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  • 1
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    Advanced Stirling Convertor Testing at GRC (2013)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). The latest version of the ASC, deemed ASC-E3, is of a design identical to the forthcoming flight convertors. The first pair of ASC-E3 units was delivered in December 2012. GRC has begun the process of adding these units to the catalog of ongoing Stirling convertor operation. This process includes performance verification, which examines the data from various tests to validate the convertors performance to the product specification.
    Keywords: Energy Production and Conversion
    Type: GRC-E-DAA-TN9002 , Interagency Advanced Power Group - Mechanical Working; May 02, 2013 - May 03, 2013; Cleveland, OH; United States
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  • 2
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    Test Hardware Design for Flight-Like Operation of Advanced Stirling Convertors (2012)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.
    Keywords: Energy Production and Conversion
    Type: E-18224-1 , International Energy Conversion Engineering Conference; Jul 30, 2012 - Aug 01, 2012; Atlanta, GA; United States
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  • 3
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    Advanced Stirling Convertor Durability Testing: Plans and Interim Results (2012)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: The U.S. Department of Energy (DOE), Lockheed Martin Corporation (LM), and NASA Glenn Research Center (GRC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. In support of this program, GRC has been involved in testing Stirling convertors, including the Advanced Stirling Convertor (ASC), for use in the ASRG. This testing includes electromagnetic interference/compatibility (EMI/EMC), structural dynamics, advanced materials, organics, and unattended extended operation. The purpose of the durability tests is to experimentally demonstrate the margins in the ASC design. Due to the high value of the hardware, previous ASC tests focused on establishing baseline performance of the convertors within the nominal operating conditions. The durability tests present the first planned extension of the operating conditions into regions beyond those intended to meet the product spec, where the possibility exists of lateral contact, overstroke, or over-temperature events. These tests are not intended to cause damage that would shorten the life of the convertors, so they can transition into extended operation at the conclusion of the tests. This paper describes the four tests included in the durability test sequence: 1) start/stop cycling, 2) exposure to constant acceleration in the lateral and axial directions, 3) random vibration at increased piston amplitude to induce contact events, and 4) overstroke testing to simulate potential failures during processing or during the mission life where contact events could occur. The paper also summarizes the analysis and simulation used to predict the results of each of these tests.
    Keywords: Energy Production and Conversion
    Type: NASA/TM-2012-217727 , AIAA Paper 2012-4249 , E-18225 , 10th International Energy Conversion Engineering Conference (IECEC); Jul 30, 2012 - Aug 01, 2012; Atlanta, GA; United States
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  • 4
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    Advanced Stirling Convertor (ASC-E2) Characterization Testing (2012)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: Testing has been conducted on Advanced Stirling Convertor (ASC-E2) convertors at NASA Glenn Research Center in support of the Advanced Stirling Radioisotope Generator (ASRG) Project. This testing has been conducted to understand sensitivities of convertor parameters due to environmental and operational changes during operation of the ASRG in missions to space. This paper summarizes test results and explains in terms of operation of the ASRG during space missions.
    Keywords: Energy Production and Conversion
    Type: E-18223-1 , International Energy Conversion Engineering Conference; Jul 30, 2012 - Aug 01, 2012; Atlanta, GA; United States
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  • 5
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    Design of a Facility to Test the Advanced Stirling Radioisotope Generator Engineering Unit (2009)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: 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.
    Keywords: Energy Production and Conversion
    Type: 7th International Energy Conversion Engineering Conference; Aug 02, 2009 - Aug 05, 2009; Denver, CO; United States
    Format: application/pdf
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  • 6
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    Test Hardware Design for Flightlike Operation of Advanced Stirling Convertors (ASC-E3) (2012)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.
    Keywords: Energy Production and Conversion
    Type: NASA/TM-2012-217726 , AIAA Paper 2012-4254 , E-18224 , 10th International Energy Conversion Engineering Conference; Jul 30, 2012 - Aug 01, 2012; Atlanta, GA; United States
    Format: application/pdf
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  • 7
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    Stirling Convertor Extended Operation Testing and Data Analysis at GRC (2009)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: This paper focuses on extended operation testing and data analysis of free-piston Stirling convertors at the NASA Glenn Research Center (GRC). Extended operation testing is essential to the development of radioisotope power systems and their potential use for long duration missions. To document the reliability of the convertors, regular monitoring and analysis of the extended operation data is particularly valuable; allowing us to better understand and quantity the long life characteristics of the convertors. Further, investigation and comparison of the extended operation data to baseline performance data provides us an opportunity for understanding system behavior should any off-nominal performance occur. GRC currently has 14 Stirling convertors under 24-hour unattended extended operation testing, including two operating the Advanced Stirling Radioisotope Generator Engineering Unit (ASRG-EU). 10 of the 14 Stirling convertors at GRC are the Advanced Stirling Convertors (ASC) developed by Sunpower, Incorporated. These are highly efficient (up to 〉 33.5% conversion efficiency), low mass convertors that have evolved through technologically progressive convertor builds. The remaining four convertors at GRC are Technology Demonstration Convertors (TDC) from Infinia Corporation. They have achieved〉 27% conversion efficiency and have accumulated over 178,000 of the total 250,622 hours of extended operation currently at GRC. A synopsis of the Stirling convertor extended operation testing and data analysis at NASA GRC is presented in this paper, as well as how this testing has contributed to the Stirling convertor's progression toward flight.
