Rad-hard Electronic Control and Power Integrated Circuit for Stirling-based Radioisotope Power System

In response to the NASA SBIR topic S13.06 “Dynamic Power Conversion”, subtopic “Radiation-hardened electronic controllers and power processing” from 1 to 100 watts, Alphacore Inc. will develop a full Radiation-Hardened (Rad Hard) Controller and Power Management Integrated Circuit (PMIC) for Radioisotope Power System (RPS) free-piston Stirling cycle converter inclusive of Stirling engine, engine controller, and DC/DC converter, yielding a 28V regulated output with total high system efficiency (>30%). We refer to it as the PMIC or simply the Controller. Alphacore controller will work with hardware from our partner Sunpower, both the 65W Sunpower Robust Stirling Convertor (SRSC) and the 35W EE-35 Stirling converter. Professor Seth Sander from University of California at Berkeley will consult with Alphacore on the controller design. Prof. Sanders spent about 15 years on the Stirling engine front, mostly developing free-piston type machines. The controller will be simulated in Phase I and a complete RPS prototype will be delivered in Phase II. The controller will have a credible path to flight and able to control a dynamic convertor without relying on feedback from vulnerable short-lived sensors. The controller radiation tolerance will be greater than 5x1011 n/cm2 + 3x102 krad + 40 MeV-cm2/mg (linear energy transfer) to achieve higher tolerance to radiation, thereby enabling a reduction in shielding mass. The controller will operate over a wide temperature range(-150 ºC to 150 ºC). The developed PMIC will have a reduced component count, enabling reduced failure modes, and smaller area of PCB (printed circuit board). It will include over-voltage protection, fault tolerance, load monitoring, as well as allow control and status monitoring by a remote power system controller. This PMIC includes all controller circuitry and drivers integrated in a single die and drives an external wide-bandgap (WBG)-based power stage for electric power delivery.

NASA is considering high efficiency dynamic power conversion technologies for use in Radioisotope Power Systems (RPS) to power science missions for the Moon and other solar system bodies of interest. This is mapped by NASA SMD's strategic technology investment plan for space power and energy storage enabling higher power systems using the same amount of fuel, enabling more spacecraft to support a single mission, or requiring less fuel for offered power levels. Highly efficient Stirling RPS could enable long-lived robotic science missions to other worlds identified in the Decadal Survey "Origins, Worlds, and Life: A Decadal Strategy for Planetary Science and Astrobiology 2023-2032", providing power and heat on landers and rovers so they may operate in dark, dusty locations throughout the solar system. High efficiency RPS are sought across a wide range of power, from 1 to 100 watts for RPS applications. Lower power conversion could convert heat from one or more small isotope heat sources to a few watts for powering battery chargers or sensors on small science stations or distributed networks. Higher power conversion could convert hundreds to thousands of thermal watts made available from one or more large isotope heat sources, such as the General Purpose Heat Source (GPHS) or an alternative isotope heat source, to hundreds of watts for powering large orbiting or surface spacecraft. Waste heat could also be removed from the power convertor for keeping spacecraft components warm enough to survive very cold environments. Alphacore proposes to develop a controller architecture with an active balancer without relying on feedback from vulnerable short-lived sensors. We will meet and exceed the radiation tolerance of electronic components found in controllers and accompanying power processing systems, as specified in the NASA SBIR topic S13.06. Higher radiation tolerance will enable a reduction in shielding mass. The proposed Power Management Integrated Circuit (PMIC) will find potential commercial applications in the consumer market as the global shift toward greener energy continues, further fueling the growth and adoption of Stirling engines across various sectors. The Stirling engine market segmentation, based on application, includes submarines, solar power generation, nuclear power plants, and others. The growth is driven by the increasing adoption of Stirling engines in nuclear power applications due to their ability to operate efficiently in various energy scenarios, including low and high-temperature differentials. The engines are also being recognized for their potential to convert nuclear energy into electricity with minimal environmental impact, making them attractive in the shift toward cleaner energy solutions. The increasing focus on reducing carbon emissions and enhancing energy efficiency in power generation is expected to boost the demand for Stirling engines. The rising global investments in sustainable energy technologies are further supporting the adoption of these engines in this sector. The Stirling engines market is witnessing significant growth owing to the increasing need for low-emission alternatives to internal combustion (IC) engines. Governments and industries worldwide are prioritizing the reduction of greenhouse gas emissions and the promotion of sustainability. A few major players in the Stirling engine market are United Sun Systems International Ltd. (TEXEL); Qnergy Ltd.; ADI Thermal Power Corporation; Shanghai Marine Diesel Engine Research Institute; Frauscher Motors GmbH; Kontax Engineering Ltd.; Sunpower, Inc. (AMETEK); and Microgen Engine Corporation. These are all potential customers and partners for our technology.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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