LAT TVAC Test Delta-PDR1 GLAST LAT Project25 May 2005 LAT Environmental Test Planning and Design...
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Transcript of LAT TVAC Test Delta-PDR1 GLAST LAT Project25 May 2005 LAT Environmental Test Planning and Design...
LAT TVAC Test Delta-PDR 1
GLAST LAT Project
25 May 2005
LAT Environmental Test Planning and DesignLAT Environmental Test Planning and Design
Delta-Preliminary Design ReviewDelta-Preliminary Design Review
25 May 200525 May 2005
LAT T-Vac TestLAT T-Vac Test
Final version: 10 June 2005Final version: 10 June 2005
LAT Environmental Test Planning and DesignLAT Environmental Test Planning and Design
Delta-Preliminary Design ReviewDelta-Preliminary Design Review
25 May 200525 May 2005
LAT T-Vac TestLAT T-Vac Test
Final version: 10 June 2005Final version: 10 June 2005
Jack GoodmanJack Goodman
LAT TVAC Test Delta-PDR 2
GLAST LAT Project
25 May 2005 Thermal-Vacuum Test SequenceThermal-Vacuum Test Sequence
Prep Lat for TVAC
Load LAT into Chamber
Connect Instrumentation
Open Door Checkout
Chamber Pump Down
Hot OpT-Balance
Hot OpThermal Control
Hot OpPeak Power
HotPerformance
Cold SurvivalT-Balance
ColdPerformance
Cold OpT-Balance
Cold OpThermal Control
ThermalCycling (4)
Bake OutReturn to
Ambient P&T
Pre-Bake
LAT TVAC Test Delta-PDR 3
GLAST LAT Project
25 May 2005 Temperature Requirements for Simulated Sink HardwareTemperature Requirements for Simulated Sink Hardware
• Operating/Performance
– Hot at 40°C
– Cold at 0°C
• Thermal Balance
– Hot balance at 30°C
– Cold balance at 0°C
– Cold survival at -2°C
• Test Cycle
– Four TVAC Cycles, 8 Transients
• Hot soak at 40°C
• Cold soak at 0°C
• Test: EGSE Failure/Safe Hold (not relevant to orbit)
– +25°C
• Bake out
– +45°C
LAT TVAC Test Delta-PDR 4
GLAST LAT Project
25 May 2005 LAT Surfaces Requiring Thermal ConditioningLAT Surfaces Requiring Thermal Conditioning
• ACD thermal conditioning
– ACD temperature controlled by thermal sink plates electrically heated with radiation cooling to TVAC Chamber cold shroud
• Radiator and X-LAT Plate MLI Blankets (Spacecraft Bus simulator) thermal conditioning
– Spacecraft bus temperature controlled by thermal sink plates electrically heated and cryogenically cooled
• Radiator thermal conditioning – 3 options
– Thermal Control Unit sink plate system
• Radiator temperature controlled by thermal sink plates heated and cooled with Thermal Control Units
– NRL thermal conditioning system
• Radiator temperature controlled by thermal sink plates electrically heated and cryogenically cooled
– Cal Rod cage system
• Radiator temperature controlled by balance of IR heating from Cal Rods and radiation cooling to TVAC chamber cold shroud
LAT TVAC Test Delta-PDR 5
GLAST LAT Project
25 May 2005 ACD Thermal ConditioningACD Thermal Conditioning
• ACD thermal conditioning
– ACD Temperature varies: -60°C to +60°C
– Thermal sink plate requirements• Dimensions 1.8 m x 1.3 m (approx)
• Temperature -89 °C to +60 °C
• Temperature Uniformity +/- 5 °C
• Emissivity ~0.5 (Anodized Al or paint)
• Power Absorption <20W from ACD (TBD)
• Cycle none
• Quantity 5
– Heating of thermal sink plates is provided by resistive heaters• Film/strip heaters—built into the plates
• Power supplies—outside chamber with feedback control off of TC’s on plates
