Multi-Evaporator Hybrid Two-Phase Loop Cooling System for ...

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1 Multi-Evaporator Hybrid Two-Phase Loop Cooling System for Small Satellites 21st Annual AIAA/USUConf. on Small Satellites

Multi-Evaporator Hybrid Two-Phase Loop Cooling System for Small Satellites

David Bugby

ATK SpaceBeltsville, MD

21st Annual AIAA/USU Conference on Small Satellites



PREVIEW QUESTIONS

Ground Testing of ME-HLHPBased Cooling Systems for ...

- Smallsats (NASA ST-8)- Five Additional Applications

> Laser Diode/Crystal> Compact Laser> Large Spacecraft> Electronics > Instruments

Multiple-Evaporator Hybrid LoopHeat Pipe (ME-HLHP)

Multiple-Evaporator CPLs... CAPL-3 Flew in 2001, None flying

Multiple-Evaporator LHPs... None have flown

Single-Evaporator CPLs... A Few Flying (e.g., HST/NCS)

Single-Evaporator LHPs... 100+ Flying on Commsats

Where do things stand today with respect totwo-phase loop cooling of spacecraft?

Is there an alternative to a CPL or an LHP?



ACKNOWLEDGEMENT

Matt BeresPete Cologer

Jessica KesterDmitry Khrustalev

Steve KreinEd Kroliczek

Chuck StoufferDave WolfKim WrennJames Yun

Key Contributors from ATK Space



INTRODUCTIONBACKGROUNDRATIONALECONCEPTDESIGNTESTINGAPPLICATIONSCONCLUSION

OUTLINE



• OBJECTIVE: Develop two-phase loop thermal management system (TMS) toreplace the traditional "cold-biasing plus heater power" approach, to enable ...

- Flexibility in component placement- Reduced mass / heater power / volume- Improved power resource efficiency- Scalability from 150 kg, 200 W nominal size

• PAPER / BRIEFING: Describes a two-phase loop based cooling system for smallsats developed during a 6-month ST-8 study and 5 subsequent ground tested cooling systems for lasers, spacecraft, electronics, and instruments.

INTRODUCTION

MLI Covers Non-Radiator Surfaces

High Power ComponentsMounted On/Near Exterior

(may need heater power when OFF)

Earth-Viewing ComponentsNeed Heater Power When OFF

Internal Components Coupled Conductivelyand/or Radiatively to the Walls

Radiator 2Sized/Coatedfor Hot Case

IncludingHot Radiator 1

Space-Viewing ComponentsNeed Heater Power When OFF

Radiator 1Sized/Coatedfor Hot Case

IncludingHot Radiator 2

CBHX

All Components Except External Viewing OnesCentrally Located Coupled to ME-HLHP Thermal Bus

Total MLI Coverage Except ProtrudingComponents, Lines, Standoffs

Radiator 1Sized/Coated forHot Case ... CanIgnore Impact ofHot Radiator 2

Subcooler 2

Radiator 2Sized/Coated forHot Case ... CanIgnore Impact ofHot Radiator 1

DHPto CBHX

Earth-Viewing ComponentsKept Warm When OFF by HLS

Space-Viewing ComponentsKept Warm When OFF by HLS

Subcooler 1 DHPto CBHX

Two-Phase Loop TMSCold-Biasing Plus Heater Power TMS

... NASA ST-8 requirements(for future missions especially those with

extended eclipses and limited power)



BACKGROUND

• Requirements (ST-8)enable component placement flexibilityminimize power/mass/volumeimprove power resource efficiencyscalable from 150 kg, 200 W nominal size

• Needed Functionalitiesmulti-evaporator busheat load sharing (HLS)miniaturized componentsthermal diode actionmultiple condensersset-point controllabilityhigh conductance

• Two-Phase Loop Architecturescapillary pumped loop (CPL)loop heat pipe (LHP)hybrid loop heat pipe (HLHP)

