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NASA NTRS2019

Maturation of Dynamic Power Convertors for Radioisotope Power Systems

Dynamic Radioisotope Power Systems (DRPS) are being developed by NASA’s Radioisotope Power Systems (RPS) Program in collaboration with the U.S. Department of Energy (DOE) for space science and exploration missions. A development effort is currently underway to mature dynamic power convertors for infusion into a potential future flight generator. This convertor maturation effort was formulated by the RPS Program at NASA Headquarters based on successful maturation models and utilizes expertise from agency’s technology and mission centers to support requirements development and technology assessments. The effort is being executed by Glenn Research Center’s (GRC) DRPS Project and the Thermal Energy Conversion Branch. The Dynamic Power Convertor (DPC) contracts consist of three phases to enable design, fabrication, and independent assessment of prototypes after delivery to the government. The contracts are intended to gather data on candidate dynamic conversion technologies to fill knowledge gaps, support assessments of dynamic conversion technologies, and elicit generator requirements. The 110-watt Stirling Radioisotope Generator (SRG-110) and Advanced Stirling Radioisotope Generator (ASRG) flight development projects provided Stirling convertor demonstration units and engineering models to verify and validate convertors against performance specifications and mission requirements. These units utilize temperature resistant materials and non-contacting bearings to demonstrate wear-free, long-life operation. This maturation effort builds on past lessons-learned and new requirements focused on demonstrating convertor robustness to critical environments meant to stress key aspects of each convertor within the margins of the design. This effort seeks to realize the full potential of dynamic power conversion technologies for NASA’s space science and exploration missions.

Wilson, Scott↗
NASA NTRS2019

Maturation of Dynamic Power Convertors for Radioisotope Power Systems

Dynamic Radioisotope Power Systems (DRPS) are being developed by NASA's RPS Program in collaboration with the U.S. Department of Energy (DOE) for space science and exploration missions. A development effort is currently underway to mature dynamic power convertors for infusion into a potential future flight generator. This convertor maturation effort was formulated by the RPS Program at NASA Headquarters based on successful maturation models and utilizes expertise from agency technology and mission centers to support requirements development and technology assessments. The effort is being executed by Glenn Research Center's Dynamic Radioisotope Power Systems (DRPS) project and the Thermal Energy Conversion Branch. The Dynamic Power Convertor (DPC) contracts consist of three phases to enable design, fabrication, and independent assessment after delivery to the government. The contracts are intended to gather data on candidate dynamic conversion technologies to fill knowledge gaps, support assessments of dynamic conversion technologies, and elicit generator requirements. The SRG-110 (Stirling Radioisotope Generator) and ASRG (Advanced Stirling Radioisotope Generator) flight development projects provided Stirling convertor demonstration units and engineering models to verify and validate convertors against performance specifications and mission requirements. These units utilize temperature resistance materials and non-contacting bearings to demonstrate wear-free, long-life operation. This maturation effort builds on past lessons learned and new requirements focused on demonstrating convertor robustness to critical environments meant to stress key aspects of each convertor within the margins of the design. This effort seeks to realize the full potential of dynamic power conversion technologies for NASA's space science and exploration missions.

Wilson, Scott↗
NASA NTRSDate not supplied

Dynamic Power Convertor Validation and Verification Thermal Analysis

NASA Glenn Research Center is preparing to perform experimental testing on various Stirling Convertors in the < 100-watt range. Prior to testing, a variety of computational simulations are being performed with the convertors-only (in isolation), and with the convertors equipped with an anticipated insulation and heating package that will be part of experimental test article. The goal is to develop a calculation methodology that will assist in predicting the convertor parasitic losses as well as estimating convertor efficiency. Three different cold-end temperatures will be explored on two different convertors, and the contribution of radiation within the heater head itself was included.

Stirling↗
NASA NTRSDate not supplied

Dynamic Power Convertor Validation and Verification Thermal Analysis

NASA Glenn Research Center is preparing to perform experimental testing on various Stirling Convertors in the < 100-watt range. Prior to testing, a variety of computational simulations are being performed with the convertors-only (in isolation), and with the convertors equipped with an anticipated insulation and heating package that will be part of experimental test article. The goal is to develop a calculation methodology that will assist in predicting the convertor parasitic losses as well as estimating convertor efficiency. Three different cold-end temperatures will be explored on two different convertors, and the contribution of radiation within the heater head itself was included.