– Cooling of thermal sink plates is passive radiation cooling to the TVAC chamber cold shroud• TVAC Chamber Cold Shroud Temperature = -150 °C
– Thermal control• 5 independent heater circuits controlled by chamber CDACS system with feedback on TC temps
– Power requirements (includes 20% margin)• ACD +X sink plate: 985 W• ACD +Y sink plate: 625 W• ACD -X sink plate: 625 W• ACD -Y sink plate: 625 W• ACD +Z sink plate: 911 W
LAT TVAC Test Delta-PDR 6
GLAST LAT Project
25 May 2005 Spacecraft Bus Thermal ConditioningSpacecraft Bus Thermal Conditioning
• Spacecraft Bus thermal conditioning
– SC Bus temperature varies: -40°C to +25°C
– Thermal sink plate requirements
• Dimensions 1.6 m x 1.8 m (approx)
• Temperature -40 °C to +25 °C
• Temperature Uniformity +/- 5 °C
• Emissivity >0.85 (Anodized Al or paint)
• Power Absorption <25W (TBD)
• Cycle none
• Quantity 3
– Heating of thermal sink plates is provided by resistive heaters
• Film/Strip heaters—built into plates
• Power supplies—outside chamber with feedback control off of TC’s on plates
– Cooling of thermal sink plates is primarily LN2/GN2 with some radiation loss
• Active cooling supplied by LN2 solenoid valves
– Thermal control
• 3 independent heater circuits controlled by chamber CDACS system with feedback on TC temps
– Power requirements (includes 20% margin)
• SC Y-side sink plates: 2 @ TBD W
• SC top-deck sink plate: TBD W
LAT TVAC Test Delta-PDR 7
GLAST LAT Project
25 May 2005 Radiator Thermal Conditioning – Option 1Radiator Thermal Conditioning – Option 1
• Option 1 - Thermal Control Unit (TCU) sink plate system
– Radiator Temperature -13°C to +2°C (Hot Case orbit average)
– Thermal Sink Plate Requirements
• Dimensions 1.65 m x 1.85 m (approx)
• Temperature -126 °C to +4 °C (Hot transient); -95 °C to -64 °C (Cold transient)
• Temperature Uniformity +/-2.5 °C (balance); +/-5 °C transient
• Emissivity >0.85 (Anodized Al or paint)
• Power Absorption 0 W to 800 W max per Plate (includes margin)
• Cycle 92 minutes sinusoidal
• Quantity 2
– Heating and cooling of thermal sink plates is provided by 1 TCU per Radiator
– Thermal control
• 1 control zone per Radiator, controlled by TCU
– Power requirements
• TBD, rough estimate by 6/15/05
LAT TVAC Test Delta-PDR 8
GLAST LAT Project
25 May 2005 Radiator Thermal Conditioning – Option 2Radiator Thermal Conditioning – Option 2
• Option 2 – NRL Thermal Conditioning System
– Radiator Temperature -13°C, +2°C (Hot Case orbit average)
– Thermal Sink Plate Requirements
• Dimensions 1.65 m x 1.85 m (approx)
• Temperature -126 °C to +4 °C (Hot transient); -95 °C to -64 °C (Cold transient)
• Desired Temperature Uniformity +/- 2.5 °C (balance); +/- 5 °C transient
• Actual Temperature Uniformity TBD; rough estimate available by 6/1/05
• Emissivity >0.85 (Anodized Al or paint)
• Power Absorption 0 W to 800 W max per Plate (includes margin)
• Cycle 92 minutes sinusoidal
• Quantity 2
• Heater Power 5 amps per circuit (max)
– Heating of thermal sink plates is provided by resistive heaters built into panels
– Cooling is provided by active cooling supplied by LN2 solenoid valves
– Thermal control
• 1 heater/cooling circuit per Rad controlled by chamber CDACS system with feedback on TC temps
– Power Requirements
