Thermal canister experiment on OSS-1
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Engineering topics
Publications and source records attributed to Ollendorf, S..
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The purpose of this paper is to present a modeling technique that has proven successful in simulating pumped, two-phase cooling systems. The technique uses the standard SINDA thermal-analysis program and thereby extends the capabilities of SINDA to complex, active spacecraft thermal-control systems. This paper provides sufficient detail that a current SINDA user will be able to apply the technique by reference to this paper alone.
The development of a capillary pump loop (CPL) heat pipe, including computer modeling and breadboard testing, is presented. The computer model is a SINDA-type thermal analyzer, combined with a pressure analyzer, which predicts the transients of the CPL heat pipe during operation. The breadboard is an aluminum/ammonia transport system which contains multiple parallel evaporator and condenser zones within a single loop. Test results have demonstrated the practicality and reliability of such a design, including heat load sharing among evaporators, liquid inventory/temperature control feature, and priming under load. Transport capability for this system is 65 KW-M with individual evaporator pumps managing up to 1.7 KW at a heat flux of 15 W/sq cm. The prediction of the computer model for heat transport capabilities is in good agreement with experimental results.
New design isolates components from vibrations. Heat-pipe thermal switch controls temperature of heat source. Ball-and-socket guide rods and bellows allow relative motion of source and its heat sink and protect source from vibrations. Designed for cooling vibration-sensitive electronic components.
The principal objectives of the experiment are to determine zero-g start-up performance for conventional and diode low temperature heat pipes, to evaluate heat pipe performance in zero-g for an extended period of time, to determine zero-g transport capability of each heat pipe, and to determine diode operation, including forward conductance, turndown ratio, and transient behavior. Two heat pipes, a fixed conductance transporter heat pipe and a thermal diode heat pipe, are coupled with a radiant cooler system. Both pipes are charged with ethane. Also integrated with the radiator is a phase change material (PCM) canister which provides temperature stability during transport tests. N-heptane, which has a melting/freezing point of 182 K, is used as the PCM. The high heat capacity (28 W-hr of latent heat) provided by the canister permits high power heat pipe testing at constant temperature.
The thermal energy management processes experiment (TEMP) will demonstrate that through the use of two-phase flow technology, thermal systems can be significantly enhanced by increasing heat transport capabilities at reduced power consumption while operating within narrow temperature limits. It has been noted that such phenomena as excess fluid puddling, priming, stratification, and surface tension effects all tend to mask the performance of two-phase flow systems in a 1-g field. The flight experiment approach would be to attack the experiment to an appropriate mounting surface with a 15 to 20 meter effective length and provide a heat input and output station in the form of heaters and a radiator. Using environmental data, the size, location, and orientation of the experiment can be optimized. The approach would be to provide a self-contained panel and mount it to the STEP through a frame. A small electronics package would be developed to interface with the STEP avionics for command and data handling. During the flight, heaters on the evaporator will be exercised to determine performance. Flight data will be evaluated against the ground tests to determine any anomalous behavior.
A pumped, two-phase heat-transport system is being developed for possible use for temperature control of scientific instruments on future NASA missions. As compared to a single-phase system, this two-phase system can maintain tighter temperature control with less pumping power. A laboratory model of the system has been built and tested. The measured heat transfer coefficients were approximately the same as in heat pipes, 220 Btu/hr-sq ft-F, as compared to 25 Btu/hr-sq ft-F for single-phase liquid flow. Heat shearing between experiments has been demonstrated wherein vapor generated in the cold plate of an active experiment was condensed in a cold, unheated experiment. System stability has been observed. However, additional development is needed. The use of non-azeotropic mixtures of coolants appears especially promising as a simple way to determine exit quality and thus control the flow rates to prevent dryout.
Because the OSS-1 pallet contained a variety of instruments with irregular surface geometry and properties which limited predictability, the total absorbed flux on thermal canister radiators was measured to determine heat rejection capability. The instrumentation and sensor cup design and locations for the thermal canister experiment are illustrated. Graphs show flux sensor history in hot and coal orbits. Kapton erosion is also considered. Results show that the flux levels measured in all STS attitudes are higher than predictions. In cold and moderate attitudes, flight results are a factor of two to three higher than predicts. In hot attitude, much better agreement occurred. It is concluded that in cold or moderate attitudes other sources may be contributing to added inputs (albedo, Earth shine, shuttle background). In hot attitude, smaller differences could be attributed to coatings assumptions or calculation uncertainty.
The purpose of the Thermal Canister Experiment carried by the Space Shuttle STS-3 flight was to determine the ability of a device using controllable heat pipes to maintain simulated instruments at selected temperature levels, in zero gravity and under varying internal and external thermal loads. A total of 11 data points were achieved during the flight, including the control of canister walls, of instrument simulators and of temperatures in two different zones, as well as passive thermal control. The set point variation ranged from 5 to 23 C, with power changes of 165-325 watts. Better fluid distribution in the heat pipes during zero-g operation showed improved performance over ground tests, and a temperature stability of + or - 2 C was demonstrated between Orbiter maneuvers in which the cargo bay was shadowed from the sun and those in which full solar exposure of the cargo bay existed.
