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At least 325 records · Page 18

Development and Buildup of a Stirling Radioisotope Generator Electrical Simulator

This paper describes the development of a Stirling Radioisotope Generator (SRG) Simulator for use in a prototype lunar robotic rover. The SRG developed at NASA Glenn Research Center (GRC) is a promising power source for the robotic exploration of the sunless areas of the moon. The simulator designed provides a power output similar to the SRG output of 5.7 A at 28 Vdc, while using ac wall power as the input power source. The designed electrical simulator provides rover developers the physical and electrical constraints of the SRG supporting parallel development of the SRG and rover. Parallel development allows the rover design team to embrace the SRG s unique constraints while development of the SRG is continued to a flight qualified version.

Prokop, Norman F.↗

Extended Operation Testing of Stirling Convertors in Support of Stirling Radioisotope Power System Development

100 We class Stirling convertors began extended operation testing at NASA Glenn Research Center (GRC) in 2003 with a pair of Technology Demonstration Convertors (TDCs) operating in air. Currently, the number of convertors on extended operation test has grown to 12, including both TDCs and Advanced Stirling Convertors (ASCs) operating both in air and in thermal vacuum. Additional convertors and an electrically heated radioisotope generator will be put on test in the near future. This testing has provided data to support life and reliability estimates and the quality improvements and design changes that have been made to the convertor. The convertors operated 24/7 at the nominal amplitude and power levels. Performance data were recorded on an hourly basis. Techniques to monitor the convertors for change in internal operation included gas analysis, vibration measurements and acoustic emission measurements. This data provided a baseline for future comparison. This paper summarizes the results of over 145,000 hours of TDC testing and 40,000 hours of ASC testing and discusses trends in the data. Data shows the importance of improved materials, hermetic sealing, and quality processes in maintaining convertor performance over long life.

Lewandowski, Edward J.↗

Extended Operation Testing of Stirling Convertors in Support of Stirling Radioisotope Power System Development

100 We class Stirling convertors began extended operation testing at NASA Glenn Research Center (GRC) in 2003 with a pair of Technology Demonstration Convertors (TDCs) operating in air. Currently, the number of convertors on extended operation test has grown to 12, including both TDCs and Advanced Stirling Convertors (ASCs) operating both in air and in thermal vacuum. Additional convertors and an electrically heated radioisotope generator will be put on test in the near future. This testing has provided data to support life and reliability estimates and the quality improvements and design changes that have been made to the convertor. The convertors operated 24/7 at the nominal amplitude and power levels. Performance data were recorded on an hourly basis. Techniques to monitor the convertors for change in internal operation included gas analysis, vibration measurements, and acoustic emission measurements. This data provided a baseline for future comparison. This paper summarizes the results of over 145,000 hr of TDC testing and 40,000 hr of ASC testing and discusses trends in the data. Data shows the importance of improved materials, hermetic sealing, and quality processes in maintaining convertor performance over long life.

Lewandowski, Edward J.↗

Design of a Facility to Test the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG), a high efficiency generator, is being considered for space missions. An engineering unit, the ASRG engineering unit (EU), was designed and fabricated by Lockheed Martin under contract to the Department of Energy. This unit is currently under extended operation test at the NASA Glenn Research Center (GRC) to generate performance data and validate the life and reliability predictions for the generator and the Stirling convertors. A special test facility was designed and built for the ASRG EU. This paper summarizes details of the test facility design, including the mechanical mounting, heat-rejection system, argon system, control systems, and maintenance. The effort proceeded from requirements definition through design, analysis, build, and test. Initial testing and facility performance results are discussed.