Stirling↗
NASA NTRS2004

NASA Multidimensional Stirling Convertor Code Developed

A high-efficiency Stirling Radioisotope Generator (SRG) for use on potential NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company, and the NASA Glenn Research Center. These missions may include providing spacecraft onboard electric power for deep space missions or power for unmanned Mars rovers. Glenn is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall power system. Performance and mass improvement goals have been established for second- and third-generation Stirling radioisotope power systems. Multiple efforts are underway to achieve these goals, both in house at Glenn and under various grants and contracts. These efforts include the development of a multidimensional Stirling computational fluid dynamics code, high-temperature materials, advanced controllers, an end-to-end system dynamics model, low-vibration techniques, advanced regenerators, and a lightweight convertor. Under a NASA grant, Cleveland State University (CSU) and its subcontractors, the University of Minnesota (UMN) and Gedeon Associates, have developed a twodimensional computer simulation of a CSUmod Stirling convertor. The CFD-ACE commercial software developed by CFD Research Corp. of Huntsville, Alabama, is being used. The CSUmod is a scaled version of the Stirling Technology Demonstrator Convertor (TDC), which was designed and fabricated by the Stirling Technology Company and is being tested by NASA. The schematic illustrates the structure of this model. Modeled are the fluid-flow and heat-transfer phenomena that occur in the expansion space, the heater, the regenerator, the cooler, the compression space, the surrounding walls, and the moving piston and displacer. In addition, the overall heat transfer, the indicated power, and the efficiency can be calculated. The CSUmod model is being converted to a two-dimensional model of the TDC at NASA Glenn. Validation of the multidimensional Stirling code is an important part of the grant effort. UMN has been generating data in an oscillating-flow test facility using two different test sections: a 90 turn and a cooler/regenerator/heater test section. CSU has created computational fluid dynamics models of both these test sections and has been making comparisons with the data, then improving their models to improve the agreement with the test data. CSU has also been using data available in the literature for code validation. UMN is now preparing to begin fabrication of a new 180 turn test section that will be more representative of certain portions of the Stirling engine geometry. Simulations to almost periodic steady state with the two-dimensional CSUmod model indicate that, to reach periodic steady state on a single 2-GHz desktop computer, 75 to 100 complete simulation cycles would be required and between 1 and 2 months of computer time. Therefore, Glenn has purchased the first 8 computers, of a 64-computer cluster, to be run in parallel to accelerate the simulation. On the basis of CFD Research Corp.'s experience with running the parallelized version of CFD-ACE on their clusters, we estimate that the complete 64-computer cluster will reduce simulation computing time by a factor of about 40. Plans are to continue development of these multidimensional Stirling codes and to use them to study the fluid-flow and heat-transfer phenomena that occur inside Stirling convertors. This is expected to lead to improved thermodynamic loss understanding, onedimensional design and performance codes, and engine performance.

Tew, Roy C.↗
NASA NTRS2003

Three-Dimensional Magnetic Analysis Technique Developed for Evaluating Stirling Convertor Linear Alternators

