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.