HLHP

CPL

LHP

Shunt

HEAT OUT

Set-Point Heater

Two-PhaseReservoir

Liqu

id

HEAT IN

Evaporator

Condenser

Vapo

r

HEAT OUT

Liqu

id

HEAT IN

Evaporator

Condenser

Vapo

rSecondaryWick

Two-PhaseReservoir

SweepageHeater

Shunt

HEAT OUT

SweepageEvaporator

Swee

page

HEAT IN

Evaporator

Condenser

Vapo

r

Set-PointHeater

Liqu

id

Two-PhaseReservoir- CPL advantages

- LHP advantages

- controllability- expandability

- instant-on- metal wicks



RATIONALE

FEATURE WHAT IT DOES WHY IT'S GOOD

Multi-Evaporator BusDecouples structure and thermal

design process so component placement is more flexible

Simplifies Design,Reduces Mass

Heat Load Sharing Keeps environmentally exposed instruments warm when not "ON"

Reduces Heater Power,Improves Efficiency

Miniaturized Components

Reduces weight ExpandsPackaging Options

Thermal Diode Action Isolates payload/components from extreme environments

ExpandsMission Options

Multiple Condensers Reduces need to adjustattitude for thermal control

Increased TimeAvailable for Science

Set-Point Controllability

Reduces payload/componenttemperature fluctuations

Minimizes Temperature Cycling, Lengthens Life

High Conductance Enables centralized component mounting configurations

Shorter Electrical Harnessing, Simpler

Structure, Reduced Mass



CONCEPT



DESIGN

Counter-FlowCondenser 2

SweepageSight Glasses

Liquid


EVAP 3(Heat Load Sharing)

Single-PhaseSweepage Vapor

EVAP 1

Cold-BiasedHeat Exchanger(CBHX)

EVAP 2EVAP 4

SecondaryEvaporator

Chiller Lines

Reservoir Shunt

BPR

Subcooler

Subcooler

Reservoir

Two-PhaseSweepage


SweepageSight Glasses

Liquid


EVAP 3(Heat Load Sharing)

Single-PhaseSweepage Vapor

EVAP 1

Cold-BiasedHeat Exchanger(CBHX)

EVAP 2EVAP 4

SecondaryEvaporator

Chiller Lines

Reservoir Shunt

BPR

Subcooler

Subcooler

Reservoir

Two-PhaseSweepage



TESTING

• RESULTS: With ammonia as the working fluid, 21 tests were carried out with the ST-8 ME-HLHP test loop resulting in:

quad-evaporator transport of 8-280 Wsingle-evaporator transport of 2-100 Wpower cycling from 50-200 Wmaximum heat flux of 30 W/cm2

conductance of 5-8 W/K per evaporatorheat load sharing greater than 95%condenser switchingfreeze-tolerant condenserset-point control to +/- 0.25 Krapid start-upsweepage evaporator power of 4Wdiode action/loop isolationTeflon evaporator 233-353 K cycling

• STATUS: All 21 tests successful ... key accomplishment was the development of a 5 μm miniaturized Teflon wick evaporator. Despite success, dual-evaporator LHP with TEC reservoir cold-biasing selected for flight experiment. Concerns ...

the risk of expanding beyond two evaporatorsthe impact of TEC failure on loop temperature controllability

Miniaturized Al BodyTeflon Wick Evaporator

5 cm

Wick 0.63 cm OD5 micron pore size

10

15

20

25

30

35

40

18:30 19:00 19:30 20:00 20:30 21:00 21:30 22:00

Time [hh:mm]

Tem

pera

ture

[C]

0

50

100

150

200

250

300

Hea

t Loa

d [W

]

Reservoir inlet (1) Reservoir (4) 2nd pump (6) BPR outlet (14)FR outlet (43) Liquid line (45) E2 body (52) E3 body (57)liquid sweepage line (68) vapor sweepage line (73) ambient (80) 2nd pump [W]E2 Power [W] E3 power [W] Total Evap Power [W]

-5

0

5

10

15

20

25

30

35

10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00

Time [hh:mm]

Tem

pera

ture

[C]

0

25

50

75

100

125

150

175

200

Hea

t Loa

d [W

]