Lewandowski, Edward J.↗

Reliability Demonstration Approach for Advanced Stirling Radioisotope Generator

Developed for future space missions as a high-efficiency power system, the Advanced Stirling Radioisotope Generator (ASRG) has a design life requirement of 14 yr in space following a potential storage of 3 yr after fueling. In general, the demonstration of long-life dynamic systems remains difficult in part due to the perception that the wearout of moving parts cannot be minimized, and associated failures are unpredictable. This paper shows a combination of systematic analytical methods, extensive experience gained from technology development, and well-planned tests can be used to ensure a high level reliability of ASRG. With this approach, all potential risks from each life phase of the system are evaluated and the mitigation adequately addressed. This paper also provides a summary of important test results obtained to date for ASRG and the planned effort for system-level extended operation.

Ha, CHuong↗

Testing to Characterize the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG), a high efficiency generator, is being considered for space missions. Lockheed Martin designed and fabricated an engineering unit (EU), the ASRG EU, under contract to the Department of Energy. This unit is currently undergoing extended operation testing at the NASA Glenn Research Center to generate performance data and validate life and reliability predictions for the generator and the Stirling convertors. It has also undergone performance tests to characterize generator operation while varying control parameters and system inputs. This paper summarizes and explains test results in the context of designing operating strategies for the generator during a space mission and notes expected differences between the EU performance and future generators.

Lewandowski, Edward↗

COMPASS Final Report: Saturn Moons Orbiter Using Radioisotope Electric Propulsion (REP): Flagship Class Mission

The COllaborative Modeling and Parametric Assessment of Space Systems (COMPASS) team was approached by the NASA Glenn Research Center (GRC) In-Space Project to perform a design session to develop Radioisotope Electric Propulsion (REP) Spacecraft Conceptual Designs (with cost, risk, and reliability) for missions of three different classes: New Frontier s Class Centaur Orbiter (with Trojan flyby), Flagship, and Discovery. The designs will allow trading of current and future propulsion systems. The results will directly support technology development decisions. The results of the Flagship mission design are reported in this document

Oleson, Steven R.↗

Miniature Radioisotope Thermoelectric Power Cubes

Cube-shaped thermoelectric devices energized by a particles from radioactive decay of Cm-244 have been proposed as long-lived sources of power. These power cubes are intended especially for incorporation into electronic circuits that must operate in dark, extremely cold locations (e.g., polar locations or deep underwater on Earth, or in deep interplanetary space). Unlike conventional radioisotope thermoelectric generators used heretofore as central power sources in some spacecraft, the proposed power cubes would be small enough (volumes would range between 0.1 and 0.2 cm3) to play the roles of batteries that are parts of, and dedicated to, individual electronic-circuit packages. Unlike electrochemical batteries, these power cubes would perform well at low temperatures. They would also last much longer: given that the half-life of Cm-244 is 18 years, a power cube could remain adequate as a power source for years, depending on the power demand in its particular application.

Patel, Jagdish U.↗

Natural Convection Cooling of the Advanced Stirling Radioisotope Generator Engineering Unit

After fueling and prior to launch, the Advanced Stirling Radioisotope Generator (ASRG) will be stored for a period of time then moved to the launch pad for integration with the space probe and mounting on the launch vehicle. During this time, which could be as long as 3 years, the ASRG will operate continuously with heat rejected from the housing and fins. Typically, the generator will be cooled by forced convection using fans. During some of the ground operations, maintaining forced convection may add significant complexity, so allowing natural convection may simplify operations. A test was conducted on the ASRG Engineering Unit (EU) to quantify temperatures and operating parameters with natural convection only and determine if the EU could be safely operated in such an environment. The results show that with natural convection cooling the ASRG EU Stirling convertor pressure vessel temperatures and other parameters had significant margins while the EU was operated for several days in this configuration. Additionally, an update is provided on ASRG EU testing at NASA Glenn Research Center, where the ASRG EU has operated for over 16,000 hr and underwent extensive testing.

