two thrusters and two cathodes having two circuits 80A and 80B which are shown in Figure 8. It would be possible to use additional cathodes, each one having associated circuits as shown in Figure 8.
Figure 8 shows command voltage circuitry 80 produces an output 880 that is used as input VCMDl 770 to a power converter 720 of Figure 7. A second command voltage circuit 80B identical to circuit 80 produces an output 880 that is used as an input VCMDl 780 to power converter 721 of Figure 7. The command circuitry produces an output to the power converter 720, which causes the cathode current to be a function of anode current.
Referring back to Figure 7, each bias power converter 720, 721 is connected to a respective shunt resistor 730, 731. The shunt resistors 730, 731 are connected to the common return 740. The shunt resistors 730, 731 can have values of approximately between 0.005 ohms and 0.02 ohms. Figure 8 shows that the command voltage circuit 80 may have a shunt voltage, which can be 0.01 volts/ Ampere for example, that is filtered to remove noise and amplified by signal amplifier 820 to increase signal voltage. The difference between the anode current sensed by anode current sensor 710 of Figure 7 and the cathode current sensed by shunt resistor 730 of Figure 7 is calculated by difference amplifier 840 of Figure 8. The error amplifier 860 amplifies this voltage in order to create a command for the cathode bias converter. If the cathode current from shunt 730 of Figure 7 is lower than the anode current from sensor 710, then the error amplifier 860 of Figure 8 output is integrated less positive causing the cathode voltage to decrease. This causes an increase in the cathode current. The integrator capacitor 862 on the error amplifier 860 is used to compensate the feedback loop so it is stable. An offset is added to the control loop from a positive reference voltage 815 to prevent the cathode from being biased until the cathode current exceeds the anode current. This is necessary to accommodate error tolerances in the sensing and control circuitry. It also insures that the cathodes are biased the minimum amount possible for control. With this control implementation the more effective cathode will be biased positive and the less effective
cathode will be at the minimum possible bias. This reduces the power that must be handled by the bias power converters.
The cathode current sharing balancing method described could also be accomplished using a negative bias voltage instead of a positive bias voltage. It should be noted that this method could be extended to three or more thruster pairs. It can also be extended to allow two or more cathodes to provide current for a single thruster. The analog control illustrated in figure 8 could also be implemented with a computer control loop. In this approach the system embedded processor would measure the cathode current and the anode current and compute a command voltage for the cathode bias supplies. While the present embodiments describe TAL thrusters and stationary plasma thruster the cathode current sharing technique described herein could also be utilized with other types of thrusters, including ion thrusters.
While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art, without departing from the scope of the present invention as set forth in the following claims.