tracker thermal control system 1 ams tracker thermal control system (ttcs) ttcs design description...

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Tracker Thermal Control System

AMS Tracker Thermal Control AMS Tracker Thermal Control System (TTCS)System (TTCS)

TTCS Design DescriptionTTCS Design DescriptionNLR-team: J. van Es, M.P.A.M. Brouwer, B. Verlaat (NIKHEF), A. Pauw, G. van

Donk, T. Zwartbol, CAM. Rens, SM. BardetSun Yat-Sen University team: ZH. He, KH. Guo, JQ. Ni, SS. Lu, XZ. Wang, XM.

Qi, TX. Li, YH Huang INFN-AMS-team: R. Batiston, M. Menichelli et al.

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Wake heat pipe radiator

Ram heat pipe radiator

TTCS com-ponent box

Condensers

Evaporator• Requirements summary

• System Lay-out & Operation

• Tube routing & condenser

• TTCS-Boxes

• Components

– Pump

– Heat exchanger

– OHP

• Safety approach

• Design challenges

• Integration

ContentsContents

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Requirements SummaryRequirements SummarySilicon wafer thermal requirements Hybrid circuit thermal requirements Operating temperature: Operating temperature: -10˚C / +25˚C -10˚C / +25˚C Survival temperature: Survival temperature: -20˚C / +40˚C -20˚C / +40˚C Temperature stability: Temperature stability: 3˚C per orbit 3˚C per orbit Maximum allowed gradient between any silicon: 10.0˚C Dissipated heat: Dissipated heat: 2.0 W EOL 144 W total (±10%)

0.75 W per hybrid pair (S=0.47 W, K=0.28 W)

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TTCS Fluid temperature ranges • Operating Temperature loop (set-point): -15˚C / +15˚C

Loop temperatures in the single-phase part can be -40˚C / +15˚C

• Survival temperature: -100 ˚C / +65˚C (also for internal pressure)

• Start-up temperature: -40 ˚C / + 20˚C (accumulator start-up

temperature)

Requirements SummaryRequirements Summary

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TTCE (Electronics) in TTCS-boxes

• Operating temperature: -20˚C / +85˚C

• Survival temperature: -40˚C / +105˚C

TTCS-box interface with USS

• Operating temperature: -40˚C / +55˚C

• Survival temperature: -40˚C / +55˚C

• Start-up temperature (driving requirement): -40 ˚C / 10 ˚C


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AMS- Tracker Thermal Control System MDP determinationAMS- Tracker Thermal Control System MDP determinationConstraint 1: max allowed system fill ratio=f (MDP, MDT)

NASA : shuttle Earth Max Design Temp (MDT)= 65 °CGiven the temperature, now FRSYSTEM is only a function of MDPAMS-team: MDP is set to 160 bar

Carbon Dioxide: Pressure - Enthalpy Diagram

Mel

ting

Line

-40

-40

oC

-20

-20

t = 0

oC

0

20

20

40

40

60

60

80

80

100

100

120

120

140

140

160

160

180

180

200

200

220

220

240

oC

240

260

280

Ent

ropy

= -

2.3

0 k

J/kg

,o C

s =

-2

.20

-2.1

0 -2.0

0

-1.9

0

-1.8

0

-1.7

0

--1.

60

-1.5

0

-1.4

0

-1.3

0

-1.2

0 -1.1

0

-1.0

0

-.70

-.90

-.80

-.60

-.50

-.40

-.30

-.20

-.10

s =

0S

ublim

atio

n Li

ne

Triple Point (5.18 bar, -56.558 oC)

r = 1

200

r = 1

150

r = 1

100

r = 1

050 r =

100

0 r = 900

r = 800

Density = 700 kg/m3

r = 600

r= 500

r = 400

r = 300

r = 200 kg/m3

r = 150

r = 100

r = 75

r = 50

r = 35

Density = 20 kg/m3

r = 10

r = 25

r =15

r = 8

r = 6

1

10

100

1,000

-500 -400 -300 -200 -100 0 100 200

Enthalpy, kJ/kg

Pre

ssu

re,

Bar

Copyright © 1999 ChemicaLogic Corporation

www.chemicalogic.com160 bar, 65 °C, System Fill Ratio=density=r=580 kg/m3

Carbon dioxide: enthalpy pressure diagram

160

Filling accuracy: ± 4%: FRSYSTEM,MAX = 580 kg/m3

FRSYSTEM,MIN = 536 kg/m3, this value to be used for further calculations

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TTCS design pressures TTCS components MDP [bar] Proof pressure [bar] Burst pressure [bar]

Evaporator tubing 160 240 640

Tubing in TTCS-P-box & TTCS-S box

160 240 640

TTCS-components - valves - pumps - APS - DPS - LFM - Accumulator - connection construction condenser lines

160 240 400

Condenser (proposed)* 3000 (TBC) 3500 (TBC) TBD

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• The overall leak tightness of the TTCS-loop is 1.0E-4 mbar.l/s CO2

at 33 bar.

