themis instrument cdr 1 ucb, april 19 - 20, 2004 efi axial booms thermal christopher smith thermal...

THEMIS Instrument CDR 1 UCB, April 19 - 20, 2004

EFI Axial Booms

Thermal

Christopher Smith

Thermal Engineer

[email protected]

510-642-2461


Axial Boom Stowed

Axial Boom (AXB)

• Two units mount inside a carbon fiber tube centrally mounted on the probe

• Tube attached to the top deck through an aluminum flange that is bare bolted

• Bare bolted to lower deck

• Two stacers, one from each unit, deploy out the tube ends

AXB Mounting

Tube

Single AXB unit


AXB / Map

80% Alum Foil Tape

20% Bare Carbon Fiber

Bare Carbon Fiber

Alodined Aluminum

VDA Tape


AXB Model Inputs

• Optical materials– Aluminum Foil Tape– Bare Carbon Fiber– Alodined Aluminum

• Thermophysical materials– Aluminum, 6061– K13D2U Carbon Fiber– T300 Carbon Fiber

• Heaters– None used at this time, though we are prepared to supply deployment heaters

if needed

• Conductors– Bare bolted top flange to deck: 0.612 W/C inc. bolts, flange, and adhesive– Bare bolted bottom flange to deck: 3.3 W/C each, 20 W/C total– Bare bolted AXB to Tube mount: 0.79 W/C each, 0.476 total

• Power Dissipation– 0 Watts

AXB Mounting Tab


AXB Case sets

• Bottom to sun a cold case boundary condition has no eclipse

• All above cases run separately with stowed boom and deployed boom


AXB Mechanical Unit Standard Plots - Deployed

-60

-40

-20

0

20

40

60

50K 100K 150K 200K 250K 300K

AXB Mechanical Unit, Deployed, Standard Case Set - Foil and Bare Carbon Fiber Mix (04/10/04)SAA 103 Hot - SAA 90 Cold - SAA 77 Cold - SAA 77 Cold Low Power

Te

mp

era

ture

Time

BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB BOT DECK TOP DECK TUBE TOP

TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB

BOTTOM AXB BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB


AXB Mechanical Unit Sunline Plots - Deployed

-60

-40

-20

0

20

40

60

80

100

40K 50K 60K 70K 80K 90K 100K 110K

AXB Mechanical Unit, Deployed, TBSun Case Set - Foil and Bare Carbon Fiber (04/10/04)SAA 0 Hot - SAA 180 Cold

Tem

pera

ture

Time

BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB



AXB Mechanical Unit Standard Plots - Stowed

-60

-40

-20

0

20

40

60

80

50K 100K 150K 200K 250K 300K

AXB Mechanical Unit, Stowed, Standard Case Set - Foil and Bare Carbon Fiber Mix (04/10/04)SAA 103 Hot - SAA 90 Cold - SAA 77 Cold - SAA 77 Cold Low Power

Te

mp

era

ture

Time

BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB BOT DECK TOP DECK TUBE TOP

TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB

BOTTOM AXB BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB


AXB Mechanical Unit Sunline Plots - Stowed

-60

-40

-20

0

20

40

60

80

100

40K 50K 60K 70K 80K 90K 100K 110K

AXB Mechanical Unit, Stowed, TBSun Case Set - Foil and Bare Carbon Fiber (04/10/04)SAA 0 Hot - SAA 180 Cold

Tem

pera

ture

Time




AXB Results Table


AXB Mounting Tube Modifications

• Spacecraft was consuming too much power in the coldest, but nominal, science case ~2.2 W

• To help mitigate this issue two modifications are being considered for the AXB Mounting tube

• Tube construction switched from all T300 ( 5 W/mK) fiber to 4 plys K13D2U (500 W/mK) + 2 plys T300

• Tube exterior changed from blanket to a mix of Foil tape and bare carbon

• Current results show the AXB unit getting too hot and we are currently exploring options to cool it down

• Increase isolation between AXBs and tube

• Isolate tube flange from top deck

• At worst, cool the tube down by reducing the percentage of foil tape

• When the design is complete it will be within limits though new temperatures may require the thermal vac hot deploy test be repeated at a new higher temperature


AXB Temp Map for Hottest Case


AXB Temp Map for Coldest Case


Axial Boom Deployed

AXB “can”

AXB PreAmp

Exposed Bit After Deploy


AXB Geometry Model

Deployed Stacer Model


AXB Deployed Elements / Map

DAG 154Alodined AluminumDAG 213

Bronze


AXB Model Inputs

• Optical materials– Acheson Coloids DAG 213 (2 part)– Acheson Coloids DAG 154– Alodined Aluminum– Bronze

• Thermophysical materials– Aluminum, 6061– Bronze– Elgiloy– PEEK

• Heaters– None

• Conductors– Main Stacer to Tip Piece, 1 rivet and circumferential contact, .3 < G <.9 W/C– Tip Piece To Bronze DDAD Lock, Large threaded interface, 10 W/C– DDAD Lock to PreAmp, large threaded bolt 3.57 W/C– PreAmp to Mini Stacer, 1 rivet and circumferential contact .3< G <.8 W/C– Mini Stacer to Can, 1 rivet, 0.3 W/C

