GPM Avionics Module Heat Pipes Design and Performance Test Results

16th Conference on Thermophysics Applications in Microgravity 19 March 2012

Laura Ottenstein

NASA/Goddard Space Flight Center Greenbelt, MD 20771

Laura.Ottenstein-1@nasa.gov Phone: 301-286-4141

Mike DeChristopher

Advanced Cooling Technologies, Inc Lancaster, PA 17601

Mike.Dechristopher@1-ACT.com Phone: 717-295-6108

Outline

• Background

• Avionics Module Thermal Design

• Spacecraft Thermal Avionics and Battery (STAB) Test

• Test Profile

• Results

• Conclusions

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BACKGROUND

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Global Precipitation Measurement

• GPM is a satellite constellation to study precipitation formed from a partnership between NASA and the Japanese Aerospace Exploration Agency (JAXA)

• The GPM Core Observatory, being developed and tested at GSFC, serves as a reference standard to unify precipitation measurements from the GPM satellite constellation

• The Core Observatory carries an advanced radar/radiometer system to measure precipitation from space

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GPM Background, cont.

• The scientific data gained from GPM will benefit both NASA and JAXA by: – Advancing our understanding of Earth’s water and energy

cycle

– Improving forecasts of extreme weather events

– Extending our current capabilities in using accurate and timely precipitation information to benefit society

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GPM Core Observatory • The GPM Core Observatory consists of three major components:

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GPM Microwave Imager (GMI)Ball Aerospace Dual Precipitation

Radar (DPR)JAXA

Spacecraft BusGSFC

Ku-Band Precipitation Radar (KuPR), JAXA

Ka-Band Precipitation Radar (KaPR), JAXA

Lower Bus Structure (LBS)GSFC

-Y Solar ArrayGSFC

+Y Solar ArrayGSFC

High Gain Antenna System (HGAS), GSFC

Avionics Module (AM)GSFC

Upper Bus Structure GSFC

PropulsionGSFC

Launch Date: Early 2014

Launch Vehicle: Mitsubishi Heavy Industries H-IIA(provided by JAXA)

AVIONICS MODULE THERMAL DESIGN

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Avionics Module

Electronics Box Number of Boxes

Thermal Control

Power System Electronics (PSE)

1 Two heat pipes transfer heat to radiator

Command and Data Handling (C & DH)

2 Two heat pipes transfer heat to radiator (shared with both boxes and with both MACE boxes)

Mechanism and Attitude Control Electronics (MACE)

2 Two heat pipes transfer heat to radiator (shared with both boxes and with both C&DH boxes)

Propulsion Interface Electronics (PIE)

1 Low heat dissipation, local thermal control (not discussed further)

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GPM Avionics Module Thermal Model

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Avionics Module Thermal Control

• A network of heat pipes are used for cooling the electronics boxes on the Avionics Module

• Two transport pipes cool the MACE and C&DH boxes (two boxes each, both pipes cool all four boxes)

• Two transport pipes cool the PSE • All transport pipes connect to a honeycomb radiator which contains

13 embedded heat pipes • The heat pipes and radiator were supplied by Advanced Cooling

Technologies – The radiator was manufactured by MDA using heat pipes supplied by ACT

• Components were delivered to GSFC in the fall of 2010 • There are survival heaters on the condensers of the PSE heat pipes

and on the radiator over the radiator spreader pipes that connect to the MACE/C&DH transport pipes

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Transport Heat Pipes

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PSE pipe (one shown)

MACE/C&DH U-shaped pipe

MACE/C&DH S-shaped pipe

Photo by ACT

MACE/C&DH Transport Pipes on Installation Fixture

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Avionics Transport Heat Pipes

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Avionics Radiator Showing Embedded Heat Pipe Layout

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Avionics Radiator (looking from back)

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PSE HP +X PSE HP -X

CDH/MACE HP -X

CDH/MACE HP +X

Heat Pipe Interface Heater

1 2 3 4 5 6 7 8 9 10

SPACECRAFT THERMAL AVIONICS AND BATTERY (STAB) TEST

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STAB Test Hardware • Flight-like Avionics Module • No Lower Bus Structure (LBS), simulated temperature/heat flows at the interface using a cold plate • Baseplate simulators for MACE and C&DH Boxes with heaters to simulate power dissipation

– Flight-like interface (NuSil) • Mass simulators for PSE and Batteries with heaters to simulate power dissipation

– Flight-like interface (NuSil for PSE, ChoTherm for batteries) • Flight Avionics radiator and installation

– Flight heaters installed • Flight-spare Avionics heat pipes

– Flight-like interfaces (NuSil at Avionics Module, eGraf at radiator) • Flight Battery Thermal Control System assembly

