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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

A Study on Effect of Tuning Capacitor in Dynamic Radioisotope Power Systems

This study presents the effect of tuning capacitors on the power factor and power output of a gas spring-based free-piston Stirling convertor—Advanced Stirling convertor—when the convertor runs on a forced-oscillation type controller. More specifically, this paper studies how off-nominal tuning capacitance values affects the Stirling convertor in terms of the piston stability and electrical power output, when the convertor is operated by forced-oscillation type controller, such as an alternating current bus controller, and operating conditions of the convertor are unchanged. It has been widely known that tuning capacitors are important circuit components to stabilize the piston amplitude of the free-piston Stirling convertors and correct the power factor for high electrical power output. Recent modeling analysis conducted by NASA Glenn Research Center, however, suggests that while the stability of the convertor is affected by the tuning capacitor value, the power factor and the electrical power output are not affected by the tuning capacitor value, as long as the convertor is controlled by a forced-oscillation controller and the convertor operating conditions, such as the hot-end/cold-end temperatures, piston amplitude, and operating frequency, are unchanged. To verify the modeling analysis results, a test setup is devised where the convertor is controlled by a forced-oscillation controller and the piston amplitude, hot-end temperature, and charge pressure are controlled to 4mm, 760˚C, and 485psig, respectively, while the tuning capacitor value is changed from its nominal value, 840μF to 1040μF and 1240μF. Furthermore, the vibration test results of the same convertor with the three tuning capacitor values are also presented in this paper to show the effect of the tuning capacitor value on the convertor stability. The test results suggest that when the convertor is controlled by a forced-oscillation, the tuning capacitor value determines the convertor stability but not the power factor nor electrical power output. Therefore, the tuning capacitance value in forced-oscillation controllers should be determined based on the convertor stability, system mass, and volume.

Free-Piston Stirling Convertor Controller↗
NASA NTRSDate not supplied

A Study on Effect of Tuning Capacitor in Dynamic Radioisotope Power Systems

This study presents the effect of the tuning capacitor on the stability and electrical power output of a gas spring-based free-piston Stirling convertor (FPSC) when the FPSC runs on a forced-oscillation type controller. It has been widely accepted that the tuning capacitor is an important circuit component of the FPSC to stabilize piston amplitude and maximize electrical power output by correcting the power factor. Recent modeling analysis, however, suggests that while the effect on the stability is significant, the effect on the electrical power output is almost negligible as long as the operating frequency the FPSC is fixed by a forced-oscillation controller and operating conditions, such as the hot-end/cold-end temperatures, piston amplitude, and pressure, are unchanged. To verify the modeling analysis results, Advanced Stirling Convertor (ASC) is controlled by an AC power supply and the piston amplitude, hot-end temperature, cold-end temperature, and pressure are actively controlled to 4.3mm, 760˚C, 40˚C and 485psig, respectively, while the tuning capacitor value is changed from 840μF to 1040μF and 1240μF. Furthermore, the vibration test results of the ASC with the three tuning capacitor values are also presented to show the effect of the tuning capacitor on stability. The test results suggest that when the FPSC operates at a fixed frequency, the effect of tuning capacitor on electrical power output is negligible while the effect on stability is rather significant. Therefore, the tuning capacitor value should be selected toward the highest stability.

Free-Piston Stirling Convertor Controller↗
NASA NTRSDate not supplied

A Study on Effect of Tuning Capacitor in Dynamic Radioisotope Power Systems

This study presents the effect of the tuning capacitor on stability and electrical power output of a gas-bearing based free-piston Stirling convertor (FPSC) when operating on a fixed-frequency type controller. It has been widely accepted that the tuning capacitor is an important circuit component of the FPSC to stabilize piston amplitude and maximize electrical power output by correcting the power factor. Models suggest the stability of the FPSC is strongly coupled to the tuning capacitance, while the coupling to the electrical power output is weak. This applies to cases where the operating frequency of the FPSC is fixed by a fixed-frequency controller and other operating conditions, such as the hot-end and cold-end temperatures, piston amplitude, and pressure are constant. To verify the modeling analysis results, an Advanced Stirling Convertor (ASC) was controlled by an AC power supply and the piston amplitude, hot-end temperature, cold-end temperature, and pressure are actively controlled to 4.3mm, 760˚C, 40˚C and 485psig, respectively, while the tuning capacitor value was changed from 840μF to 1040μF and 1240μF. Furthermore, the vibration test results of the ASC with different tuning capacitor values are also presented to show the effect of the tuning capacitor on stability. The experimental test results verified that the effect of tuning capacitor on electrical power output is negligible while the effect on stability is rather noticeable. Therefore, the ideal tuning capacitor value should be selected based on required stability of the FPSC.