• Power Dissipation– 0.07 Watts Nominal at Preamp

AXB Preamp


AXB Deployed Elements Case Sets

• Top and Bottom to sun cases after deployment are limited to no less than 11 degrees off the sun line

• The Model for the Top and Bottom to Sun cases goes through a 180 min eclipse. A 100 min eclipse is the actual limit and is shown in plots


AXB Boom Elements Standard Plots - Deployed

-150

-100

-50

0

50

50K 100K 150K 200K 250K 300K

AXB Boom Elements, Deployed, Standard Case Set (04/10/04)SAA 103 Hot - SAA 90 Cold - SAA 77 Cold - SAA 77 Cold Low Power

Tem

pera

ture

Time

AXBROD.T14 AXBCAN.T6 AXBDDAD.T6 AXBPAMP.T10 AXBSTACR.T28 AXBTIP.T7 AXBROD.T14 AXBCAN.T6 AXBDDAD.T6

AXBPAMP.T10 AXBSTACR.T28 AXBTIP.T7 AXBPAMP.Q10 AXBROD.T14 AXBCAN.T6 AXBDDAD.T6 AXBPAMP.T10 AXBSTACR.T28

AXBTIP.T7 AXBROD.T14 AXBCAN.T6 AXBDDAD.T6 AXBPAMP.T10 AXBSTACR.T28 AXBTIP.T7


AXB Boom Elements Sunline Plots - Deployed

-180

-160

-140

-120

-100

-80

-60

-40

-20

20K 30K 40K 50K 60K 70K 80K 90K 100K 110K 120K 130K

AXB Boom Elements, Deployed, TBSun Case Set (04/10/04)SAA 11 Cold - SAA 169 Cold

Tem

pera

ture

Time

AXBROD.T14 AXBCAN.T6 AXBDDAD.T6 AXBPAMP.T10 AXBSTACR.T28 AXBTIP.T7

AXBROD.T14 AXBCAN.T6 AXBDDAD.T6 AXBPAMP.T10 AXBSTACR.T28 AXBTIP.T7


AXB Preamp Results Table

• Science operation limited to a 36 min eclipse

• Current predicts show Preamp falling below the limit on the TO99 can.


AXB Preamp Qualification

• AXB Preamp model is currently a simple lump with the proper radiative surfaces

• Thermal isolation of the TO-99 from the outer shell is complicated and difficult to reliably model

• Thermal Vacuum test planned determine the thermal isolation of the TO-99 from the preamp outer surface (April 12th – April 23rd)

• This thermal isolation determined by test will be input into the thermal model to determine a reliable qualification temperature, still likely to be under the current qualified temp of –65


AXB Preamp Models


EFI Spin Plane Booms

Thermal

Christopher Smith

Thermal Engineer

[email protected]

510-642-2461


SPB

• 4 separate units mounted to the bottom deck

• Snout pokes out the solar panel

• Sphere and Preamp deploy out the snout on a wire (Half Sphere shown in picture)

• Sphere and preamp separate as rotation unwinds a thin wire from a spring loaded wheel


SPB / Map

AZ 2000 IECW Inorganic White Paint

MLI

Alodined Aluminum


SPB Model Inputs

• Optical materials– Germanium Black Kapton (Sheldahl 275XC Black Kapton)– Alodined Aluminum– AZ 2000 IECW Inorganic White Paint– Blanket: .01 < < .05

• Thermophysical materials– Aluminum, 6061– ULTEM

• Heaters– None used at this time, though we are prepared to supply deployment heaters

if needed

• Conductors– 1/8” Ultem isolators for top deck: 0.01 W/C each, 0.04 W/C total

• Power Dissipation– 0 Watts


SPB Case Sets


SPB Mechanical Unit Standard Plots

-40

-30

-20

-10

0

10

20

30

40

50K 100K 150K 200K 250K 300K

SPB - Alodine w/ AZ 2000 IECW (04/12/04)SAA 103 Hot - SAA 90 Cold - SAA 77 Cold - SAA 77 Cold Low Power

Te

mp

era

ture

Time

TOP HAT TOP HAT TOP REAR PANEL BOTTOM REAR PANEL BOTDECK





SPB Mechanical Unit Sunline Plots

15

20

25

30

35

40

45

20000 25000 30000 35000 40000 45000 50000 55000 60000 65000

SPB - Alodine w/ AZ 2000 IECW (04/12/04)SAA 0 Hot - SAA 180 Hot

Te

mp

era

ture

Time




SPB Results Table


SPB Heat Map for Coldest Case


SPB Heat Map for Hottest Case


SPB Deployed Elements

• Preamp and sphere are connected by a thin wire

• Preamp is connected to SPB deployment unit by another wire

• Preamp is nearly identical to Axial version

• Sphere is only a mechanical element

Titanium Nitride

DAG 213


Preamp and Sphere Analysis


SPB Sphere and Preamp Model

• Nodes 3 and 4 are for the sphere hot and cold cases

• Nodes 5 and 6 are for the preamp hot and cold cases

• As with the axial preamp the SPB preamp falls below its limit by a bit. Qualification plan is in the works


SPB Sphere and Preamp Plot

themis instrument cdr 1 ucb, april 19 - 20, 2004 efi axial booms thermal christopher smith thermal...

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