The Department of Energy, the Stirling Technology Company (STC), and the NASA Glenn Research Center are developing Stirling convertors for Stirling radioisotope generators to provide electrical power for future NASA deep space missions. STC is developing the 55-We technology demonstration convertor (TDC) under contract to the Department of Energy. The Department of Energy recently named Lockheed Martin as the system integration contractor for the Stirling radioisotope generator development project. Lockheed Martin will develop the Stirling radioisotope generator engineering unit and has contract options to develop the qualification unit and the first flight unit. Glenn s role includes an in-house project to provide convertor, component, and materials testing and evaluation in support of the overall power system development. As a part of this work, Glenn has established an in-house Stirling research laboratory for testing, analyzing, and evaluating Stirling machines. STC has built four 55-We convertors for NASA, and these are being tested at Glenn. A cross-sectional view of the 55-We TDC is shown in the figure. Of critical importance to the successful development of the Stirling convertor for space power applications is the development of a lightweight and highly efficient linear alternator. In support, Glenn has been developing finite element analysis and finite element method tools for performing various linear alternator thermal and electromagnetic analyses and evaluating design configurations. A three-dimensional magnetostatic finite element model of STC's 55-We TDC linear alternator was developed to evaluate the demagnetization fields affecting the alternator magnets. Since the actual linear alternator hardware is symmetric to the quarter section about the axis of motion, only a quarter section of the alternator was modeled. The components modeled included the mover laminations, the neodymium-iron-boron magnets, the stator laminations, and the copper coils. The three-dimensional magnetostatic model was then coupled with a circuit simulator model of the alternator load and convertor controller. The coupled model was then used to generate alternator terminal voltage and current predictions. The predicted voltage and current waveforms agreed well with the experimental data, which tended to validate the accuracy of the coupled model. The model was then used to generate predictions of the demagnetization fields acting on the alternator magnets for the alternator under load. The preliminary model predictions indicate that the highest potential for demagnetization is along the inside surface of the uncovered magnets. The demagnetization field for the uncovered magnets when the mover is positioned at the end of a stroke is higher than it is when the mover is at the position of maximum induced voltage or maximum alternator current. Assuming normal load conditions, the model predicted that the onset of demagnetization is most likely to occur for magnet temperatures above 101 C.

Geng, Steven M.↗
NASA NTRS2007

New 5 Kilowatt Free-Piston Stirling Space Convertor Developments

NASA has recently funded development of a 5 kW (or greater) free-piston Stirling conversion system for reactor power systems. A nominal 5 kW convertor allows two of these units to be dynamically balanced. A group of three dual-convertor combinations would yield the desired 30 kW. The status of this program will be presented. Goals include a specific power in excess of 140 W/kg at the convertor level, lifetime in excess of five years and AC output. The initial step is the design and development of a nominal 5 kW per cylinder Stirling convertor assembly (SCA) which will serve as a prototype of one or more SCAs that will make up the final 30 kW Stirling Convertor Power System. Assumed requirements for this new convertor for lunar fission power systems will be presented. The primary objective of this development effort will be to demonstrate a 5 kW SCA that can be tested to validate the viability of Stirling technology for space fission surface power systems.

Brandhorst, Henry W.↗
NASA NTRS2008

5-kWe Free-piston Stirling Engine Convertor

The high reliability, long life, and efficient operation of Free-Piston Stirling Engines (FPSEs) make them an attractive power system to meet future space power requirements with less mass, better efficiency, and less total heat exchanger area than other power convertor options. FPSEs are also flexible in configuration as they can be coupled with many potential heat sources and various heat input systems, heat rejection systems, and power management and distribution systems. Development of a 5-kWe Stirling Convertor Assembly (SCA) is underway to demonstrate the viability of an FPSE for space power. The design is a scaled-down version of the successful 12.5-kWe Component Test Power Converter (CTPC) developed under NAS3-25463. The ultimate efficiency target is 25% overall convertor efficiency (electrical power out over heat in). For the single cylinder prototype now in development, cost and time constraints required use of economical and readily available materials (steel versus beryllium) and components (a commercially available linear alternator) and thus lower efficiency. The working gas is helium at 150 bar mean pressure. The design consists of a displacer suspended on internally pumped gas bearings and a power piston/alternator supported on flexures. Non-contacting clearance seals are used between internal volumes. Heat to and from the prototype convertor is done via pumped liquid loops passing through shell and tube heat exchangers. The preliminary and detail designs of the convertor, controller, and support systems (heating loop, cooling loop, and helium supply system) are complete and all hardware is on order. Assembly and test of the prototype at Foster- Miller is planned for early 2008, when work will focus on characterizing convertor dynamics and steady-state operation to determine maximum power output and system efficiency. The device will then be delivered to Auburn University where assessments will include start-up and shutdown characterization and transient response to temperature and load variations. Future activities may include testing at NASA GRC.

Chapman, Peter A.↗
NASA NTRS2008

Progress in High Power Free-Piston Stirling Convertor Development

The U.S. Space Exploration Policy has established a vision for human exploration of the moon and Mars. One option for power for future outposts on the lunar and Martian surfaces is a nuclear reactor coupled with a free-piston Stirling convertor at a power level of 30-40 kWe. A 25 kW convertor was developed in the 1990s under the SP-100 program. This system consisted of two 12.5 kWe engines connected at their hot ends and mounted in tandem to cancel vibration. Recently, NASA began a new project with Auburn University to develop a 5 kWe, single convertor for use in such a possible lunar power system. Goals of this development program include a specific power in excess of 140 We/kg at the convertor level, lifetime in excess of five years and a control system that will safely manage the convertors in case of an emergency. Foster-Miller, Inc. is developing the 5 kWe Stirling Convertor Assembly. The characteristics of the design along with progress in developing the system will be described.