Leak tightness budget

• Remark1: This leak tightness requirement defines (in)directly the fill rate of the TTCS as overpressurizing the system has to be avoided.

• Remark2: Calculation of the equivalent He-leakrate at standard pressure and temperature should be carried out.


Leak tightness budget Components < 1*10-6 mbar*l/s CO2 at 33 bar

Welds < 1*10-6 mbar*l/s CO2 at 33 bar

Hydraulic connectors < 1*10-6 mbar*l/s CO2 at 33 bar (TBC)

Pinching system (GSE) < 1*10-6 mbar*l/s CO2 at 33 bar

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Orbital data on the radiator is given in the following format: – MERAT temperatures of the RAM and Wake Tracker radiators.

– View temperatures at the back side of the radiator

– Orbital load (sun solar earth) on the RAM and Wake Tracker radiators

– Orbital load at the back (inside) of the RAM and Wake radiators

Requirements Summary: EnvironmentRequirements Summary: Environment

RAM

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Requirements Summary: EnvironmentRequirements Summary: EnvironmentI/F DATA BETA_0-15-20-15_hot

-225,0

-175,0

-125,0

-75,0

-25,0

25,0

75,0

125,0

0 2 4 6 8 10 12 14

Orbital Position (1-13)

Tem

per

atu

re [

C]

-400,0

-300,0

-200,0

-100,0

0,0

100,0

200,0

RAM Merat 81100

RAM Merat 81101

RAM Merat 81102

RAM Merat 81103

WAKE Merat 82100

WAKE Merat 82101

WAKE Merat 82102

WAKE Merat 82103

Tinside 381100

Tinside 381101

Tinside 381102

Tinside 381103

Tinside 382100

Tinside 382101

Tinside 382102

Tinside 382103

RAM Load 81100

RAM Load 81101

RAM Load 81102

RAM Load 81103

WAKE Load 82100

WAKE Load 82101

WAKE Load 82102

WAKE Load 82103

Inside Load 381100

Inside Load 381101

Inside Load 381102

Inside Load 381103

Inside Load 382100

Inside Load 382101

Inside Load 382102

Orbital Data TTCS Radiators Incl. Orbital load

Orbital load (solar + albedo + earth)

Radiator back side mean I/F temperatures

WAKE Merat temperatures

RAM Merat temperatures

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Typical Operational Radiator Temperatures Typical Operational Radiator Temperatures (BBM)(BBM)

Datafile name: d:\CO2-loop data\030527 CO2 0906.asc

-40

-35

-30

-25

-20

-15

-10

-5

0

5

15500 17500 19500 21500 23500 25500

time[s]

AccuTop

LiqHX_in

LiqTopHX_out

LiqLowHX_out

RAM-out

WAKE-out

To7

To12

To16

To22

To30

Ti1

Ti12

Ti18

Ti21

Ti23

Ti24

HX-vap-out

Tracker thermal I/F temperatures (evaporators)Accu

wake out

ram out

HX in

RAM and WAKE heat sinks are forced to thermal model radiator temperature profile

HX out

Tem

pera

ture

[C

]

Time [s]

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TTCS Functionality TTCS Functionality Component Function Pump Transport the fluid through the loop Accumulator Regulate the evaporator temperature in the tracker

Account for the expansion of the working fluid Accumulator Peltier elements Regulate evaporation set-point in all operation modes (cooling) Accumulator heaters Regulate evaporation set-point in all operation modes (heating)

Emergency accumulator heat-up in case liquid line temperature approaches saturation temperature (to avoid cavitation in pump)

Valves (liquid line) Control the mass flow distribution between Wake and RAM radiator

Heat Exchanger Exchange heat between hot evaporator outlet and cold evaporator inlet. Reduction of pre-heater power

Evaporator Collect heat at the tracker electronics. The evaporation process provides the temperature stability required.

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TTCS Functionality TTCS Functionality

Condensers Remove the heat from the working fluid to the radiators. The condensing process makes the heat transfer effective.

