Gajanana C. Birur

NASA thermal control technologies for robotic spacecraft

Technology development is inevitably a dynamic process in search of an elusive goal. It is never truly clear whether the need for a particular technology drives its development, or the existence of a new capability initiates new applications. Technology development for the thermal control of spacecraft presents an excellent example of this situation. Nevertheless, it is imperative to have a basic plan to help guide and focus such an effort. Although this plan will be a living document that changes with time to reflect technological developments, perceived needs, perceived opportunities, and the ever-changing funding environment, it is still a very useful tool. This presentation summarizes the current efforts at National Aeronautics and Space Administration (NASA)/Goddard and NASA/JPL to develop new thermal control technology for future robotic NASA missions.

Large, Switchable Electrochromism in the Visible Through Far‐Infrared in Conducting Polymer Devices

Advanced materials with large and dynamic variation in thermal properties, sought for urgent defense and space applications, have heretofore been elusive. Conducting polymers (CPs) have shown some intrinsic variation of mid- to far-infrared (IR) signature in this respect, but the practical utilization of this has remained elusive. We report herein the first significant IR electrochromism in any material, to our knowledge, in the 0.4 through 45 μm region. This is seen in practical CP devices in the form of thin (<0.5 mm), flexible, entirely solid-state, variable area (1 cm2 to 1 m2) flat panels. Typical properties include: very high reflectance variation; switching times <2 s; cyclabilities of 105 cycles; emittance variation from 0.32 to 0.79; solar absorptance variation from 0.39 to 0.79; operating temperatures of –35 to +85 °C; durability against γ-radiation to 7.6 Mrad, vacuum to 10–6 torr, and simulated solar wind (e.g., 6.5 × 1016 e/cm2 @ 10 keV).

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.

Micro/nano spacecraft thermal control using a MEMS-based pumped liquid cooling system

The thermal control of future micro/nano spacecraft will be challenging due to power densities which are expected to exceed 25 W/cm2. Advanced thermal control concepts and technologies are essential to keep their payload within allowable temperature limits and also to provide accurate temperature control required by the science instruments and engineering equipment on board. To this end, a MEMS-based pumped liquid cooling system is being investigated at the Jet Propulsion Laboratory (JPL). The mechanically pumped cooling system consists of a working fluid circulated through microchannels by a micropump. Microchannel heat exchangers have been designed and fabricated in silicon at JPL and currently are being tested for hydraulic and thermal performance in simulated microspacecraft heat loads using deionized water as the working fluid. The microchannels are 50 microns deep with widths ranging from 50 to 100 microns. The hydraulic and thermal test data was used for numerical model validation. Optimization studies are being conducted using these numerical models on various microchannel configurations, working fluids, and micropump technologies. This paper presents background on the need for pumped liquid cooling systems for future micro/nano spacecraft and results from this ongoing numerical and experimental investigation.

Mars Pathfinder Active Heat Rejection System: Successful Flight Demonstration of a Mechanically Pumped Cooling Loop

One of the new technologies successfully demonstrated on the recent Mars Pathfinder mission was the active Heat Rejection System (HRS). This system consisted of a mechanicaily pumped cooling loop, which actively controlled the temperatures of the various parts of the spacecraft. A single phase Refrigerant 11 liquid was mechanically circulated through the lander and cruise electronics box heat exchangers. This liquid transferred the excess heat to an external radiator on the cruise stage. This is the first time in unmanned spacecraft history that an active heat rejection system of this type has been used on a long duration spacecraft mission. Pathfinder was launched in December 1996 and landed on the Martian surface on July 4, 1997. The system functioned flawlessly during the entire seven months of flight from Earth to Mars. A life test set up of the cooling loop was used to verify the life of the system. The life test system was run for over 14, 000 hours before complete examination of the components used in the life test was made. Some of the components used in the system were tested in the life test set up. The results from the life test loop indicate no major issues that would hinder the pumped loop operation for many more years.

