Post on 31-Dec-2015
THEMIS Instrument CDR 1 UCB, April 19 - 20, 2004
EFI Axial Booms
Thermal
Christopher Smith
Thermal Engineer
csmith@ssl.berkeley.edu
510-642-2461
THEMIS Instrument CDR 2 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 3 UCB, April 19 - 20, 2004
AXB / Map
80% Alum Foil Tape
20% Bare Carbon Fiber
Bare Carbon Fiber
Alodined Aluminum
VDA Tape
THEMIS Instrument CDR 4 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 5 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 6 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 7 UCB, April 19 - 20, 2004
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
BOT DECK TOP DECK TUBE TOP TUBE MIDDLE TUBE BOTTOM TOP AXB BOTTOM AXB
THEMIS Instrument CDR 8 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 9 UCB, April 19 - 20, 2004
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
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
THEMIS Instrument CDR 10 UCB, April 19 - 20, 2004
AXB Results Table
THEMIS Instrument CDR 11 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 12 UCB, April 19 - 20, 2004
AXB Temp Map for Hottest Case
THEMIS Instrument CDR 13 UCB, April 19 - 20, 2004
AXB Temp Map for Coldest Case
THEMIS Instrument CDR 14 UCB, April 19 - 20, 2004
Axial Boom Deployed
AXB “can”
AXB PreAmp
Exposed Bit After Deploy
THEMIS Instrument CDR 15 UCB, April 19 - 20, 2004
AXB Geometry Model
Deployed Stacer Model
THEMIS Instrument CDR 16 UCB, April 19 - 20, 2004
AXB Deployed Elements / Map
DAG 154Alodined AluminumDAG 213
Bronze
THEMIS Instrument CDR 17 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 18 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 19 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 20 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 21 UCB, April 19 - 20, 2004
AXB Preamp Results Table
• Science operation limited to a 36 min eclipse
• Current predicts show Preamp falling below the limit on the TO99 can.
THEMIS Instrument CDR 22 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 23 UCB, April 19 - 20, 2004
AXB Preamp Models
THEMIS Instrument CDR 24 UCB, April 19 - 20, 2004
EFI Spin Plane Booms
Thermal
Christopher Smith
Thermal Engineer
csmith@ssl.berkeley.edu
510-642-2461
THEMIS Instrument CDR 25 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 26 UCB, April 19 - 20, 2004
SPB / Map
AZ 2000 IECW Inorganic White Paint
MLI
Alodined Aluminum
THEMIS Instrument CDR 27 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 28 UCB, April 19 - 20, 2004
SPB Case Sets
THEMIS Instrument CDR 29 UCB, April 19 - 20, 2004
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
TOP HAT TOP HAT TOP REAR PANEL BOTTOM REAR PANEL BOTDECK
TOP HAT TOP HAT TOP REAR PANEL BOTTOM REAR PANEL BOTDECK
TOP HAT TOP HAT TOP REAR PANEL BOTTOM REAR PANEL BOTDECK
THEMIS Instrument CDR 30 UCB, April 19 - 20, 2004
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
TOP HAT TOP HAT TOP REAR PANEL BOTTOM REAR PANEL BOTDECK
TOP HAT TOP HAT TOP REAR PANEL BOTTOM REAR PANEL BOTDECK
THEMIS Instrument CDR 31 UCB, April 19 - 20, 2004
SPB Results Table
THEMIS Instrument CDR 32 UCB, April 19 - 20, 2004
SPB Heat Map for Coldest Case
THEMIS Instrument CDR 33 UCB, April 19 - 20, 2004
SPB Heat Map for Hottest Case
THEMIS Instrument CDR 34 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 35 UCB, April 19 - 20, 2004
Preamp and Sphere Analysis
THEMIS Instrument CDR 36 UCB, April 19 - 20, 2004
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
THEMIS Instrument CDR 37 UCB, April 19 - 20, 2004
SPB Sphere and Preamp Plot