• # of circuits and power per circuit TBD, rough estimate available by 6/15/05
LAT TVAC Test Delta-PDR 9
GLAST LAT Project
25 May 2005 Radiator Thermal Conditioning – Option 3Radiator Thermal Conditioning – Option 3
• Option 3 - CAL Rod Cage System
– Radiator Temperature -13°C, +2°C (Hot Case orbit average)
– Thermal Sink Cage Requirements
• Dimensions 1.6 m x 1.8 m (approx)
• Temperature Uniformity +/- 2.5 °C (balance); +/- 5 °C transient
• Emissivity >0.38 (sandblasted stainless steel)
• Power Absorption N/A
• Cycle 92 minutes sinusoidal
• Quantity 2
– Heating and cooling
• Radiator temperature control is by balance of radiation loss to TVAC chamber cold shroud (-150 °C) and IR Heating from CAL Rod cage
• IR power from Cal-Rod resistive heating elements
• TVAC Chamber Cold Shroud Temperature = -150 °C
– Thermal Control
• 3 independent Cal-Rod circuits per Radiator controlled by chamber CDACS system with feedback from radiometers mounted in front of Radiators
– Power Requirements (includes 50% margin)
• 2400 W/cage– Radiator top: ~400 W– Radiator middle: ~ 1600 W– VCHP reservoirs: ~400 W
LAT TVAC Test Delta-PDR 10
GLAST LAT Project
25 May 2005 Trade Study - Radiator Thermal ConditioningTrade Study - Radiator Thermal Conditioning
THERMAL CONTROL UNIT SYSTEM
NRL THERMAL CONDITIONING SYSTEM
CALROD SYSTEM
Temp Control System Availability Thermal Control Unit (QTY = 2) CDACS System (QTY = 1) CDACS System (QTY = 1)
Proportional Solenoid Valves (QTY = 2) Calrod Heating Elements (QTY = 22)
Heaters (QTY = TBD, rough estimate by 6/15/05)
Thermal Sink Plates
Radiator Sink Plates/Calrod Box (QTY = 2) (QTY = 2) (QTY = 2)
Temp Uniformity Across Plate 5 °C Steady-State, 10 °C Transient 5 °C Steady-State, 10 °C Transient 5 °C Steady-State, 10 °C Transient
Pow er Absorption (total) 0 W to 800 W (max) - per Plate 0 W to 800 W (max) - per Plate N/A
Pow er Dissipation to Shroud Minimal Minimal TBD
Pow er Requirements
Max Current N/A 5 A per Circuit (max) 5 A per Circuit (max)
Pow er Supplies N/A (QTY = TBD, rough estimate by 6/1/05) (QTY = 8)
Pow er Feedthroughs N/A (QTY = TBD, rough estimate by 6/1/05) (QTY = 1)
Req'd TC's/Heat Flux Meters
LAT SupportSee Table 3 of LAT Intrumentation Plan
See Table 3 of LAT Intrumentation PlanSee Table 3 of LAT Intrumentation Plan
Test SupportSee Table 3 of LAT Intrumentation Plan
See Table 3 of LAT Intrumentation PlanSee Table 3 of LAT Intrumentation Plan
Thermcouple Feedthroughs TBD TBD TBD
Cost TCU Purchase = $84,250 each
TCU Rental = $100,000 - $120,000 for tw o
Sink Plates = estimated at $12K each; true pricing available by 6/15/05
CAL Rods: $1100 per cage for rods
Sink Plates = $7,450 each
• A trade study of the three Radiator thermal control options was done to establish the optimal solution
• The results of this show that the Cal-Rod cage system is the preferred implementation
• Baseline: Cal-Rod cage
LAT TVAC Test Delta-PDR 11
GLAST LAT Project
25 May 2005 Option 3 Cal-Rod/Baffle Sensitivity StudyOption 3 Cal-Rod/Baffle Sensitivity Study
Cal-Rod spacing = 5.6”
Cal-Rod Box Offset = 1.0”
Cal-Rod Box Height = 12”
Panel Dimensions = ~1.5 x 1.5 m (for the study)
Polished Al Frame
RadTemp (C) Per Rod Total Min Max Spread
0 55 600 -1.4 0.6 220 100 1100 18.5 21.8 3.340 153 1685 37.5 42.0 4.5
