Robert Winsor, NSS's Laser man, and Nic DeGrazia, our filmographer in residence, observing the NSS climber during the power test.

NSS's TPV array

Moving to photovoltaics, NSS settled on a PV technology called TPV – Thermal Photovoltaics. These cells are optimized to operate with thermal IR radiation (longer wavelength than TRUMPF’s NIR 1030 nm beam) but have acceptable performance at this wavelength as well. More importantly, these cells can work with high light intensities, which means that you can get more power out of a smaller (and thus lighter) array, if only you can get the transfer the excess heat away from the cells.

What this calls for is a good heat exchanger – and this turned out to be the highlight of the day.

Check out the images of the climber. The TPV cells are completely immersed in acetone (4 ounces) which is vigorously boiling away under the heat load of the beam, completely evaporating every 15 seconds – only to be continuously captured by the bags and dripped back down onto the cells.

Acetone was chosen since it has the lowest boiling temperature, and so will be most effective as the working fluid.  This is a basically a cooling tower (or heat pipe) – something that was used by Centaurus Aerospace back in the 2005 games – using water in vacuum, in their case. The acetone solution is a lot lighter, and yes – more flammable.

We’ve looked into this issue, and we recognize that there are failure modes under which the system can develop a leak, but we feel that a) the acetone is far removed from any spark sources, b) there is only a small amount of acetone in the system, and c) there is no place for leaking acetone to accumulate, and so the consequences of an acetone leak are acceptable. We will also be monitoring the temperature of the PV receiver, and if we see it rising above the boiling point of acetone, we will know that the acetone is depleted and the climb is over.

So after observing the climber operating under full laser power, and with some modifications required, we’ve decided to ok the design, and allow NSS to catch up and participate in this year’s challenge.

One of the nice things about having multiple teams is that you get to see different ideas at work, and NSS is definitely not short on ideas.

Their first climber design featured a thermal (rather than photovoltaic) receiver, based on a Stirling engine. (Stirling engines are high efficiency engines often used for solar power generation) Stirling engines are a difficult proposition for a Space Elevator climber, since they typically weigh a lot more than a PV panel, and so NSS had to design and manufacture their own engine – and it is indeed a beauty. Using Helium as the working fluid, this engine also uses a transparent cylinder head in order to get the laser beam directly into a thermal absorber that is placed inside the cylinder – a perfect way to avoid the latency associated with the thermal mass of a regular absorber plate.

The problem NSS ran into was with properly sealing the engine while keeping the weight down. Anyone who’s ever worked with Helium knows how difficult it is to seal – it is a noble gas, and so is monatomic, which means its molecules are really small, and they get around most seals.

The other problem faced by thermodynamic engines is that while they are able to capture 100% of the energy of the beam (unlike the 30-50% of PV cells) they have to waste a good fraction of it at the heat exhaust side, and this gets worse the hotter the exhaust is. Which means that a thermodynamic engine needs to be coupled to an efficient heat exchanger – something that NSS started to design as well.

As it turned out, NSS was not able to solve the He sealing issue, and started working fast towards a photovoltaic “plan B” climber. However, not all of the effort was wasted – the heat exchanger design turns out to be very important in keeping their PV cells cool – more on that on the next post.

As a side note, Bert Murray and Matt Abrams have vowed that if the prize money is not awarded this year, they will solve the Helium seal issue and be back next year with a working Stirling climber.