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NASA NTRS2000

Technology Development for a Stirling Radioisotope Power System

NASA Glenn Research Center and the Department of Energy are developing a Stirling convertor for an advanced radioisotope power system to provide spacecraft on-board electric power for NASA deep space missions. NASA Glenn is addressing key technology issues through the use of two NASA Phase II SBIRs with Stirling Technology Company (STC) of Kennewick, WA. Under the first SBIR, STC demonstrated a synchronous connection of two thermodynamically independent free-piston Stirling convertors and a 40 to 50 fold reduction in vibrations compared to an unbalanced convertor. The second SBIR is for the development of an Adaptive Vibration Reduction System (AVRS) that will essentially eliminate vibrations over the mission lifetime, even in the unlikely event of a failed convertor. This paper presents the status and results for these two SBIR projects and also discusses a new NASA Glenn in-house project to provide supporting technology for the overall Stirling radioisotope power system development. Tasks for this new effort include convertor performance verification, controls development, heater head structural life assessment, magnet characterization and thermal aging tests, FEA analysis for a lightweight alternator concept, and demonstration of convertor operation under launch and orbit transfer load conditions.

Thieme, Lanny G.↗

NASA NTRS2000

Parametric Study of Radiator Concepts for a Stirling Radioisotope Power System Applicable to Deep Space Mission

The Department of Energy (DOE) and the NASA Glenn Research Center are developing a Stirling converter for an advanced radioisotope power system to provide spacecraft onboard electric power for NASA deep space missions. This high-efficiency converter is being evaluated as an alternative to replace the much lower efficiency radioisotope thermoelectric generator (RTG). The current power requirement (six years after beginning of mission (BOM) for a mission to Jupiter) is 210 W(sub e) (watts electric) to be generated by two separate power systems, one on each side of the spacecraft. Both two-converter and four-converter system designs are being considered, depending on the amount of required redundancy.

Juhasz, Albert J.↗

NASA NTRS2002

Outer Planet Exploration with Advanced Radioisotope Electric Propulsion

In response to a request by the NASA Deep Space Exploration Technology Program, NASA Glenn Research Center conducted a study to identify advanced technology options to perform a Pluto/Kuiper mission without depending on a 2004 Jupiter Gravity Assist, but still arriving before 2020. A concept using a direct trajectory with small, sub-kilowatt ion thrusters and Stirling radioisotope power systems was shown to allow the same or smaller launch vehicle class as the chemical 2004 baseline and allow a launch slip and still flyby in the 2014 to 2020 timeframe. With this promising result the study was expanded to use a radioisotope power source for small electrically propelled orbiter spacecraft for outer planet targets such as Uranus, Neptune, and Pluto.

Oleson, Steven↗

NASA NTRS2002

Radioisotope Electric Propulsion for Fast Outer Planetary Orbiters

Recent interest in outer planetary targets by the Office of Space Science has spurred the search for technology options to enable relatively quick missions to outer planetary targets. Several options are being explored including solar electric propelled stages combined with aerocapture at the target and nuclear electric propulsion. Another option uses radioisotope powered electric thrusters to reach the outer planets. Past work looked at using this technology to provide faster flybys. A better use for this technology is for outer planet orbiters. Combined with medium class launch vehicles and a new direct trajectory these small, sub-kilowatt ion thrusters and Stirling radioisotope generators were found to allow missions as fast as 5 to 12 years for objects from Saturn to Pluto, respectively. Key to the development is light spacecraft and science payload technologies.

Oleson, Steven↗

NASA NTRS2004

Development of a Multi-bus, Multi-source Reconfigurable Stirling Radioisotope Power System Test Bed

The National Aeronautics and Space Administration (NASA) has typically used Radioisotope Thermoelectric Generators (RTG) as their source of electric power for deep space missions. A more efficient and potentially more cost effective alternative to the RTG, the high efficiency 110 watt Stirling Radioisotope Generator 110 (SRG110) is being developed by the Department of Energy (DOE), Lockheed Martin (LM), Stirling Technology Company (STC) and NASA Glenn Research Center (GRC). The SRG110 consists of two Stirling convertors (Stirling Engine and Linear Alternator) in a dual-opposed configuration, and two General Purpose Heat Source (GPHS) modules. Although Stirling convertors have been successfully operated as a power source for the utility grid and as a stand-alone portable generator, demonstration of the technology required to interconnect two Stirling convertors for a spacecraft power system has not been attempted. NASA GRC is developing a Power System Test Bed (PSTB) to evaluate the performance of a Stirling convertor in an integrated electrical power system application. This paper will describe the status of the PSTB and on-going activities pertaining to the PSTB in the NASA Thermal-Energy Conversion Branch of the Power and On-Board Propulsion Technology Division.