Reservoir inlet (1) Reservoir (4) 2nd pump (6) BPR outlet (14)FR outlet (43) Liquid line (45) E1 body (48) E2 body (53)E3 body (57) E4 body (62) liquid sweepage line (68) vapor sweepage line (73)ambient (80) Q-meter (82) Q-meter (83) 2nd pump [W]E1 Power [W] E2 Power [W] E3 power [W] Total Evap Power [W]

DIODE ACTION

POWER CYCLING

10

15

20

25

30

35

40

45

6:00 6:30 7:00 7:30 8:00 8:30

Time [hh:mm]

Tem

pera

ture

[C]

0

50

100

150

200

250

300

350

Hea

t Loa

d [W

]

Reservoir inlet (1) Reservoir (4) 2nd pump (6) BPR outlet (14)FR outlet (43) Liquid line (45) E2 body (52) E3 body (57)liquid sweepage line (68) vapor sweepage line (73) ambient (80) 2nd pump [W]E2 Power [W] E3 power [W] Total Evap Power [W]

Reservoir

Primary Evaporators

FR outlet

HEAT LOAD SHARING

-40

-30

-20

-10

0

10

20

30

40

50

7:00 8:00 9:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00

Time [hh:mm]

Tem

pera

ture

[C]

0

25

50

75

100

125

150

175

200

225

Hea

t Loa

d [W

]

Reservoir inlet (1) Reservoir (4) 2nd pump (6) BPR outlet (14)Liquid line (45) E1 body (47) E2 body (52) E3 body (58)E4 body (62) ambient (80) Cond #2 (25) Total Evap Power [W]

SET-POINT CONTROL



APPLICATIONS

Four Parallel Condenser Lines

Flow Regulator (4)

Liquid Header

Condenser Vapor Header

Back Pressure Regulator (BPR) Secondary Evaporator

Reservoir

Evaporator Mounting Plate(Four parallel four-port evaporators)

Liquid Cooled Shield (LCS)

Vapor Line

SecondaryEvaporator

Condenser

LCS

4 Primary Evaporators in Al Heat Sink

VaporHeader

Reservoir

FlowReg.

LiquidHeader

Alum.Shunt

SecondaryEvaporator

Condenser

LCS

4 Primary Evaporators in Al Heat Sink

VaporHeader

Reservoir

FlowReg.

LiquidHeader

Alum.Shunt

COMPACT LASER COOLINGDual-Evap., Two-Sided Heat Input, 50 W/cm2, Mechanical Pump

LASER DIODE/CRYSTAL COOLINGQuad-Evap., Diode 50 W/cm2, Crystal 30 W/cm2 (tested w/ laser)

1

2

3

5

4

6

78

9

10

11

12

13

14151617

1

2

3

5

4

6

78

9

10

11

12

13

14151617

1. Mechanical Pump2. Filter3. Calorimeter4. Evaporator 15. Evaporator 26. Evap 1-2 Liquid Line7. Vapor Line8. Condenser9. Reservoir 10. Sweepage Valve11. Reservoir Chiller/Shunt12. Chiller Path 213. Chiller Path 214. Chiller Path 115. Chiller Path 116. DP Transducer17. Fill Tube



APPLICATIONSRACK ELECTRONICS COOLING

Navy SBIR with TA&T, 3-Evap. ME-HLHP, 300 W, WaterHIGH POWER SPACECRAFT COOLING

6-Evap., 10 kW, Mech./Capillary Pumping ... AFRL DUS&T

132”

V1

V18

V3

V11

V7

V12

Pressure Transducer (4)

V6

V5

Sight Glass (2)

V13 V16 V10

V15V9

V8V14

V4

V2

V17

Flowmeter Mechanical Pump

Filter

Subcooler

Condenser Plate (3)

E1SN010

E2SN006

E3SN012

E4SN011

E5SN008

E6SN007

Vapo

r Lin

e 93

”

Liquid Line 93”

Liquid Line 93”

Sweepage Line 93”

p body)

Vapor Sweepage Line 93”

Sweepage Line 93”