    Keywords: Energy Production and Conversion
    Type: 7th International Energy Conversion Engineering Conference; Aug 02, 2009 - Aug 05, 2009; Denver, CO; United States
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  • 8
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    Redesign of Glenn Research Center D1 Flywheel Module (2002)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: Glenn Research Center has completed the redesign of the D1 flywheel module. The redesign includes a new rotor with a composite rim, motor/generator, touchdown bearings, sensors, and a magnetic actuator. The purpose of the relatively low cost module upgrade is to enable it to continuously operate throughout its speed range of 0 to 60,000 RPM. The module will be used as part of a combined attitude control and bus regulation experiment.
    Keywords: Energy Production and Conversion
    Type: NASA/TM-2002-211788 , IECEC-2002-20075 , NAS1.15.211788 , E-13483 , 37th Intersociety Energy Conversion Engineering Conference; Jul 28, 2002 - Aug 02, 2002; Washington, DC; United States
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  • 9
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    Processing and Preparation of Advanced Stirling Convertors for Extended Operation (2008)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: The U.S. Department of Energy (DOE), Lockheed Martin Space Company (LMSC), 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 the free-piston Stirling convertors to achieve higher conversion efficiency than currently available alternatives. NASA GRC is supporting the development of the ASRG by providing extended operation of several Sunpower Inc. Advanced Stirling Convertors (ASCs). In the past year and a half, eight ASCs have operated in continuous, unattended mode in both air and thermal vacuum environments. Hardware, software, and procedures were developed to prepare each convertor for extended operation with intended durations on the order of tens of thousands of hours. Steps taken to prepare a convertor for long-term operation included geometry measurements, thermocouple instrumentation, evaluation of working fluid purity, evacuation with bakeout, and high purity charge. Actions were also taken to ensure the reliability of support systems, such as data acquisition and automated shutdown checkouts. Once a convertor completed these steps, it underwent short-term testing to gather baseline performance data before initiating extended operation. These tests included insulation thermal loss characterization, low-temperature checkout, and full-temperature and power demonstration. This paper discusses the facilities developed to support continuous, unattended operation, and the processing results of the eight ASCs currently on test.
    Keywords: Energy Production and Conversion
    Type: E-16916 , 6th International Energy Conversion Engineering Conference (IECEC 2008); Jul 28, 2008 - Jul 30, 2008; Cleveland, OH; United States
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  • 10
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    Test Program for Stirling Radioisotope Generator Hardware at NASA Glenn Research Center (2015)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: Stirling-based energy conversion technology has demonstrated the potential of high efficiency and low mass power systems for future space missions. This capability is beneficial, if not essential, to making certain deep space missions possible. Significant progress was made developing the Advanced Stirling Radioisotope Generator (ASRG), a 140-W radioisotope power system. A variety of flight-like hardware, including Stirling convertors, controllers, and housings, was designed and built under the ASRG flight development project. To support future Stirling-based power system development NASA has proposals that, if funded, will allow this hardware to go on test at the NASA Glenn Research Center. While future flight hardware may not be identical to the hardware developed under the ASRG flight development project, many components will likely be similar, and system architectures may have heritage to ASRG. Thus, the importance of testing the ASRG hardware to the development of future Stirling-based power systems cannot be understated. This proposed testing will include performance testing, extended operation to establish an extensive reliability database, and characterization testing to quantify subsystem and system performance and better understand system interfaces. This paper details this proposed test program for Stirling radioisotope generator hardware at NASA Glenn. It explains the rationale behind the proposed tests and how these tests will meet the stated objectives.
    Keywords: Energy Production and Conversion
    Type: NASA/TM-2015-218458 , AIAA Paper 2014-3964 , E-19015 , GRC-E-DAA-TN17260 , AIAA/ASME/SAE/ASEE Joint Propulsion Conference; Jul 28, 2014 - Jul 30, 2014; Cleveland, OH; United States
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