On the Space Shuttle's third flight, scientific instruments will study the electromagnetic environment with charging and electron beams. Beam plasma discharge will be studied. The plasma diagnostics package contains electromagnetic and particle sensors to study the ionosphere. An attempt will be made to establish a more accurate base of solar UV irradiance measurements with an absolute error of 10 percent or less over the wavelength region 120-400 nm. The solar flare X-ray polarimeter will observe flare X-rays emitted between 5 and 30 keV and measure their polarization as a function of time and photon energy. A photopolarimeter will help study zodiacal light, and interplanetary dust will be sampled by a section of thick aluminum foil. Plant seedlings will be grown to research the effect of near-zero gravity on lignification. A thermal canister experiment will help determine whether instruments can be maintained at a fixed temperature under varying thermal loads.
Current thermal distribution systems on large spacecraft, such as the Space Shuttle and Spacelab, use pumped fluid loops that circulate the coolant between a series of user stations and a single rejection point, involving complex plumbing and controls with a significant power penalty and limited reliability. In order to provide heat transport at near-isothermal conditions in future large spacecraft, two-phase flow systems will be implemented by taking advantage of the heat of vaporization and condensation of common working fluids at minimal expenditure of power and temperature variation. Such systems are considered for the cases of the thermal requirements of nearly 100 potential astrophysics and astronomy instruments. Data on temperature requirements, power dissipations, environmental fluxes, heat addition or rejection, and general description, are used to form conceptual designs for the thermal utility.
Twelve engineering type tests were performed on several subsystems and experiment(s) of the OAO 3 spacecraft near its end of mission. The systems tested include: Princeton experiment package (PEP), fine error system guidance, inertial reference unit, star trackers, heat pipes, thermal control coatings, command and data handling, solar array; batteries, and onboard processor/power boost regulator. Generally, the systems performed well for the 8 1/2 years life of OAO 3, although some degradation was noted in the sensitivity of PEP and in the absorptivity of the skin coatings. Battery life was prolonged during the life of the mission in large part by carefully monitoring the charge-discharge cycle with careful attention not to overcharge.
A thermal utility is a high-capacity heat transport system that serves as a common, temperature-controlled heat sink or source to more than one payload. The feasibility of using a thermal utility for space-platform-mounted instruments which have a range of temperature level and heat rejection requirements is examined and significant design parameters are identified. A baseline, pumped, two-phase heat transport system has been defined for NASA's proposed Space Platform, and its capability to satisfy the thermal requirements of a range of multidisciplinary instruments has been assessed.
The rationale for the implementation of an Instrument Thermal Data Base System (ITDBS) is discussed and the potential application of a data base management system in support of future space missions, the design of scientific instruments needed, and the potential payload groupings is described. Two basic data files are suggested, the first containing a detailed narrative information list pertaining to design configurations and optimum performance of each instrument, and the second consisting of a description of the parameters pertinent to the instruments' thermal control and design in the form of a summary record of coded information, and serving as a recall record. The applicability of a data request sheet for preliminary planning is described and is concluded that the proposed system may additionally prove to be a method of inventory control.
The thermal canister represents a new approach to instrument thermal control for Shuttle experiments which require tight temperature control. The canister substitutes a known, benign thermal environment for the variable and uncertain environment of space, the space environment being neutralized by a system of feedback controlled variable conductance heat pipes. A proto-flight unit has been fabricated and this paper describes the acceptance thermal vacuum test results of the thermal canister experiment which will fly on an early Space Shuttle flight.
A system utilizing a pumped, two-phase single component working fluid for heat exchange and transport services necessary to meet the temperature control requirements of typical orbiting instrument payloads on space platforms is described. The design characteristics of the system is presented, together with a presentation of a laboratory apparatus for demonstration of proof of concept. Results indicate that the pumped two-phase design concept can meet a wide range of thermal performance requirements with the only penalty being the requirement for a small liquid pump.
An apparatus for maintaining a heat dissipating load at a substantially constant temperature, and more particularly, to such an apparatus where in variable conductance heat pipes control the radiating area of a radiator is described.
This paper addresses the potential for enhanced solar system performance through sophisticated control of the collector loop flow rate. Computer simulations utilizing the TRNSYS solar energy program were performed to study the relative effect on system performance of eight specific control algorithms. Six of these control algorithms are of the proportional type: two are concave exponentials, two are simple linear functions, and two are convex exponentials. These six functions are typical of what might be expected from future, more advanced, controllers. The other two algorithms are of the on/off type and are thus typical of existing control devices. Results of extensive computer simulations utilizing actual weather data indicate that proportional control does not significantly improve system performance. However, it is shown that thermal stratification in the liquid storage tank may significantly improve performance.