Absolute Pressure Sensors Monitor the absolute pressure inside the loop Differential Pressure Sensor Monitor pump pressure head LFM Monitor mass flow Pre-heaters Heat evaporator liquid inlet to saturation point Start-up heaters Additional heater for cold start-up (off during nominal

operation) Dallas Temperature Sensors Monitor temperatures TTCS temperatures Pt1000 Temperature Sensors Control pre-heater power

Control accumulator temperature Control liquid line valves (under discussion) Monitor cold temperatures on radiator and liquid lines

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TTCS Operation TTCS Operation

AMSPayloadOps & Control

TTCSGroundOps &MonitoringSystem

TTCS-SS

CAN busses

Primary Loop (PL)

aequipment

bequipment

Secondary Loop (SL)

aequipment

bequipment

TTCE-A

aP aS

TTCE-B

bP bS

TMTC JMDC-CAN I/F

JMDC SW

TTCE Manager

Architectural overview

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TTCS Operational modes TTCS Operational modes

M onito ring O pera ting M ode (M O M )

TTC E O n

TC

TC

S econdary loopO n

N orm alO pera tiona l

M ode

LoopS hut-downM ode

LoopS tart-up

M ode

TCTC

TC

TCauto(sfgrd)

auto(sfgrd)

TC

N orm alO pera tiona l

M ode

LoopS hut-downM ode

LoopS tart-up

M ode

P rim ary loopO n TCTC

TCauto(sfgrd)

auto(sfgrd)

TC

TC

M O M P rim ary Loop(M O M P L)

M O M S econdary Loop(M O M S L)

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TTCS tube routing (schematic)TTCS tube routing (schematic)

WAKE

RAM

Primary TTCS

Secondary TTCSCircular tube routing using outer cylinder generic hole pattern

Condenser manifold Circular tube routing using former ACC/PMT mounting hole pattern

Two tube support beams

Condenser tubes supported by radiator diagonal strut

Evaporator lineCondenser line

Welded connectionsmade on site

Hydraulic connectors

Also at bottom evaporator branch not shown

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Tube routingTube routing

Dimensions

• All tubing Do = 4 mm, Di=2.6 mm

• 1 Tracker return line (combined part) Do = 6 mm, Di=2.6

mm (only in box)

Additional integration issues

• Wire and start-up heaters are located at evaporator

tubes from box to Tracker

• All tubing wrapped in MLI or located below Flange MLI.

• Two support beams from top to bottom at wake side

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Tube routing (support beams)Tube routing (support beams)

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Condenser tube routingCondenser tube routing• Condenser design

– 14 capillary Inconel tubes (7 feed and 7 return lines) from each

manifold to the condensers (Di= 1mm, Do=2-3 mm

– Each capillary tube is wired with a wire heater to thaw the line

after AMS02 complete power down.

– Tubes are wrapped in MLI to minimise environmental heat leak.

– Each radiator is equipped with 2 x 3 redundant Pt1000’s for

switching.

– Each radiator is also equipped with heater cabling A & B for

health heaters.

– Electrical connectors located on a bracket boxes at main radiators

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Condenser tubingCondenser tubingManifold positions

• Location at upper trunnion bridges T>-40 in all cases

– Condenser lines from manifold to box T > 40 C (no freezing)

– Parallel condenser lines are installed together with condenser

• Manifold design Y:\Projects\AMS-Tracker\Technical\Components\condensers\CondenserManifold25feb05.pdf

– brazed and welded design

– Manifold orientation should be convenient for tube routing.

– the manifold has a stainless steel tube end attached on the

box side

– tube end is orbital welded to the tube routed to the box right

after installation of the condenser

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Condenser manifold locations Condenser manifold locations

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Condenser Manifold location (detail)Condenser Manifold location (detail)

Upper trunnion bridge

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Condenser tube routingCondenser tube routing• Electrical connectors (terminal blocks) are located on a

bracket boxes at main radiators

Picture CGS (Assenza)

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Condenser Design & tube routingCondenser Design & tube routing

Tracker radiator Condenser inserts OHB Sept 2004

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Condenser Design & tube routingCondenser Design & tube routing

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Condenser Design & tube routing (MGSE)Condenser Design & tube routing (MGSE)

Rod I/F Bracket

Rod I/F Bracket

Rod I/F Bracket

Integration Bar 1 (temporary)In

tegr

atio

n B

ar 2

(te

mpo

rary

)

TTCS Condensator

Schematic OHB Sept 2004

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TTCS BoxesTTCS Boxes

TTCS Box envelopes

Secondary & Starboard TTCSComponent Box

(TTCBS)

WAKERAM

TTCS Envelope location

X

Y

Z

Y

B. Verlaat (NIKHEF), 21 March 2003

Primary & Port TTCS Component Box

(TTCBP)

Starboard

Port

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TTCS BoxesTTCS Boxes

TTCBP

Tracker radiator

Condenser

TTCE

TTPD

TTCBS

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TTCS Box lay-outTTCS Box lay-out

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TTCS Box lay-outTTCS Box lay-out

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Components: PumpComponents: Pump

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Components: PumpComponents: Pump• Initial Data Drop for PDR is performed

• Data only available for safety panel

(export license agreement)