Coleman, Anthony S.↗

NASA NTRS2004

Reliability Issues in Stirling Radioisotope Power Systems

Stirling power conversion is a potential candidate for use in a Radioisotope Power System (RPS) for space science missions because it offers a multifold increase in the conversion efficiency of heat to electric power and reduced requirement of radioactive material. Reliability of an RPS that utilizes Stirling power conversion technology is important in order to ascertain long term successful performance. Owing to long life time requirement (14 years), it is difficult to perform long-term tests that encompass all the uncertainties involved in the design variables of components and subsystems comprising the RPS. The requirement for uninterrupted performance reliability and related issues are discussed, and some of the critical areas of concern are identified. An overview of the current on-going efforts to understand component life, design variables at the component and system levels, and related sources and nature of uncertainties are also discussed. Current status of the 110 watt Stirling Radioisotope Generator (SRG110) reliability efforts is described. Additionally, an approach showing the use of past experience on other successfully used power systems to develop a reliability plan for the SRG110 design is outlined.

Shah, Ashwin R.↗

NASA NTRS2005

Reliability Issues in Stirling Radioisotope Power Systems

Schreiber, Jeffrey↗

NASA NTRS2005

Radioisotope Electric Propulsion (REP) Spacecraft Design Concept Considerations

Radioisotopic Electric Propulsion (REP) has the potential to provide certain advantages for outer planetary exploration involving small bodies and long term investigation s for medium class missions requiring power comparable to past outer planetary exploration missions. This paper describes a preliminary conceptual design of a REP-based spacecraft where the mission of interest involves a spacecraft with a radioisotope power supply less than one kilowatt while operating at a minimum of 10-years. A key element of the REP spacecraft is to insure sustained science return by orbiting or flying in formation with selected targets. Utilizing current/impending technological advances, REP orbiter/explorer missions may provide a valuable tool for extended scientific investigations of small bodies in the outer solar system.

Edwards, Daryl A.↗

NASA NTRS2005

Utilizing Radioisotope Power Systems for Human Lunar Exploration

The Vision for Space Exploration has a goal of sending crewed missions to the lunar surface as early as 2015 and no later than 2020. The use of nuclear power sources could aid in assisting crews in exploring the surface and performing In-Situ Resource Utilization (ISRU) activities. Radioisotope Power Systems (RPS) provide constant sources of electrical power and thermal energy for space applications. RPSs were carried on six of the crewed Apollo missions to power surface science packages, five of which still remain on the lunar surface. Future RPS designs may be able to play a more active role in supporting a long-term human presence. Due to its lower thermal and radiation output, the planned Stirling Radioisotope Generator (SRG) appears particularly attractive for manned applications. The MCNPX particle transport code has been used to model the current SRG design to assess its use in proximity with astronauts operating on the surface. Concepts of mobility and ISRU infrastructure were modeled using MCNPX to analyze the impact of RPSs on crewed mobility systems. Strategies for lowering the radiation dose were studied to determine methods of shielding the crew from the RPSs.

Schreiner, Timothy M.↗

NASA NTRS2006

Radioisotope Power Systems for In-situ Exploration of Titan and Venus

This viewgraph presentation reviews the timeline for the robotic in situ investigation of Titan and Venus, and the use of radioisotope power systems in this exploration. The atmospheric and surface conditions of both sites are reviewed. The presentation also examines the conceptual design of the Venus Mobile Explorer and the Titan orbiter and in situ explorer. After this the presentation reviews the radioisotope power systems for each of the vehicles, with some explanation of the different requirements based on the vastly different environments that they would be investigating

mission concepts↗

NASA NTRS2007

Final Results for the GRC Supporting Technology Development Project for the 110-Watt Stirling Radioisotope Generator (SRG110)

From 1999-2006, the NASA Glenn Research Center (GRC) supported the development of a high-efficiency, nominal 110-We Stirling Radioisotope Generator (SRG110) for potential use on NASA missions, including deep space missions, Mars rovers, and lunar applications. Lockheed Martin (LM) was the system integrator for the SRG110, under contract to the Department of Energy (DOE). Infinia Corporation (formerly Stirling Technology Company) developed the Stirling convertor, first as a contractor to DOE and then under subcontract to LM. The SRG110 development has been redirected, and recent program changes have been made to significantly increase the specific power of the generator. System development of an Advanced Stirling Radioisotope Generator (ASRG) has now begun, using a lightweight, advanced convertor from Sunpower, Inc. This paper summarizes the results of the supporting technology effort that GRC completed for the SRG110. GRC tasks included convertor extended-duration testing in air and thermal vacuum environments, heater head life assessment, materials studies, permanent magnet aging characterization, linear alternator evaluations, structural dynamics testing, electromagnetic interference (EMI) and electromagnetic compatibility (EMC) characterization, organic materials evaluations, reliability studies, and development of an end-to-end system dynamic model. Related efforts are now continuing in many of these areas to support ASRG development.