Brandhorst, Henry W., Jr.↗
NASA NTRS2010

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

The NASA Glenn Research Center (GRC) has been testing high-efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multiyear missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test setup to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging micro-porous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-film heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slipcasting and using Physical Vapor Deposition (PVD). One-micron-thick noble metal thermocouples measure temperature on the surface of an alumina ceramic disk and heat flux is calculated. Fabrication, integration, and test results of a thin-film heat flux sensor are presented.

Wilson, Scott D.↗
NASA NTRS2010

Test Rack Development for Extended Operation of Advanced Stirling Convertors at NASA Glenn Research Center

The U.S. Department of Energy, Lockheed Martin Space Systems Company, Sunpower Inc., and NASA Glenn Research Center (GRC) have been developing an Advanced Stirling Radioisotope Generator (ASRG) for use as a power system on space science missions. This generator will make use of free-piston Stirling convertors to achieve higher conversion efficiency than with currently available alternatives. One part of NASA GRC's support of ASRG development includes extended operation testing of Advanced Stirling Convertors (ASCs) developed by Sunpower Inc. and GRC. The ASC consists of a free-piston Stirling engine integrated with a linear alternator. NASA GRC has been building test facilities to support extended operation of the ASCs for several years. Operation of the convertors in the test facility provides convertor performance data over an extended period of time. One part of the test facility is the test rack, which provides a means for data collection, convertor control, and safe operation. Over the years, the test rack requirements have changed. The initial ASC test rack utilized an alternating-current (AC) bus for convertor control; the ASRG Engineering Unit (EU) test rack can operate with AC bus control or with an ASC Control Unit (ACU). A new test rack is being developed to support extended operation of the ASC-E2s with higher standards of documentation, component selection, and assembly practices. This paper discusses the differences among the ASC, ASRG EU, and ASC-E2 test racks.

Dugala, Gina M.↗
NASA NTRS2009

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

The NASA Glenn Research Center (GRC) has been testing high efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multi-year missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test set up to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging microporous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-mm heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slip casting and using Physical Vapor Deposition (PVD). One micron thick noble metal thermocouples measure temperature on the surface of an Alumina ceramic disc and heat flux is calculated. Fabrication, integration, and test results of a thin film heat flux sensor are presented.

Wilson, Scott D.↗
NASA NTRS2012

Pathfinding the Flight Advanced Stirling Convertor Design with the ASC-E3

The Advanced Stirling Convertor (ASC) was initially developed by Sunpower, Inc. under contract to NASA Glenn Research Center (GRC) as a technology development project. The ASC technology fulfills NASA s need for high efficiency power convertors for future Radioisotope Power Systems (RPS). Early successful technology demonstrations between 2003 to 2005 eventually led to the expansion of the project including the decision in 2006 to use the ASC technology on the Advanced Stirling Radioisotope Generator (ASRG). Sunpower has delivered 22 ASC convertors of progressively mature designs to date to GRC. Currently, Sunpower with support from GRC, Lockheed Martin Space System Company (LMSSC), and the Department of Energy (DOE) is developing the flight ASC-F in parallel with the ASC-E3 pathfinders. Sunpower will deliver four pairs of ASC-E3 convertors to GRC which will be used for extended operation reliability assessment, independent validation and verification testing, system interaction tests, and to support LMSSC controller verification. The ASC-E3 and -F convertors are being built to the same design and processing documentation and the same product specification. The initial two pairs of ASC-E3 are built before the flight units and will validate design and processing changes prior to implementation on the ASC-F flight convertors. This paper provides a summary on development of the ASC technology and the status of the ASC-E3 build and how they serve the vital pathfinder role ahead of the flight build for ASRG. The ASRG is part of two of the three candidate missions being considered for selection for the Discovery 12 mission.

