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Launch vehicles that use electric actuators for thrust vector or flight control require a safe, reliable and lightweight source of electrical power. Honeywell, working with NASA Glenn Research Center and Lockheed Martin Space Systems, has developed and successfully tested a turbine-driven electric power generation system which meets these needs. This Turbine Power Unit (TPU) uses hydrogen and oxygen propellants which react catalytically to drive a shaft-speed turboalternator mounted on foil bearings. A high-reactance permanent-magnet machine (HRPMM) was selected for this application. The power conditioning and control electronics can be located within the TPU housing and the hydrogen fuel can be used to pressurize the bearings and electronics and to regeneratively cool the machine. A brassboard unit incorporating many of these features was successfully tested at output power levels from 0 to 138 kilowatts (kW).

Honeywell is working with Lockheed Martin and NASA to develop a lightweight, turbine-driven electric power generation system that offers greatly increased safety and reduced operating costs as compared to existing systems. The approach is to utilize a “bang-bang” speed control system with fuel-rich, catalytically-reacted hydrogen and oxygen propellants to drive a turbine and shaft-speed, high-reactance permanent-magnet generator. The rotating assembly is supported by gas-cooled “foil” bearings. The flight system is envisioned to be regeneratively cooled and have power conditioning and control electronics integrated within the pressurized turbogenerator housing. System definition and component development have been completed. “Brassboard” system testing is currently underway.