Free-Piston Stirling Convertor Controller↗
NASA NTRS2022

Maturation of Dynamic Power Convertors for RPS Robotic Space Exploration

NASA is developing dynamic power conversion technologies for future robotic space science and exploration missions powered by Radioisotope Power Systems (RPS). The Dynamic Radioisotope Power Systems (DRPS) Project is working to mature numerous dynamic power convertors and controllers for potential infusion into future flight generators. Maturation of power conversion technologies is being managed by the RPS Program and executed by the DRPS Project and Thermal Energy Conversion Branch located at NASA’s Glenn Research Center (GRC). Convertor maturation includes multiple convertor technology development contracts to deliver new prototypes and continued testing of relevant legacy convertors, commissioned during past projects. The convertor technology development contracts include two Stirling contractor teams and one Brayton team. All contracts have now completed prototype fabrication and testing planned during Phase 2. Government assessment of the new prototypes includes verification of performance in relevant environments and validation of the design with a focus on robustness.

Scott Wilson↗
NASA NTRSDate not supplied

Maturation of Dynamic Power Convertors for RPS Robotic Space Exploration

NASA is developing dynamic power conversion technologies for future robotic space science and exploration missions powered by Radioisotope Power Systems (RPS). The Dynamic Radioisotope Power Systems (DRPS) Project is working to mature numerous dynamic power convertors and controllers for potential infusion into future flight generators. Maturation of power conversion technologies is being managed by the RPS Program and executed by the DRPS Project and Thermal Energy Conversion Branch located at NASA’s Glenn Research Center (GRC). Convertor maturation includes multiple convertor technology development contracts to deliver new prototypes and continued testing of relevant legacy convertors, commissioned during past projects. The convertor technology development contracts include two Stirling contractor teams and one Brayton team. All contracts have now completed prototype fabrication and testing planned during Phase 2. Government assessment of the new prototypes includes verification of performance in relevant environments and validation of the design with a focus on robustness.

Scott Wilson↗
NASA NTRS2022

Mission Incredible: A Titan Sample Return Using In-Situ Propellants

An analysis of the use of in-situ volatile propellants for a sample return mission from Titan shows that this mission should be feasible. Such a mission would be invaluable for its science return, and its contribution to our understanding the origins of organic compounds in the solar system and our place in the universe.

Titan↗
NASA NTRS2023

Development of Stirling Convertors for Radioisotope and Fission Power Systems

NASA has been developing free-piston Stirling-cycle power convertors over the past 22 years for use in nuclear power systems that would provide electricity for space science missions to dark, dusty, or distant destinations where solar power is not practical. These nuclear power systems would generate heat from either the radioactive decay of isotopes or fission nuclear reactors. That heat would be converted to usable electricity using highly efficient Stirling convertors for a wide range of power needs needing 10s of watts to 50 kWe. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced thermoelectric and dynamic conversion technologies that would increase the system efficiency beyond what is currently possible using heritage systems to enable a larger number of robotic missions or higher power missions to solar system bodies of interest. The Dynamic Radioisotope Power Systems (DRPS) Project has matured prototype Stirling convertors to sufficiently increase the technology readiness level for infusion into flight development. Flexure and gas-bearing free-piston Stirling convertors were developed under contract by commercial partners and delivered to enable government evaluation. Gas-bearing designs have met performance and robustness requirements and were selected for flight development. This paper provides the status of SRSC test campaign and maturity level.

Dynamic↗
NASA NTRSDate not supplied

Development of Stirling Convertors for Radioisotope and Fission Power Systems

NASA has been developing free-piston Stirling-cycle power convertors over the past 22 years for use in nuclear power systems that would provide electricity for space science missions to dark, dusty, or distant destinations where solar power is not practical. These nuclear power systems would generate heat from either the radioactive decay of isotopes or fission nuclear reactors. That heat would be converted to usable electricity using highly efficient Stirling convertors for a wide range of power needs needing 10s of watts to 50 kWe. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced thermoelectric and dynamic conversion technologies that would increase the system efficiency beyond what is currently possible using heritage systems to enable a larger number of robotic missions or higher power missions to solar system bodies of interest. The Dynamic Radioisotope Power Systems (DRPS) Project has matured prototype Stirling convertors to sufficiently increase the technology readiness level for infusion into flight development. Flexure and gas-bearing free-piston Stirling convertors were developed under contract by commercial partners and delivered to enable government evaluation. Gas-bearing designs have met performance and robustness requirements and were selected for flight development. This paper provides the status of SRSC test campaign and maturity level.