Wong, Wayne A.↗
NASA NTRS2013

Structural Dynamics Testing of Advanced Stirling Convertor Components

NASA Glenn Research Center has been supporting the development of Stirling energy conversion for use in space. Lockheed Martin has been contracted by the Department of Energy to design and fabricate flight-unit Advanced Stirling Radioisotope Generators, which utilize Sunpower, Inc., free-piston Advanced Stirling Convertors. The engineering unit generator has demonstrated conversion efficiency in excess of 20 percent, offering a significant improvement over existing radioisotope-fueled power systems. NASA Glenn has been supporting the development of this generator by developing the convertors through a technology development contract with Sunpower, and conducting research and experiments in a multitude of areas, such as high-temperature material properties, organics testing, and convertor-level extended operation. Since the generator must undergo launch, several launch simulation tests have also been performed at the convertor level. The standard test sequence for launch vibration exposure has consisted of workmanship and flight acceptance levels. Together, these exposures simulate what a flight convertor will experience. Recently, two supplementary tests were added to the launch vibration simulation activity. First was a vibration durability test of the convertor, intended to quantify the effect of vibration levels up to qualification level in both the lateral and axial directions. Second was qualification-level vibration of several heater heads with small oxide inclusions in the material. The goal of this test was to ascertain the effect of the inclusions on launch survivability to determine if the heater heads were suitable for flight.

Heaters↗
NASA NTRS2013

Structural Dynamics Testing of Advanced Stirling Convertor Components

NASA Glenn Research Center has been supporting the development of Stirling energy conversion for use in space. Lockheed Martin has been contracted by the Department of Energy to design and fabricate flight-unit Advanced Stirling Radioisotope Generators, which utilize Sunpower, Inc., free-piston Advanced Stirling Convertors. The engineering unit generator has demonstrated conversion efficiency in excess of 20 percent, offering a significant improvement over existing radioisotope-fueled power systems. NASA Glenn has been supporting the development of this generator by developing the convertors through a technology development contract with Sunpower, and conducting research and experiments in a multitude of areas, such as high-temperature material properties, organics testing, and convertor-level extended operation. Since the generator must undergo launch, several launch simulation tests have also been performed at the convertor level. The standard test sequence for launch vibration exposure has consisted of workmanship and flight acceptance levels. Together, these exposures simulate what a flight convertor will experience. Recently, two supplementary tests were added to the launch vibration simulation activity. First was a vibration durability test of the convertor, intended to quantify the effect of vibration levels up to qualification level in both the lateral and axial directions. Second was qualification-level vibration of several heater heads with small oxide inclusions in the material. The goal of this test was to ascertain the effect of the inclusions on launch survivability to determine if the heater heads were suitable for flight.

Oriti, Sal↗
NASA NTRS2012

Pathfinding the Flight Advanced Stirling Convertor Design with the ASC-E3

The Advanced Stirling Convertor (ASC) was initially developed by Sunpower, Inc. under contract to NASA Glenn Research Center (GRC) as a technology development project. The ASC technology fulfills NASA's need for high efficiency power convertors for future Radioisotope Power Systems (RPS). Early successful technology demonstrations between 2003 to 2005 eventually led to the expansion of the project including the decision in 2006 to use the ASC technology on the Advanced Stirling Radioisotope Generator (ASRG). Sunpower has delivered 22 ASC convertors of progressively mature designs to date to GRC. Currently, Sunpower with support from GRC, Lockheed Martin Space System Company (LMSSC), and the Department of Energy (DOE) is developing the flight ASC-F in parallel with the ASC-E3 pathfinders. Sunpower will deliver four pairs of ASC-E3 convertors to GRC which will be used for extended operation reliability assessment, independent validation and verification testing, system interaction tests, and to support LMSSC controller verification. The ASC-E3 and -F convertors are being built to the same design and processing documentation and the same product specification. The initial two pairs of ASC-E3 are built before the flight units and will validate design and processing changes prior to implementation on the ASC-F flight convertors. This paper provides a summary on development of the ASC technology and the status of the ASC-E3 build and how they serve the vital pathfinder role ahead of the flight build for ASRG. The ASRG is part of two of the three candidate missions being considered for selection for the Discovery 12 mission.