Lewandowski, Edward J.↗

Small Radioisotope Power System at NASA Glenn Research Center

In April 2009, NASA Glenn Research Center (GRC) formed an integrated product team (IPT) to develop a Small Radioisotope Power System (SRPS) utilizing a single Advanced Stirling Convertor (ASC) with passive balancer for possible use by the International Lunar Network (ILN) program. The ILN program is studying the feasibility of implementing a multiple node seismometer network to investigate the internal lunar structure. A single ASC produces approximately 80 W(sub e) and could potentially supply sufficient power for that application. The IPT consists of Sunpower, Inc., to provide the single ASC with balancer, The Johns Hopkins University Applied Physics Laboratory (JHU/APL) to design an engineering model Single Convertor Controller (SCC) for an ASC with balancer, and NASA GRC to provide technical support to these tasks and to develop a simulated lunar lander test stand. A controller maintains stable operation of an ASC. It regulates the alternating current produced by the linear alternator of the convertor, provides a specified output voltage, and maintains operation at a steady piston amplitude and hot end temperature. JHU/APL also designed an ASC dynamic engine/alternator simulator to aid in the testing and troubleshooting of the SCC. This paper describes the requirements, design, and development of the SCC, including some of the key challenges and the solutions chosen to overcome those issues. In addition, it describes the plans to analyze the effectiveness of a passive balancer to minimize vibration from the ASC, characterize the effect of ASC vibration on a lunar lander, characterize the performance of the SCC, and integrate the single ASC, SCC, and lunar lander test stand to characterize performance of the overall system.

Dugala, Gina M.↗

Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover

The addition of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to the Mars Science Laboratory (MSL) Rover requires an advanced thermal control system that is able to both recover and reject the waste heat from the MMRTG as needed in order to maintain the onboard electronics at benign temperatures despite the extreme and widely varying environmental conditions experienced both on the way to Mars and on the Martian surface. Based on the previously successful Mars landed mission thermal control schemes, a mechanically pumped fluid loop (MPFL) architecture was selected as the most robust and efficient means for meeting the MSL thermal requirements. The MSL heat recovery and rejection system (HRS) is comprised of two Freon (CFC-11) MPFLs that interact closely with one another to provide comprehensive thermal management throughout all mission phases. The first loop, called the Rover HRS (RHRS), consists of a set of pumps, thermal control valves, and heat exchangers (HXs) that enables the transport of heat from the MMRTG to the rover electronics during cold conditions or from the electronics straight to the environment for immediate heat rejection during warm conditions. The second loop, called the Cruise HRS (CHRS), is thermally coupled to the RHRS during the cruise to Mars, and provides a means for dissipating the waste heat more directly from the MMRTG as well as from both the cruise stage and rover avionics by promoting circulation to the cruise stage radiators. A multifunctional structure was developed that is capable of both collecting waste heat from the MMRTG and rejecting the waste heat to the surrounding environment. It consists of a pair of honeycomb core sandwich panels with HRS tubes bonded to both sides. Two similar HX assemblies were designed to surround the MMRTG on the aft end of the rover. Heat acquisition is accomplished on the interior (MMRTG facing) surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the fluid loops to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aluminum facesheets and aerogel as insulation inside a composite honeycomb core. Complex assemblies of hand-welded and uniquely bent aluminum tubes are bonded onto each side of the HX panels, and are specifically designed to be easily mated and demated to the rest of the RHRS in order to ease the integration effort.

Mastropietro, A. J.↗

Design of a Facility to Test the Advanced Stirling Radioisotope Generator Engineering Unit

The Advanced Stirling Radioisotope Generator (ASRG) is being considered to power deep space missions. An engineering unit, the ASRG-EU, was designed and fabricated by Lockheed Martin under contract to the Department of Energy. This unit is currently on an extended operation test at NASA Glenn Research Center to generate performance data and validate the life and reliability predictions for the generator and the Stirling convertors. A special test facility was designed and built for testing the ASRG-EU. Details of the test facility design are discussed. The facility can operate the convertors under AC bus control or with the ASRG-EU controller. It can regulate input thermal power in either a fixed temperature or fixed power mode. An enclosure circulates cooled air around the ASRG-EU to remove heat rejected from the ASRG-EU by convection. A custom monitoring and data acquisition system supports the test. Various safety features, which allow 2417 unattended operation, are discussed.