Development of a Thermal Control Architecture for the Mars Exploration Rovers

In May and June of 2003, the National Aeronautics and Space Administration (NASA) will launch two roving science vehicles on their way to Mars. They will land on Mars in January and February of 2004 and carry out 90‐Sol missions. This paper addresses the thermal design architecture of the Mars Exploration Rover (MER) developed for Mars surface operations. The surface atmosphere temperature on Mars can vary from 0°C in the heat of the day to −100°C in the early morning, prior to sunrise. Heater usage at night must be minimized in order to conserve battery energy. The desire to minimize nighttime heater energy led to a design in which all temperature sensitive electronics and the battery were placed inside a well‐insulated (carbon‐opacified aerogel lined) Warm Electronics Box (WEB). In addition, radioisotope heater units (RHU’s, non‐electric heat sources) were mounted on the battery and electronics inside the WEB. During the Martian day, the electronics inside the WEB dissipate a large amount of energy (ove...

An Experimental Study of the Operating Temperature in a Loop Heat Pipe with Two Evaporators and Two Condensers

This paper presents a comprehensive experimental study of the loop operating temperature in a loop heat pipe (LHP) which has two parallel evaporators and two parallel condensers. In a single evaporator LHP, it is well known that the loop operating temperature is a function of the heat load, the sink temperature and the ambient temperature. The objective of the present study emphasizes on the stability of the loop operating temperature and parameters that affects the loop operation. Tests results show that the loop operating temperature is a function of the total system heat load, sink temperature, ambient temperature, and beat load distribution between the two evaporators. Under most conditions, only one compensation chamber (CC) contains two-phase fluid and controls the loop operating temperature, and the other CC is completely filled with liquid. Moreover, as the test condition changes, control of the loop operating temperature often shifted from one CC to another. In spite of complex interactions between various components, the test loop has demonstrated very robust operation even during fast transients.

Testing of a Loop Heat Pipe with Two Evaporators and Two Condensers

Most existing Loop Heat Pipes (LHPs) consist of one single evaporator and one single condenser. LHPs with multiple evaporators will be very desirable for cooling multiple heat sources or a heat source with large thermal footprints. Extending the LHP technology to include multiple evaporators and multiple condensers faces some challenges, including the interaction between individual compensation chambers, operating temperature stability, and adaptability to rapid power and sink temperature transients. This paper describe extensive testing of an LHP with two evaporators and two condensers. Tests performed include start-up, power cycle, sink temperature cycle, reservoir temperature cycle, and capillary limit. Test results showed that the loop could operate successfully under various heat load and sink conditions. The loop operating temperature is a function of the total heat load, the heat load distribution between the two evaporators, and temperatures of the two condenser sinks. Under most conditions, only one reservoir contained two-phase fluid and the other reservoir was completely liquid filled. Moreover, control of the loop operating temperature could shift from one reservoir to the other as the test condition changed.

Active Control of the Operating Temperature in a Loop Heat Pipe with Two Evaporators and Two Condensers

The operating temperature of a loop heat pipe (LHP) with multiple evaporators is a function of the total heat load, heat load distribution among evaporators, condenser temperature and ambient temperature. Because of the many variables involved, the operating temperature also showed more hystereses than an LHP with a single evaporator. Tight temperature control can be achieved by controlling its compensation chamber (CC) temperatures at the desired set point. This paper describes a test program on active control of the operating temperature in an LHP with two evaporators and two condensers. Temperature control was achieved by heating one or both CCs. Tests performed included start-up, power cycle, sink temperature cycle, CC temperature cycle, and capillary limit. Test results show that, regardless one or two CCs were heated to the set point temperature, one of CCs was always flooded with liquid. The loop could operate successfully at the desired set point temperature under most conditions, including some fast transients. At low heat loads, however, the CC temperature could suddenly increase above the set point temperature, possibly due to a sudden change of the vapor content inside the evaporator core.

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.