Schreiber, Jeffrey G.↗

NASA NTRS2007

Status of the NASA Stirling Radioisotope Project

Free-piston Stirling power conversion has been considered a candidate for radioisotope power systems for space for more than a decade. Prior to the free-piston Stirling architecture, systems were designed with kinematic Stirling engines that used linkages and rotary alternators to convert heat to electricity. These systems were able to achieve long life by lightly loading the linkages; however, the live was nonetheless limited. When the free-piston configuration was initially proposed, it was thought to be attractive due to the relatively high conversion efficiency, acceptable mass, and the potential for long life and high reliability based on wear-free operation. These features have consistently been recognized by teams that have studied technology options for radioisotope space power systems. Since free-piston Stirling power conversion was first considered for space power applications, there have been major advances in three general areas of development: hardware that has demonstrated long-life and reliability, the success achieved by Stirling cryocoolers in space, and the overall developmental maturity of the technology for both space and terrestrial applications. Based on these advances, free-piston Stirling convertors are currently being developed for space power, and for a number of terrestrial applications. They commonly operate with the power, efficiency, life, and reliability as intended, and much of the development now centers on system integration. This paper will summarize the accomplishments of free-piston Stirling power conversion technology over the past decade, review the status of development with regard to space power, and discuss the challenges that remain.

Schreiber, Jeffrey G.↗

NASA NTRS2007

Final Results for the GRC Supporting Technology Development Project for the 110-Watt Stirling Radioisotope Generator (SRG110)

From 1999 to 2006, the NASA Glenn Research Center (GRC) supported the development of a high-efficiency, nominal 110-We Stirling Radioisotope Generator (SRG110) for potential use on NASA missions, including deep space missions, Mars rovers, and lunar applications. Lockheed Martin (LM) was the system integrator for the SRG110, under contract to the Department of Energy (DOE). Infinia Corporation (formerly Stirling Technology Company) developed the Stirling convertor, first as a contractor to DOE and then under subcontract to LM. The SRG110 development has been redirected, and recent program changes have been made to significantly increase the specific power of the generator. System development of an Advanced Stirling Radioisotope Generator (ASRG) has now begun, using a lightweight, advanced convertor from Sunpower, Inc. This paper summarizes the results of the supporting technology effort that GRC completed for the SRG110. GRC tasks included convertor extended-duration testing in air and thermal vacuum environments, heater head life assessment, materials studies, permanent magnet aging characterization, linear alternator evaluations, structural dynamics testing, electromagnetic interference (EMI) and electromagnetic compatibility (EMC) characterization, organic materials evaluations, reliability studies, and development of an end-to-end system dynamic model. Related efforts are now continuing in many of these areas to support ASRG development.

Schreiber, Jeffrey G.↗

NASA NTRS2008

Development of a Power Electronics Controller for the Advanced Stirling Radioisotope Generator

Under a U.S. Department of Energy program for radioisotope power systems, Lockheed Martin is developing an Engineering Unit of the Advanced Stirling Radioisotope Generator (ASRG). This is an advanced version of the previously reported SRG110 generator. The ASRG uses Advanced Stirling Convertors (ASCs) developed by Sunpower Incorporated under a NASA Research Announcement contract. The ASRG makes use of a Stirling controller based on power electronics that eliminates the tuning capacitors. The power electronics controller synchronizes dual-opposed convertors and maintains a fixed frequency operating point. The controller is single-fault tolerant and uses high-frequency pulse width modulation to create the sinusoidal currents that are nearly in phase with the piston velocity, eliminating the need for large series tuning capacitors. Sunpower supports this effort through an extension of their controller development intended for other applications. Glenn Research Center (GRC) supports this effort through system dynamic modeling, analysis and test support. The ASRG design arrived at a new baseline based on a system-level trade study and extensive feedback from mission planners on the necessity of single-fault tolerance. This paper presents the baseline design with an emphasis on the power electronics controller detailed design concept that will meet space mission requirements including single fault tolerance.

