David Bame

AN OVERVIEW OF MEMS-BASED MICROPROPULSION DEVELOPMENTS AT JPL

Development of MEMS (Microelectromechanical Systems) micropropulsion at the Jet Propulsion Laboratory (JPL) is reviewed. This includes a vaporizing liquid micro-thruster for microspacecraft attitude control, a micro-ion emgine for microspacecraft primary propulsion or large spacecraft fine attitude control, as well as several valve studies, including a solenoid valve studied in collaboration with Moog Space Products Division, and a piezoelectric micro-valve.

Mars Science Laboratory thermal control architecture

The Mars Science Laboratory (MSL 1 ) mission to land a large rover on Mars is being planned for Launch in 2009. As currently conceived, the rover would use a Multimission Radioisotope Thermoelectric Generator (MMRTG) to generate about 110 W of electrical power for use in the rover and the science payload. Usage of an MMRTG allows for a large amount of nearly constant electrical power to be generated day and night for all seasons (year around) and latitudes. This offers a large advantage over solar arrays. The MMRTG by its nature dissipates about 2000 W of waste heat. The basic architecture of the thermal system utilizes this waste heat on the surface of Mars to maintain the rovers temperatures within their limits under all conditions. In addition, during cruise, this waste heat needs to be dissipated safely to protect sensitive components in the spacecraft and the rover. Mechanically pumped fluid loops 2 are used to both harness the MMRTG heat during surface operations as well as reject it to space during cruise. This paper will describe the basic architecture of the thermal control system, the challenges and the methods used to overcome them by the use of an innovative architecture to maximize the use of heritage from past projects while meeting the requirements for the design.

JPL micro-thrust propulsion activities

Formation flying and microspacecraft constellation missions pose new propulsion requirements. Formationflying spacecraft, due to the tight positioning and pointing control requirements, may need thrust control within 1- 20 uN to an accuracy of 0.1 uN for LISA and ST-7, for example. Future missions may have extended thrust ranges into the sub - mN range. However, all do require high specific impulses (>500 sec) due to long required thruster firings.

The Hardware Challenges for the Mars Exploration Rover Heat Rejection System

The primary objective of the Mars Exploration Rover (MER) 2003 Project focused on the search for evidence of water on Mars. The launch of two identical flight systems occurred in June and July of 2003. The roving science vehicles are expected to land on the Martian surface in early and late January of 2004, respectively. The flight system design inherited many successfully features and approaches from the Mars Pathfinder Mission. This included the use of a mechanically‐pumped fluid loop, known as the Heat Rejection System (HRS), to transport heat from the Rover to radiators on the Cruise Stage during the quiescent trek to Mars. While the heritage of the HRS was evident, application of this system for MER presented unique and difficult challenges with respect to hardware implementation. We will discuss these hardware challenges in each HRS hardware element: the integrated pump assembly, cruise stage HRS, lander HRS, and Rover HRS. These challenges span the entire development cycle including fabrication, as...

Mechanically Pumped Fluid Loop Technologies for Thermal Control of Future Mars Rovers

Mechanically pumped fluid loop has been the basis of thermal control architecture for the last two Mars lander and rover missions and is the key part of the MSL thermal architecture. Several MPFL technologies are being developed for the MSL rover include long-life pumps, thermal control valves, mechanical fittings for use with CFC-11 at elevated temperatures of approx.100 C. Over three years of life tests and chemical compatibility tests on these MPFL components show that MPFL technology is mature for use on MSL. The advances in MPFL technologies for MSL Rover will benefit any future MPFL applications on NASA s Moon, Mars and Beyond Program.

From Concept-to-Flight: An Active Active Fluid Loop Based Thermal Control System for Mars Science Laboratory Rover

The Mars Science Laboratory (MSL) rover, Curiosity, which was launched on November 26, 2011, incorporates a novel active thermal control system to keep the sensitive electronics and science instruments at safe operating and survival temperatures. While the diurnal temperature variations on the Mars surface range from -120 C to +30 C, the sensitive equipment are kept within -40 C to +50 C. The active thermal control system is based on a single-phase mechanically pumped fluid loop (MPFL) system which removes or recovers excess waste heat and manages it to maintain the sensitive equipment inside the rover at safe temperatures. This paper will describe the entire process of developing this active thermal control system for the MSL rover from concept to flight implementation. The development of the rover thermal control system during its architecture, design, fabrication, integration, testing, and launch is described.