V19

V20

Heater Blocks

Coolant Block

Flat PlateFlat Plate

SERVERIN RACK

WEDGERECEIVER

WEDGE

WEDGE CONDENSER

SCREWTIGHTENEDTO FINALIZECONNECTION

WEDGE MATES TORECEIVER



APPLICATIONSINTERMITTENT-POWER INSTRUMENT COOLING

Dual-Cascaded Loop, 0-400 W 4-Evap. Instrument Side ME-HLHP, 100 W Avg. 1-Evap./2-Condenser Radiator Side HLHP

Instrument-Side Valves to Enable 3 vs. 4 Port ME-HLHPSweepage Plumbing and Enhanced Reservoir Transient Operation(5X Regular Valves, 2X Check Valves [CV], Test Only)

Radiator-SideCondenser #2

(lines on other side)

Instrument-Side Secondary Evaporator

Instrument-Side Primary Evaporator Plate (4X)

Instrument-Side Reservoir

Subcooler for C

ondenser #2

Radiator-SideCondenser #1

(lines on other side)

Radiator-Side Reservoir,Secondary Evaporator,

TEC, and Strap

Instrument-SideTSU/Condenser

Radiator-SidePrimary Evaporator

Instrument-Side Thermal Switch (TSW)

Radiator-Side Flow Regulators (2X)(to maximize condenser utilization)

Radiator-SideLiquid-Cooled Shield (LCS)

Instrument-Side Heat Pipes(to spread heat on TSU bottom)

Subcooler for C

ondenser #1

Instrument-Side Back Pressure Regulator (BPR)

6"

20"

6"

20"

Instrument-Side Valves to Enable Parallel or SeriesME-HLHP Flow Configurations (12 X, Test Only)

CV

CV

Instrument-Side Primary Evaporator (4X)

Patent US 6,889,754

LCS LINE "OUT"

CO

ND

ENSE

R 1

TSU

EVA

P

CO

ND

ENSE

R 2

CONDENSER

HEAT PIPES

EVAP2ND EVAP

TSW

RSVR

RSVR 2ND EVAP

STRAP

TEC STRAPEV

AP

EVA

PEV

AP

INS

TRU

ME

NT

RA

DIA

TOR

2

INSTRUMENT-SIDE

INSTR-RADINTERFACE

LCS

RA

DIA

TOR

1

SOLDERED (LOC. FOR HP)

SWEE

PAG

E LI

NES

VAPOR LINE

LIQHDR

LCS LINE "IN"

LIQUID LINE

LIQUID LINE

VAPOR LINE

SWEEPAGE LINES

SWPHDR

VAPHDR

HTR1 HTR2

HTR3

HTR4

RADIATOR-SIDE

HTR5HTR6

ADDTIONALTECHNOLOGIESDEMONSTRATED

ON THIS PROJECT1. Integral Condenser/TSU

2. DTE-TSW Reservoir Shunt3. Liquid Cooled Shield (LCS)

4. TEC Reservoir Cold-Biasing5. Parallel or Series Plumbing



APPLICATIONS

SUMMARY OF ME-HLHP GROUND TESTING

5

Diode

2

1a 1b 2 3a 3b 4 5a 5b

5002000

Compact



CONCLUSION

OVERALL: This briefing has described the development and testing of a multi-evaporator two-phase loop based cooling system for small satellite thermal control.

TECHNOLOGY BASIS: Multi-evaporator hybrid loop heat pipe (ME-HLHP), a two-phase loop cooling system with CPL and LHP underpinnings, but with key advantages over each.

PRIMARY APPLICATION: Cooling system designed/built/ground-tested as part of the NASA ST-8 Phase A study from Jan-Jun 2004. At that time, it was the first-ever ground test of a miniaturized ME-HLHP cooling system.

ADDITIONAL APPLICATIONS: The design and successful ground testing of five subsequent ME-HLHP based cooling systems -- in the areas of laser, spacecraft, electronics, and instrument cooling -- were also described.

FLIGHT EXPERIMENT: The ME-HLHP architecture has clearly been proven through extensive ground testing for a variety of applications ... to fully validate it for future smallsat missions, an ME-HLHP flight experiment is needed !

NOTE: Paper Was Originally a Backup for Session X, so its file name on the Proceedings CD is SSC07-X-11.pdf

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Multi-Evaporator Hybrid Two-Phase Loop Cooling System for ...

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