AMS TIM January, 2007 - Houston 1

AMS 02 –Thermal Control

System Design

AMS Thermal Control System (TCS): A Status Report

Group Leaders: Drj Sun – AIDC, M. Molina –

CGS, J. Burger – MIT, J.-R. Tsai – NSPO,

L. Cheng – SDU

Presented by M. Molina, T.Luan, DrjSun

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AMS 02 –Thermal Control

System Design

AMS TCS - main componentsZenith Radiator

Tracker Radiator

WAKE Radiator

Tracker Radiator

RAM Radiator

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AMS 02 –Thermal Control

System Design

TCS Mass budget

Target mass for the TCS = 274 Kg

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AMS 02 –Thermal Control

System Design

Gemini structure

(radiator backbone)

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AMS 02 –Thermal Control

System Design

Main radiators• They provide the sink to most of the electronic

units• The wake one provides the sink to the CAB LHP

Zenith Radiator

Tracker Radiator

WAKE Radiator

Tracker Radiator

RAM Radiator

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AMS 02 –Thermal Control

System Design

Radiator cross section

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AMS 02 –Thermal Control

System Design

CAB LHP is to be fixed outside the WAKE radiator

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AMS 02 –Thermal Control

System Design

Integration jig

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AMS 02 –Thermal Control

System Design

Tracker radiators

Zenith Radiator

Tracker Radiator

WAKE Radiator

Tracker Radiator

RAM Radiator

•They provide the sink to the TTCS

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AMS 02 –Thermal Control

System Design

Tracker radiator assembly

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AMS 02 –Thermal Control

System Design

Zenith radiators

• They provide the sink to the Cryocoolers LHP

Zenith Radiator

Tracker Radiator

WAKE Radiator

Tracker Radiator

RAM Radiator

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AMS 02 –Thermal Control

System Design

4 zenith radiator quadrants

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AMS 02 –Thermal Control

System Design

Activities since last TIM (Oct 2006)

• STA structural analysis• Inserts specimen construction• TWG activities

– test review– Thermal analysis

• TCS STA Integration• Work with AIDC

– Integration Jig– Test coupon design

AMS TIM January, 2007 - Houston 14

AMS 02 –Thermal Control

System Design

STA structural analysis

• STA will undergo – Static test with 5 load cases– Modal survey test

• JS provided CGS/SDU the load cases and a new model of the USS to be used

AMS TIM January, 2007 - Houston 16

AMS 02 –Thermal Control

System Design

First vibration mode, Wake radiator

23 Hz

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AMS 02 –Thermal Control

System Design

Max tension force on insertsELEMENT ID LOAD CASE

MAGNITUDE[N]

21720678 102 597.316711 580.621521 137.215958 -28.942692 140.2351545

32239096 105 348.924988 292.973907 144.361237 -122.779312 189.5123379

32239096 102 322.776215 283.009338 128.283264 -87.370445 155.2101494

32239104 105 303.510437 273.447235 -119.608879 55.126308 131.7011533

32239101 105 321.080902 268.477295 -157.126923 79.523697 176.1047652

Main radiator

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AMS 02 –Thermal Control

System Design

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AMS 02 –Thermal Control

System Design

TENSION TEST

1792 N

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AMS 02 –Thermal Control

System Design

ELEMENT ID LOAD CASEMAGNITUDE

[N]

18603286 102 1813.010742 52.8596 852.435913 1599.239502 1812.240042

17987995 102 1474.954346 -70.584541 698.876343 -1296.950317 1473.264493

18602973 102 1392.331055 6.274923 64.934883 1390.80188 1392.316921

6651201 102 1362.02356 -1.169043 979.706299 -946.193665 1362.023085

18603286 101 1269.333618 41.167435 360.135895 1216.476563 1268.665871

Max shear force on inserts

Main radiator

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AMS 02 –Thermal Control

System Design

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AMS 02 –Thermal Control

System Design

SHEAR TEST

5375 N

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AMS 02 –Thermal Control

System Design

ELEMENT ID LOAD CASEMAGNITUDE

[N]

627914 110 40.321503 8.971233 33.61179 20.385983 39.31082205

627916 110 16.732525 7.8978 -12.77207 -7.380809 14.75134277

629770 105 26.405626 6.407794 -20.211269 15.738546 25.61634683

627915 110 32.558479 5.928661 30.758074 8.879548 32.01414514

629770 101 25.713232 5.925188 -21.430447 12.915047 25.02124093

Max tension force on inserts

Tracker radiator

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AMS 02 –Thermal Control

System Design

ELEMENT ID LOAD CASEMAGNITUDE

[N]AXIAL_COMP

[N]

628022 110 182.667206 -49.305359 155.512589 -82.171318 175.8871537

628022 105 160.07933 -41.509838 139.396027 -66.866089 154.6037716

627914 101 144.563919 -39.510414 -120.965324 -68.59333 139.0598955

628023 110 100.227081 -22.461021 96.742104 -13.488372 97.67789343

628022 102 100.472633 -28.368942 87.86232 -39.625317 96.38440239

Max shear force on inserts

Tracker radiator

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AMS 02 –Thermal Control

System Design

60 samples sent to NASA for testing

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AMS 02 –Thermal Control

System Design

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AMS 02 –Thermal Control

System Design

Drum peel test Rupture Test

Load [Nmm/mm]