Dynamic↗
NASA NTRSDate not supplied

Modeling and Analysis of Stirling Power Convertors

Modeling and Analysis of Stirling Power Convertors Luis A. Rodriguez1 Steven M. Geng, Terry V. Reid, Scott D. Wilson NASA Glenn Research Center, Cleveland, OH, 44135, USA NASA Glenn’s Thermal Energy Conversion Branch is supporting the development of the next generation free-piston Stirling power convertors. American Superconductor (AMSC) and Sunpower Inc. are the two firms under contract to develop the Flexure Isotope Stirling Convertor (FISC) and the Sunpower Robust Stirling Convertor (SRSC), respectively. To comprehend and forecast convertor performance, Sage, ANSYS® Maxwell, and ANSYS® Fluent were used to model the Stirling thermodynamic cycle, alternator electromagnetics, and piston and displacer dynamics. I. Introduction Stirling convertors are being developed by NASA as a potential steady source of electrical power for NASA’s future scientific space missions. Currently, NASA Glenn Research Center has two corporations under contract, American Superconductor (AMSC) and Sunpower Inc., for the development of the next generation of free-piston Stirling convertors for dynamic radioisotope power systems. AMSC is developing the Flexure Isotope Stirling Convertor (FISC), which uses flexures to prevent side motion and rubbing of the piston. Similarly, Sunpower Inc, is developing the Sunpower Robust Stirling Convertor (SRSC). The SRSC uses gas bearings to prevent radial contact of the moving piston. As convertor development continues, it is increasingly important to understand and predict the interactions of components in the system, how they respond to one another, and how they perform as a response to changes in operating conditions. A suitable and enlightening way to demonstrate and foresee these interactions is with the use of accurate modeling software. Sage, ANSYS® Maxwell, and ANSYS® Fluent are the current modeling tools used by NASA to analytically determine convertor performance. Sage is a one-dimensional object-oriented commercial software package used for modeling and optimizing Stirling convertors for Dynamic Radioisotope Power Systems (DRPS) and it is one of the most accurate Stirling convertor codes in use by NASA. This code is the successor to GLIMPS (Globally-Implicit Stirling Cycle Simulation) and GLOP (GLIMPS Optimization) software created by Gedeon Associates [1]. Model input parameters are typically material/gas type, component physical dimensions, temperatures, frequency, charge pressure, and number of time/space nodes. Sage is used to model both the FISC’s and SRSC’s Stirling cycle thermodynamics and piston/displacer dynamics. Performance maps were created and analyzed for both power systems to better understand the relationship between the following conditions: cold-end temperature, hot-end temperature, piston/displacer amplitudes, pressure drop, and thermal input power. The synergy between these conditions will help determine parameter sensitivity. ANSYS® Maxwell was used to create a three-dimensional (3-D) axisymmetric model for both FISC and SRSC alternators. The significant physical components included in each model are the magnets, magnet carrier, outer/inner laminations, and the coil. Inputs to the model are piston amplitude, piston frequency, alternator load, coil resistance, tuning capacitance, and specific material properties. The alternator models calculate terminal voltage, current, piston/current phase, voltage/current phase, coil inductance, terminal power and efficiency. The RI2 losses, core (hysteresis and eddy) losses, and magnet/can eddy losses are also a part of the final results. ANSYS® Fluent is used to build 3-D computational fluid dynamic (CFD) models to examine the Stirling cycle thermodynamics for both the FISC and SRSC systems. Three-dimensional Computer Aided Design (CAD) models were used to create the physical components of each convertor. Steady-state simulations were conducted for hardware testing, prediction of environmental losses during testing, and generation of radiation look-up tables. The model inputs to the aforementioned analysis are the material properties and boundary thermal conditions. The steady-state model calculates temperature and heat flow distributions. Transient 3-D calculations were also part of the CFD analysis. In this study a physically reduced version of the FISC is used to obtain a prediction of available engine power. For the gas bearing SRSC, the transient effort is used to obtain a prediction of bearing pad performance and its sensitivity to micro-channel geometric variation. The model inputs to the transient simulations are the piston amplitude, displacer amplitude, frequency, displacer/piston phase angle, dynamic deforming CFD grid, temperature boundary conditions, and user defined files describing motion profile of piston/displacer. The results of the model are temperature distributions, heat distributions, and PV power produced at pre-determined conditions.