Wong, Wayne A.↗
NASA NTRS2018

Stirling Convertor Controller Development at NASA Glenn Research Center

For nearly two decades, NASA Glenn Research Center (GRC) has been supporting the development of Radioisotope Power Systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long life design. Dynamic conversion, such as Stirling and Brayton, offer the potential for higher conversion efficiencies than current RPS but have yet to be demonstrated in a flight application. The RPS program sent out a solicitation to investigate options for dynamic conversion technologies. As a result of this solicitation, four dynamic power convertor (DPC) technologies were selected for design and three are proceeding to the fabrication phase of prototype dynamic convertors. One lesson learned from the Advanced Stirling Radioisotope Generator (ASRG) project is that controller development should be coordinated with the development of a dynamic convertor. As a result of this, NASA GRC has been utilizing hardware from past Stirling convertor projects including that of the ASRG to support controller development for the DPC's. NASA GRC has developed a strong knowledge base on both analog and digital Stirling dynamic power convertor controllers and will continue to expand and apply that knowledge to the DPC's. Over the past 15 years, controllers were developed at GRC, at Lockheed Martin (LM) and by the Johns Hopkins University/Applied Physics Laboratory (JHU/APL). Various generations of the controllers have been developed as lessons were learned through various component and system level tests. Some of the tests performed were fault tolerance, flight acceptance vibration, electromagnetic interference (EMI), spacecraft integration, and extended operation. The fault tolerance test characterized the controller's ability to handle various fault conditions, including high or low bus power consumptions, total open load or short circuit, and replacing a failed controller card while the backup maintains control of the Stirling convertor. The vibration test confirms the controller's ability to control an ASC during launch. The EMI test characterized the AC and DC magnetic and electric fields emitted by the single ASC and if the controller has an impact on the radiated EMI. Spacecraft integration testing in the Radioisotope Power Systems System Integration Laboratory (RSIL) provided insight into the electrical interactions between the representative RPS, its associated control schemes, and realistic electric system loads. The extended operation test allows data to be collected over a period of thousands of hours to obtain long term performance data of the system. This paper describes the history of controller development at NASA GRC, tests performed on these controllers, and lessons learned.

Dugala, Gina M.↗
NASA NTRS2018

Stirling Convertor Controller Development at NASA Glenn Research Center

For nearly two decades, NASA Glenn Research Center has been supporting the development of radioisotope power systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long-life design. Dynamic conversion, such as Stirling and Brayton, offer the potential for higher conversion efficiencies than current RPS but have yet to be demonstrated in a flight application. The RPS program sent out a solicitation to investigate options for dynamic conversion technologies. As a result of this solicitation, four dynamic power convertor (DPC) technologies were selected for design and three are proceeding to the fabrication phase of prototype dynamic convertors. One lesson learned from the Advanced Stirling Radioisotope Generator (ASRG) project is that controller development should be coordinated with the development of a dynamic convertor. As a result of this, Glenn has been utilizing hardware from past Stirling convertor projects, including that of the ASRG, to support controller development for the DPCs. Glenn has developed a strong knowledge base on both analog and digital Stirling DPC controllers and will continue to expand and apply that knowledge to the DPCs. Over the past 15 years, controllers were developed at Glenn, at Lockheed Martin (LM), and by the Johns Hopkins University Applied Physics Laboratory (APL). Various generations of the controllers have been developed as lessons were learned through various component- and system-level tests. Some of the tests performed were fault tolerance, flight acceptance vibration, electromagnetic interference (EMI), spacecraft integration, and extended operation. The fault tolerance test characterized the controller’s ability to handle various fault conditions, including high or low bus power consumption, total open load or short circuit, and replacing a failed controller card while the backup maintains control of the Stirling convertor. The vibration test confirms the controller’s ability to control an Advanced Stirling Convertor (ASC) during launch. The EMI test characterized the alternating-current (AC) and direct-current (DC) magnetic and electric fields emitted by the single ASC and if the controller has an impact on the radiated EMI. Spacecraft integration testing in the Radioisotope Power Systems (RPS), System Integration Laboratory (RSIL) provided insight into the electrical interactions between the representative RPS, its associated control schemes, and realistic electric system loads. The extended operation test allows data to be collected over a period of thousands of hours to obtain long-term performance data of the system. This paper describes the history of controller development at Glenn, tests performed on these controllers, and lessons learned.

Dugala, Gina M.↗