34.21

154.61

36.27

27.33

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AMS 02 –Thermal Control

System Design

Flat wise test

Rupture Test Load [Kg]

64.61

68.43

54.01

156

65.51

54.21

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AMS 02 –Thermal Control

System Design

Lap shear

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AMS 02 –Thermal Control

System Design

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AMS 02 –Thermal Control

System Design

Flight loads analysis

• When subjected to FM loads inserts will show– Positive margin to tension– Positive margin to shear ONLY with an

improved configuration (heavier, i.e. with more glue)

• No problem for the STA, because loads are lower• Need of a stronger glue = HOT BONDING

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AMS 02 –Thermal Control

System Design

RADIATOR INSERT SPECIMEN TENSION TESTS (Summary Table) 

CGS Sample

Identification Number

PLYFORM Sample

Identification Number

Ultimate Test Load

[N]

Analysis Limit Load

[N]

MoS[SF 1.4]

Remarks

1 T 06023 ISO1

1841.55  

600

 600

 

1.19

2 T 06023 ISO2

1792.78 1.13

3 T 06031 ISO1

2217.25 1.63

4 T 06031 ISO2

2356.70 1.8

5 T 06031 ISO3

2410.88 1.87

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AMS 02 –Thermal Control

System Design

 RADIATOR INSERT SPECIMEN SHEAR TESTS (Summary Table)

 

CGS Sample

Identification

Number

PLYFORM Sample

Identification Number

Ultimate Test Load

[N]

Analysis Limit Load

[N]

MoS[SF 1.4]

Remarks

1 T 06028 ST01

4301.94 3526 -0.12

2 T 06028 ST02

5375.96 3526 -0.088

3 T 06028 ST03

5457.32 3526 -0.1

4 T 06028 ST04

7967.05 3526 0.62

5 T 06028 ST05

6887.25 3526 0.39

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AMS 02 –Thermal Control

System Design

Conclusion on inserts testing

• A first set of samples has been tested in Italy– OK for the STA– OK for the FM with an improved (heavier)

configuration• SOLUTION = Hot bonding process

• Cold bonded samples have been sent to NASA for testing and SWG approval

• Hot bonded samples will be built and tested by AIDC

AMS TIM January, 2007 - Houston 35

AMS 02 –Thermal Control

System Design

Test coupon

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AMS 02 –Thermal Control

System Design

Aim of test coupon

• Establish and test CGS-AIDC data exchange

• Set-up Rohacell sandwich panel technology– Inserts precise positioning– Heat pipes bending and gluing– Skin joining

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AMS 02 –Thermal Control

System Design

AMS TIM January, 2007 - Houston 38

AMS 02 –Thermal Control

System Design

Inserts

• Built by AIDC

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AMS 02 –Thermal Control

System Design

Skins joint

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AMS 02 –Thermal Control

System Design

Heat pipe

• Filled with Ammonia, straight and bent

• Profiles only, to be machined at AIDC

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AMS 02 –Thermal Control

System Design

Test spec. for the test coupon• Document „AMS-PR-CGS-002“ has

been issued and delivered to AIDC– DISTRUCTIVE TESTS ON SPECIMENS– NON DISTRUCTIVE TESTS ON THE TWO

TEST COUPONS• Mechanical tests• Thermal tests

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AMS 02 –Thermal Control

System Design

Distructive test (1)

• The specimens shall be manufactured in according to the following requirements:– Same item materials, coming from the same

production lot.– Same surface treatment (according to the Test

Coupon Engineering Drawing).– Same item manufacturing procedures.– Same vacuum bag.– Same curing cycle.

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AMS 02 –Thermal Control

System Design

Distructive test (2) Reference values

Test Type Test Requirement

Specimens Quantity

INSERT TENSILE ≥ 2350 [N] 15 (TBC)

INSERT SHEAR ≥ 7500 [N] 15 (TBC)

DRUM PEEL ≥ 5.5 [Nxmm/mm]

5

FLAT-WISE ≥ 610 [N] 5

LAP SHEAR ≥ 37 [N/mm2] 5

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AMS 02 –Thermal Control

System Design

Non-distructive tests

• Visual inspection

• CMM measurement– Inserts position

• Geometrical Tolerances

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AMS 02 –Thermal Control

System Design

Thermal test at NSPO

• Scope– Determine suitable heat conductance

between radiator skin and heat pipes

• Details are to be defined by NSPO

• Concept: IR Lamp one side, IR camera on the opposite

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AMS 02 –Thermal Control

System Design

FM schedule

• Integration jig and crate linksJul 2007

• All radiators, brackets and rodsJan 2008 (TBC with

AIDC)

• Zenith radiator delivery Jun 2008

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AMS 02 –Thermal Control

System Design

FM schedule

• MLI Mar 2008

• CAB LHP Apr 2008