Design of Accumulators and Liquid/Gas Charging of Single Phase Mechanically Pumped Fluid Loop Heat Rejection Systems

For single phase mechanically pumped fluid loops used for thermal control of spacecraft, a gas charged accumulator is typically used to modulate pressures within the loop. This is needed to accommodate changes in the working fluid volume due to changes in the operating temperatures as the spacecraft encounters varying thermal environments during its mission. Overall, the three key requirements on the accumulator to maintain an appropriate pressure range throughout the mission are: accommodation of the volume change of the fluid due to temperature changes, avoidance of pump cavitation and prevention of boiling in the liquid. The sizing and design of such an accumulator requires very careful and accurate accounting of temperature distribution within each element of the working fluid for the entire range of conditions expected, accurate knowledge of volume of each fluid element, assessment of corresponding pressures needed to avoid boiling in the liquid, as well as the pressures needed to avoid cavitation in the pump. The appropriate liquid and accumulator strokes required to accommodate the liquid volume change, as well as the appropriate gas volumes, require proper sizing to ensure that the correct pressure range is maintained during the mission. Additionally, a very careful assessment of the process for charging both the gas side and the liquid side of the accumulator is required to properly position the bellows and pressurize the system to a level commensurate with requirements. To achieve the accurate sizing of the accumulator and the charging of the system, sophisticated EXCEL based spreadsheets were developed to rapidly come up with an accumulator design and the corresponding charging parameters. These spreadsheets have proven to be computationally fast and accurate tools for this purpose. This paper will describe the entire process of designing and charging the system, using a case study of the Mars Science Laboratory (MSL) fluid loops, which is en route to Mars for an August 2012 landing.

Design and Preliminary Thermal Performance of the Mars Science Laboratory Rover Heat Exchangers

The challenging range of proposed landing sites for the Mars Science Laboratory Rover requires a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as -123 degrees Centigrade and as warm as 38 degrees Centigrade, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) and external radiators to maintain the temperature of sensitive electronics and science instruments within a -40 degrees Centigrade to 50 degrees Centigrade range. The MPFL also manages significant waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG). The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Two similar Heat Exchanger (HX) assemblies were designed to both acquire the heat from the MMRTG and radiate waste heat from the onboard electronics to the surrounding Martian environment. Heat acquisition is accomplished on the interior surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the MPFL to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aerogel as an insulator inside composite honeycomb sandwich panels. A complex assembly of hand welded and uniquely bent aluminum tubes are bonded onto the HX panels and were specifically designed to be easily mated and demated to the rest of the Rover Heat Recovery and Rejection System (RHRS) in order to ease the integration effort. During the cruise phase to Mars, the HX assemblies serve the additional function of transferring heat from the Rover MPFL to the separate Cruise Stage MPFL so that heat generated deep inside the Rover can be dissipated via the Cruise Stage radiators. Significant fabrication challenges had to be overcome in order to make the HX design a reality. The cruise phase thermal performance of the Rover HXs was verified in the cruise phase system level thermal vacuum test that was performed at JPL in January of 2009. The Rover HXs were modeled in I-DEAS TMG and predictions are compared to actual data from the test.

The micro-isolation valve - Introduction of concept and preliminary results

A feasibility investigation for a newly proposed microfabricated, normally-closed i so la t ion valve was initiated. The micro-isolation valve is silicon based and relies on the principle of melting a doped plug, opening an otherwise sealed flow passage. This valve may thus serve a similar role as a conventional pyrovalve and is intended for use in micropropulsion systems onboard future microspacecraft, having wet masses of no more than 10-20 kg, as well as in larger scale propulsion systems having only low flow rate requirements, such as ion propulsion or Hall thruster systems. Two key feasibility issues melting of the plug and pressure handling capability were addressed. Thermal finite .element modeling showed that valves with plugs having widths between 10 and 50 (im have power requirements of only 10 30 Watts to open over a duration of 0.5 ms or less. Valve chips featuring 50 micron plugs were burst pressure tested and reached maximum pressure values of 2850 psig (19.4 Mpa).

Proof-of-concept demonstration of a vaporizing liquid micro-thruster

Proof-of-concept testing of a microfabricated vaporizing liquid thruster was performed. In this liquid-fed thruster concept, propellant vaporization is achieved in a microfabricated thin film heater arrangement. Chip temperatures of 100, 150 and 200 C were achieved at power levels of 3.5, 5.5 and 7.5 W. Voltage requirements were below 5 V for these temperature values. A substantial fraction of the heat was believed to have been conducted into the packaging material. Thermal characterization tests of chips placed onto insulating Pyrex blocks resulted in temperatures of about 90 and 150 C for power levels of 1.2 and 2.5 W, respectively, thus cutting thermal losses by more than half. One thruster chip was tested using water as a liquid propellant and vaporization was achieved at 7 W electric input power.