Power (W) Temperature (C) • Basis of study and boundary conditions:
– Chamber shroud temperature = -150C
– Panel internal heat gen = 300W
– Panel temp uniformity goal: 5 C
– Size system to maintain Rad temp at 0 C, 20 C, and 40 C
– Stainless steel Cal Rods, 0.25” OD
• Results: Cal-rods need 5.6” max spacing 7” set-back from Rad surface
Results of Thermal Analysis
LAT TVAC Test Delta-PDR 12
GLAST LAT Project
25 May 2005 Option 3 Cal-Rod Panel Temperature DistributionOption 3 Cal-Rod Panel Temperature Distribution
LAT TVAC Test Delta-PDR 13
GLAST LAT Project
25 May 2005 Option 3 Cal-Rod Cage Heater Circuit RequirementsOption 3 Cal-Rod Cage Heater Circuit Requirements
• Transient and steady-state thermal analyses of LAT system shows that the hot-case transient test case is the defining case for the heater system
– At one extreme of the transient, all 600 W of LAT power is radiated off of one Radiator
– The Cal-Rod cage on the opposite side of the LAT draws the most power at that time
• Max power needed: 1600 W/Radiator
• Heater cage requirements and boundary conditions
– Power: 1600 W * 1.5 margin = 2400 W/Rad
– Temp uniformity: 5 degC over surface of Radiator
– Max process power: 300 W (with Cal-Rods operating at full-power)
– Minimum of 3 control zones
– Cold shroud minimum temp: -150 C
– Low-profile/low-mass design toincrease cool-down and warm-up rates
-200-150-100-50
050
100150200250300350400450500550600650700750
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Time(min.)
Cal
rod
Tem
per
atu
re(°
C)
500 W
250 W
100 W
Calrod Dissipation
LAT TVAC Test Delta-PDR 14
GLAST LAT Project
25 May 2005 Option 3 Cal-Rod Cage Heater Circuit ImplementationOption 3 Cal-Rod Cage Heater Circuit Implementation
• Power requirements (includes 50% margin)
– 2400 W/cage
• Radiator top: ~400 W
• Radiator middle: ~ 1600 W
• VCHP reservoirs: ~400 W
• Cal-Rods
– Heated length of 60 inches
– O.D of 0.25 inches
– Emissivity >0.38 (sandblasted stainless steel)
– Resistance of at least 89 ohms
– Max operating temperature: 750°C
– Min non-operating temperature: -150°C
• Use standard NRL power supplies
– 1000 W max and 5 A max or 240 V max
– Cal-Rod cage will likely be powered by 4 supplies: one for top, one for reservoirs, and two ganged together for middle zone
Cal-Rod Heater
LAT TVAC Test Delta-PDR 15
GLAST LAT Project
25 May 2005 Summary of Heater RequirementsSummary of Heater Requirements
Area Tot Pwr4 Req'dSink Location m2 W Control
Min Max Min Max Zones
Radiator11 -77 -14 N/A N/A 3.0 2400 3
Radiator21 -77 -14 N/A N/A 3.0 2400 3ACD +X Sink -76 60 36 342 2.4 985 1ACD +Y Sink -89 25 26 217 2.4 625 1ACD -X Sink -79 25 34 217 2.4 625 1ACD -Y Sink -89 25 26 217 2.4 625 1ACD +Z Sink -82 25 31 217 3.5 911 1
SC +Y-Side Sink3 -40 25 N/A N/A 3.0 TBD 1
SC -Y-Side Sink3 -40 25 N/A N/A 3.0 TBD 1
SC Top-Deck Sink3 -40 25 N/A N/A 3.0 TBD 1Test Stand TBD TBD TBD 4
1Note: Cal Rod Cage power for Rad's calc'd based on 4C Rad temp2Note: ACD heater power based on 0.5 plate emissivity and 123K ultimate sink3Note: SC sink heater power calc'd based on cryogen temperature and flow rate4Note: Tot pwr includes 20% margin on sink plates, 50% margin on Cal-Rod cages Note: 1000W DC power supply limited to 240 volt or 5 amp
Equiv Sink Temp Htr Pwr2
W/m2deg C