• B-field test set-up is being manufactured

• BBM model impeller test starting in May

• Electronics design EM and QM will start next week

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Components: Heat Exchanger Components: Heat Exchanger approx 68

approx 87 36 X18 x liquid18 x two-phase

=

weld

• two-phase to single phase plate type heat exchanger

• welded housing

• soldered stack of plates

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Components: Heat Exchanger Components: Heat Exchanger

soldered stack of plates

• Soldering tests will be performed as soon as solder is delivered

bottom view

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Components: Heat Exchanger Components: Heat Exchanger • Heat exchanger design is updated for box tubing

• Strength calculations show 4 mm wall thickness is

required

• Material is stainless steel

• The weld cannot be done by orbital welding (4 mm)

• EM prototype is planned end of April

– depends on a successful soldering test

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Components: Oscillating Heat Pipe Components: Oscillating Heat Pipe

• Working Fluid FC-87 (inert, non-toxic)

• Volume tubing: 2.3 ml

• Fill rate 70% (i.e. 1.6 ml FC-87)

• Heat supply by Minco foil heater Minco foil K5229 type 1 see specs below

• Cooling by two-phase line

• Operation only in cold orbits at set-points below 5 C Default disabled

• Construction needs to be ruggedized by a TBD frame

Heater modelBranch Voltage type Length (mm) Width (mm) Total length (mm) area (inch^2) area (cm^2)5229 28 Type 1 139.7 10.9 N/A 1.7 11.0

R (ohm) Current (A) Power Max. Power (W) [=V^2/R] Power density (W/cm^2)17.5 1.6 44.8 49.73 4.53

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Safety Approach (thermal aspects)Safety Approach (thermal aspects)• Safety requirement box -40 C <T < 65 C

– hot case solved thermostats on power line (see lay-out)

– cold case solved by USS worst case cold temperature and

safety heaters as back-up

(to avoid freezing and for electronics survival)

• Safety requirement radiator -40 C <T < 80 C

– hot case shown by analysis (this afternoon)

– cold case solved by health heaters

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Safety Approach (thermal aspects)Safety Approach (thermal aspects)• 9 parallel heater lines on PDS switch

(redundant 9A and 9B)

• 5 parallel lines on radiator

• 4 parallel lines on condensers

• Switch control by TTCE

– 6 Pt1000’s (3A and 3B)

• Switch performed by PDS

C om puterP t1000

condenser

P D S B U S AP D S

return

live TB

TB

41


Safety Approach (thermal aspects)Safety Approach (thermal aspects)• Condenser heater lay-out

340 mm

460 mm

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Design Challenges/RisksDesign Challenges/RisksInterface temperature USS

– Start-up at + 10 C USS is extreme

– TEC coolers next to the pumps are foreseen in

case margin is small

Accumulator (design performed by CAST)

– During launch temperatures above T(critical) can easily occur

– Concern about bubbles in accumulator

– CAST is investigating this issue by test

Freezing

– Freezing test to “measure” MDP

– More in separate presentation

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Integration aspects Integration aspects (welding/hydraulic connectors)(welding/hydraulic connectors)

Hydraulic connectors

– Type: Dynatube fitting, Resistoflex Aerospace

– Stainless Steel 15-5PH H1075 (-81 C to 343 C)

– No leaks (MIL-F-85720) upto 8000 psi

– Technical reply supplier (expected any moment)

Micro-welding

– Swagelock offers a “new” micro-welding technique

– A meeting between AMS02 integration specialists and

swagelock weld specialists is proposed to investigate the

feasibility of this method

44


Electrical schematic and routingElectrical schematic and routing

PDS

thermostats

T T -C ra te

T T C E C o ld

T T C E H o t

JM D C

T T P DT T C S

P rim a ry L o o p

T T C SS e c o n d a ry L o o p

T ra c k e r

Secondory Cold Cables:1) Heater/peltier power2) Tem perature/Pressure3) Valve/Pum p power4) Valve/Pum p feedback

Secondary Hot Cables:1) Heater/peltier power2) Tem perature/Pressure3) Valve/Pum p power4) Valve/Pum p feedback

Prim ary Cold Cables:1) Heater/peltier power2) Tem perature/Pressure3) Valve/Pum p power4) Valve/Pum p feedback

Prim ary Hot Cables:1) Heater/peltier power2) Tem perature/Pressure3) Valve/Pum p power4) Valve/Pum p feedback

Prim ary Cold Cables:1) Heater power2) Tem perature

Prim ary Hot Cables:1) Heater power2) Tem perature

Secondary Cold Cables:1) Heater power2) Tem perature

Secodary Hot Cables:1) Heater power2) Tem perature

Power Hot Cables:1) Power2) Power control

Power Cold Cables:1) Power2) Power control

Com m unication Hot Cables:1) CAN

Com m unication Cold Cables:1) CAN

tracker thermal control system 1 ams tracker thermal control system (ttcs) ttcs design description...

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