Lewandowski, Edward J.↗

Advanced Stirling Radioisotope Generator Thermal Power Model in Thermal Desktop SINDA/FLUINT Analyzer

This paper presents a three-dimensional Advanced Stirling Radioisotope Generator (ASRG) thermal power model that was built using the Thermal Desktop SINDA/FLUINT thermal analyzer. The model was correlated with ASRG engineering unit (EU) test data and ASRG flight unit predictions from Lockheed Martin's Ideas TMG thermal model. ASRG performance under (1) ASC hot-end temperatures, (2) ambient temperatures, and (3) years of mission for the general purpose heat source fuel decay was predicted using this model for the flight unit. The results were compared with those reported by Lockheed Martin and showed good agreement. In addition, the model was used to study the performance of the ASRG flight unit for operations on the ground and on the surface of Titan, and the concept of using gold film to reduce thermal loss through insulation was investigated.

Wang, Xiao-Yen↗

Methods of Fabricating Scintillators with Radioisotopes for Beta Battery Applications

Technology has been developed for a class of self-contained, long-duration power sources called beta batteries, which harvest the energy contained in the radioactive emissions from beta decay isotopes. The new battery is a significant improvement over the conventional phosphor/solar cell concept for converting this energy in three ways. First, the thin phosphor is replaced with a thick scintillator that is transparent to its own emissions. By using a scintillator sufficiently thick to completely stop all the beta particles, efficiency is greatly improved. Second, since the energy of the beta particles is absorbed in the scintillator, the semiconductor photodetector is shielded from radiation damage that presently limits the performance and lifetime of traditional phosphor converters. Finally, instead of a thin film of beta-emitting material, the isotopes are incorporated into the entire volume of the thick scintillator crystal allowing more activity to be included in the converter without self-absorption. There is no chemical difference between radioactive and stable strontium beta emitters such as Sr-90, so the beta emitter can be uniformly distributed throughout a strontium based scintillator crystal. When beta emitter material is applied as a foil or thin film to the surface of a solar cell or even to the surface of a scintillator, much of the radiation escapes due to the geometry, and some is absorbed within the layer itself, leading to inefficient harvesting of the energy. In contrast, if the emitting atoms are incorporated within the scintillator, the geometry allows for the capture and efficient conversion of the energy of particles emitted in any direction. Any gamma rays associated with secondary decays or Bremsstrahlung photons may also be absorbed within the scintillator, and converted to lower energy photons, which will in turn be captured by the photocell or photodiode. Some energy will be lost in this two-stage conversion process (high-energy particle to low-energy photons to electric current). The geometric advantage partially offsets this as well, since the absorption depth of high-energy beta radiation is much larger than the depth of a p-n junction. Thus, in a p-n junction device, much of the radiation is absorbed far away from the junction, and the electron- hole pairs are not all effectively collected. In contrast, with a transparent scintillator the radiation can be converted to light in a larger volume, and all of the light can be collected in the active region of the photodiode. Finally, the new device is more practical because it can be used at much higher power levels without unduly shortening its lifetime. While the crystal structure of scintillators is also subject to radiation damage, their performance is far more tolerant of defects than that of semiconductor junctions. This allows the scintillator- based approach to use both higher energy isotopes and larger quantities of the isotopes. It is projected that this technology has the potential to produce a radioisotope battery with up to twice the efficiency of presently used systems.