Luis A Rodriguez↗
NASA NTRS2019

Small Stirling Technology Exploration Power for Future Space Science Missions

High efficiency dynamic Radioisotope Power Systems (RPS) could be mission enabling for low power space applications such as small probes, landers rovers, and communication repeaters. These applications would contain science instruments and be distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Small RPS could be used to provide power for sensing radiation, temperature, pressure, seismic activity, and other measurements of interest to planetary scientists. Small RPS would use fractional versions of the General Purpose Heat Source (GPHS) or Light Weight Radioisotope Heater Units (LWRHU), to heat power conversion technologies. Dynamic power systems are capable of three to four times higher conversion efficiency compared to static power conversion technologies, and would provide an equal amount of power using less fuel or more power using an equal amount of fuel. Providing spacecraft with more power could decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. NASA GRC is developing a low power dynamic RPS that would convert heat from multiple LWRHU to one watt of usable direct current electric power for spacecraft instrumentation and communication. The power system could be used to charge batteries or capacitors for higher power burst usage. The initial design, called Small Stirling Technology Exploration Power (smallSTEP), is around 3 kg, 11 cm diameter X 32 cm long, and converts 8 watts of heat to one watt of electricity using a Stirling convertor. This low power conversion system represents a new class of RPS with power levels two orders of magnitude lower than prototypes currently being developed for space applications under NASA contracts. Development of the 1-watt RPS includes maturation of convertor and controller designs, performance evaluation of an evacuated metal foil insulation, and development of system interfaces. Initial demonstration of the subsystems has been completed in a laboratory environment and a higher fidelity system is being pursued for demonstration in relevant environments for use on small spacecraft needed to carry out future space science missions.

Wilson, Scott D.↗
NASA NTRS2019

Small Stirling Technology Exploration Power for Future Space Science Missions

High efficiency dynamic Radioisotope Power Systems (RPS) could be mission enabling for low power space applications such as small probes, landers rovers, and communication repeaters. These applications would contain science instruments and be distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Small RPS could be used to provide power for sensing radiation, temperature, pressure, seismic activity, and other measurements of interest to planetary scientists. Small RPS would use fractional versions of the General Purpose Heat Source (GPHS) or Light Weight Radioisotope Heater Units (LWRHU), to heat power conversion technologies. Dynamic power systems are capable of three to four times higher conversion efficiency compared to static power conversion technologies, and would provide an equal amount of power using less fuel or more power using an equal amount of fuel. Providing spacecraft with more power could decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. NASA Glenn Research Center (GRC) is developing a low power dynamic RPS that would convert heat from multiple LWRHU to one watt of usable direct current electric power for spacecraft instrumentation and communication. The power system could be used to charge batteries or capacitors for higher power burst usage. The initial design, called Small Stirling Technology Exploration Power (smallSTEP), is around 3 kg, 11 cm diameter X 32 cm long, and converts 8 watts of heat to one watt of electricity using a Stirling convertor. This low power conversion system represents a new class of RPS with power levels two orders of magnitude lower than prototypes currently being developed for space applications under NASA contracts. Development of the 1-watt RPS includes maturation of convertor and controller designs, performance evaluation of an evacuated metal foil insulation, and development of system interfaces. Initial demonstration of the subsystems has been completed in a laboratory environment and a higher fidelity system is being pursued for demonstration in relevant environments for use on small spacecraft needed to carry out future space science missions.

Wilson, Scott↗
NASA NTRSDate not supplied

Modeling and Analysis of Stirling Power Convertors

NASA Glenn’s Thermal Energy Conversion Branch is supporting the development of the next generation free-piston Stirling power convertors for Dynamic Radioisotope Power Systems (DRPS). American Superconductor (AMSC) and Sunpower Inc. are the two of the firms under contract to develop the Flexure Isotope Stirling Convertor (FISC) and the Sunpower Robust Stirling Convertor (SRSC), respectively, to meet DRPS requirements. To comprehend and forecast convertor performance, Sage, ANSYS® Maxwell, and ANSYS® Fluent were used to model the Stirling thermodynamic cycle, alternator electromagnetics, and piston and displacer dynamics.

Stirling↗