Leland, Douglas K.↗

NASA NTRS2008

GRC Supporting Technology for NASA's Advanced Stirling Radioisotope Generator (ASRG)

From 1999 to 2006, the NASA Glenn Research Center (GRC) supported a NASA project to develop a high-efficiency, nominal 110-We Stirling Radioisotope Generator (SRG110) for potential use on NASA missions. Lockheed Martin was selected as the System Integration Contractor for the SRG110, under contract to the Department of Energy (DOE). The potential applications included deep space missions, and Mars rovers. The project was redirected in 2006 to make use of the Advanced Stirling Convertor (ASC) that was being developed by Sunpower, Inc. under contract to GRC, which would reduce the mass of the generator and increase the power output. This change would approximately double the specific power and result in the Advanced Stirling Radioisotope Generator (ASRG). The SRG110 supporting technology effort at GRC was replanned to support the integration of the Sunpower convertor and the ASRG. This paper describes the ASRG supporting technology effort at GRC and provides details of the contributions in some of the key areas. The GRC tasks include convertor extended-operation testing in air and in thermal vacuum environments, heater head life assessment, materials studies, permanent magnet characterization and aging tests, structural dynamics testing, electromagnetic interference and electromagnetic compatibility characterization, evaluation of organic materials, reliability studies, and analysis to support controller development.

Schreiber, Jeffrey G.↗

NASA NTRS2009

High Temperature Variable Conductance Heat Pipes for Radioisotope Stirling Systems

In a Stirling radioisotope system, heat must continually be removed from the GPHS modules, to maintain the GPHS modules and surrounding insulation at acceptable temperatures. Normally, the Stirling convertor provides this cooling. If the Stirling convertor stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS, but also ending the mission. An alkali-metal Variable Conductance Heat Pipe (VCHP) is under development to allow multiple stops and restarts of the Stirling convertor. The status of the ongoing effort in developing this technology is presented in this paper. An earlier, preliminary design had a radiator outside the Advanced Stirling Radioisotope Generator (ASRG) casing, used NaK as the working fluid, and had the reservoir located on the cold side adapter flange. The revised design has an internal radiator inside the casing, with the reservoir embedded inside the insulation. A large set of advantages are offered by this new design. In addition to reducing the overall size and mass of the VCHP, simplicity, compactness and easiness in assembling the VCHP with the ASRG are significantly enhanced. Also, the permanently elevated temperatures of the entire VCHP allows the change of the working fluid from a binary compound (NaK) to single compound (Na). The latter, by its properties, allows higher performance and further mass reduction of the system. Preliminary design and analysis shows an acceptable peak temperature of the ASRG case of 140 C while the heat losses caused by the addition of the VCHP are 1.8 W.

Tarau, Calin↗

NASA NTRS2013

Potential Applications for Radioisotope Power Systems in Support of Human Exploration Missions

Radioisotope power systems (RPS) for space applications have powered over 27 U.S. space systems, starting with Transit 4A and 4B in 1961, and more recently with the successful landing of the Mars Science Laboratory rover Curiosity in August 2012. RPS enable missions with destinations far from the Sun with faint solar flux, on planetary surfaces with dense or dusty atmospheres, and at places with long eclipse periods where solar array sizes and energy storage mass become impractical. RPS could also provide an enabling capability in support of human exploration activities. It is envisioned that with the higher power needs of most human mission concepts, a high efficiency thermal-to-electric technology would be required such as the Advanced Stirling Radioisotope generator (ASRG). The ASRG should be capable of a four-fold improvement in efficiency over traditional thermoelectric RPS. While it may be impractical to use RPS as a main power source, many other applications could be considered, such as crewed pressurized rovers, in-situ resource production of propellants, back-up habitat power, drilling, any mobile or remote activity from the main base habitat, etc. This paper will identify potential applications and provide concepts that could be a practical extension of the current ASRG design in providing for robust and flexible use of RPS on human exploration missions.

Cataldo, Robert L.↗

NASA NTRS2009

Sodium Variable Conductance Heat Pipe for Radioisotope Stirling Systems

In a Stirling radioisotope system, heat must continually be removed from the General Purpose Heat Source (GPHS) modules to maintain the modules and surrounding insulation at acceptable temperatures. Normally, the Stirling convertor provides this cooling. If the converter stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS, and also ending the mission. An alkali-metal Variable Conductance Heat Pipe (VCHP) has been designed to allow multiple stops and restarts of the Stirling convertor in an Advanced Stirling Radioisotope Generator (ASRG). When the Stirling convertor is turned off, the VCHP will activate when the temperatures rises 30 C above the setpoint temperature. A prototype VCHP with sodium as the working fluid was fabricated and tested in both gravity aided and against gravity conditions for a nominal heater head temperature of 790 C. The results show very good agreement with the predictions and validate the model. The gas front was located at the exit of the reservoir when heater head temperature was 790 C while cooling was ON, simulating an operating Advanced Stirling Converter (ASC). When cooling stopped, the temperature increased by 30 C, allowing the gas front to move past the radiator, which transferred the heat to the case. After resuming the cooling flow, the front returned at the initial location turning OFF the VCHP. The against gravity working conditions showed a colder reservoir and faster transients.

Tarau, Calin↗