Rensing, Noa M.↗

Testing of the Advanced Stirling Radioisotope Generator Engineering Unit at NASA Glenn Research Center

The Advanced Stirling Radioisotope Generator (ASRG) is a high-efficiency generator being developed for potential use on a Discovery 12 space mission. Lockheed Martin designed and fabricated the ASRG Engineering Unit (EU) under contract to the Department of Energy. This unit was delivered to NASA Glenn Research Center in 2008 and has been undergoing extended operation testing to generate long-term performance data for an integrated system. It has also been used for tests to characterize generator operation while varying control parameters and system inputs, both when controlled with an alternating current (AC) bus and with a digital controller. The ASRG EU currently has over 27,000 hours of operation. This paper summarizes all of the tests that have been conducted on the ASRG EU over the past 3 years and provides an overview of the test results and what was learned.

Lewandowski, Edward J.↗

External Magnetic Field Reduction Techniques for the Advanced Stirling Radioisotope Generator

Linear alternators coupled to high efficiency Stirling engines are strong candidates for thermal-to-electric power conversion in space. However, the magnetic field emissions, both AC and DC, of these permanent magnet excited alternators can interfere with sensitive instrumentation onboard a spacecraft. Effective methods to mitigate the AC and DC electromagnetic interference (EMI) from solenoidal type linear alternators (like that used in the Advanced Stirling Convertor) have been developed for potential use in the Advanced Stirling Radioisotope Generator. The methods developed avoid the complexity and extra mass inherent in data extraction from multiple sensors or the use of shielding. This paper discusses these methods, and also provides experimental data obtained during breadboard testing of both AC and DC external magnetic field devices.

Thermoelectric Power Generation↗

Summary of Stirling Convertor Testing at NASA Glenn Research Center in Support of Stirling Radioisotope Power System Development

The NASA Glenn Research Center (GRC) has been testing 100 We class, free-piston Stirling convertors for potential use in Stirling Radioisotope Power Systems (RPS) for space science and exploration missions. Free-piston Stirling convertors are capable of achieving a 38% conversion efficiency, making Stirling attractive for meeting future power system needs in light of the shrinking U.S. plutonium fuel supply. Convertors currently on test include four Stirling Technology Demonstration Convertors (TDCs), manufactured by the Stirling Technology Company (STC), and six Advanced Stirling Convertors (ASCs), manufactured by Sunpower, Inc. Total hours of operation is greater than 514,000 hours (59 years). Several tests have been initiated to demonstrate the functionality of Stirling convertors for space applications, including: in-air extended operation, thermal vacuum extended operation. Other tests have also been conducted to characterize Stirling performance in anticipated mission scenarios. Data collected during testing has been used to support life and reliability estimates, drive design changes and improve quality, and plan for expected mission scenarios. This paper will provide a summary of convertors tested at NASA GRC and discuss lessons learned through extended testing.

Energy Conversion Efficiency↗

Radioisotope Stirling Engine Powered Airship for Atmospheric and Surface Exploration of Titan

The feasibility of an advanced Stirling radioisotope generator (ASRG) powered airship for the near surface exploration of Titan was evaluated. The analysis did not consider the complete mission only the operation of the airship within the atmosphere of Titan. The baseline airship utilized two ASRG systems with a total of four general-purpose heat source (GPHS) blocks. Hydrogen gas was used to provide lift. The ASRG systems, airship electronics and controls and the science payload were contained in a payload enclosure. This enclosure was separated into two sections, one for the ASRG systems and the other for the electronics and payload. Each section operated at atmospheric pressure but at different temperatures. The propulsion system consisted of an electric motor driving a propeller. An analysis was set up to size the airship that could operate near the surface of Titan based on the available power from the ASRGs. The atmospheric conditions on Titan were modeled and used in the analysis. The analysis was an iterative process between sizing the airship to carry a specified payload and the power required to operate the electronics, payload and cooling system as well as provide power to the propulsion system to overcome the drag on the airship. A baseline configuration was determined that could meet the power requirements and operate near the Titan surface. From this baseline design additional trades were made to see how other factors affected the design such as the flight altitude and payload mass and volume.

Titan↗