– Flight heat pipes – Flight heaters, thermostats, temperature sensors installed – Flight radiator with flight thermal hardware installed

• Heaters to simulate flight harness heating and any additional heating from the PIE, ST/SSIRU bracket, or GPS and OMNI towers

• Flight and Non-flight MLI – MLI used to close out Avionics Module and Battery assembly – Preliminary radiator closeout MLI, flight MLI on Avionics radiator backside

• Cryopanel simulating sink for battery and avionics radiators

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STAB Test Concept

• Three thermal balance points: – Hot Beta 0

– Cold Beta 0

– Cold Beta 90 Nominal Operations

• Transient power simulation for batteries and PSE (Beta 0)

• Thermostat and survival heater check-outs

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STAB TEST CONCEPT

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PSE simulator

Battery simulators

MACE simulators

C&DH simulators (not shown) Battery

Radiator

Avionics Radiator

Cryopanel

Coldplate

Test Assembly Being Removed from Chamber

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Avionics Radiator

Battery Radiator

Avionics Radiator Temperature Sensors

CTM-325

CTM-326

CTM-327 CTM-328 TC-101

TC-102 TC-103

TC-104 TC-105

TC-106

CTM-330

CTM-331 CDH/MACE HP +X

TC-110

TC-111

TC-107 TC-108

TC-109

TC-119 CTM-329

TC-112

PSE HP +X PSE HP -X

CTM-332

CDH/MACE HP -X

TC-41 TC-45 TC-58 TC-44 TC-59

TC-56

TC-57

TC-42 TC-43 TC-46 T

TC-47

TC-49

TC-51

TC-99

21

+X +Z

TC = Thermocouple (Type T) CTM = Thermistor

Avionics Transport Heat Pipe Thermocouples

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TC-154 TC-140

TC-142

TC-145

TC-76

TC-108

TC-119 TC-112 TC-113

TC-115

TC-116 TC-114

TC-117 TC-118

TCs 113-118 on the heat pipe body on the opposite side of the flange than shown.

TEST PROFILE

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Tem

pera

ture

Time

0

1

2 3

4

5

6

8

9

10 11

12

13

7

Planned Test Profile

0. Test chamber checkout, pump down, battery thermostat verification

1. Transition to hot balance2. Hot Beta 0 balance 3. Transition to CDH-1 & 2 to full power4. Both CDHs to full power5. Transition to Hot Beta 06. Hot Beta 07. Transient profile:

a. Transient PSE power simulationb. Battery Failure checkout

8. Transition to cold Beta 0 nominal ops, nominal power balance

9. Cold Beta 0 nominal ops, nominal power balance

10. Transition to cold beta 90 balance 11. Cold beta 90 balance

a. Avionics survival Heater checkoutb. Battery Heater Control Algorithm Testing

12. Transition to ambient13. Return to ambient

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Actual Test Profile (requested)

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-150

-100

-50

0

50

100

0

50

100

150

200

250

0:00:00 24:00:00 48:00:00 72:00:00 96:00:00 120:00:00 144:00:00 168:00:00 192:00:00 216:00:00

Tem

pera

ture

(°C)

Pow

er (W

)

Time (HH:MM:SS)

PSE Power BAT 1 Sim Power BAT 2 Sim Power BAT 3 Sim Power

CDH 1 Sim Power CDH 2 Sim Power MACE 1 Sim Power MACE 2 Sim Power

Facility Shroud Temp Cryopanel Fixture Temp Cold Plate Temp

Chamber pump-down and battery thermostat verification

Hot Beta 0 Balance Cold Beta 0 nominal ops

Cold Beta 90 balance, survival heater verification, battery algorithm checkout

Return to Ambient

TEST RESULTS

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Results

• Transport pipes started as soon as power was applied and operated throughout test – Temperature data accuracy was not sufficient to allow

calculation of conductances

• Very limited data is available for straight radiator pipes, but these appear to start immediately and operate throughout the test

• L-pipe radiator spreaders showed delayed start-up, some may not have started at all – This result was expected for these small heat pipes tested

in reflux mode and is consistent with pre-delivery tests

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MACE/C&DH Transport Pipes

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0

50

100

150

200

250

300

-30

-20

-10

0

10

20

30

11/13/11 17:00 11/14/11 11:00 11/15/11 5:00 11/15/11 23:00 11/16/11 17:00 11/17/11 11:00 11/18/11 5:00 11/18/11 23:00 11/19/11 17:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

112 +X MACE/CDH HP Condnsr 113 -X MACE/CDH HP Evap MACE B 114 -X MACE/CDH HP Evap CDH B

115 +X MACE/CDH HP Evap MACE A 116 +X MACE/CDH HP Evap CDH A 119 -X MACE/CDH HP Condensr

142 -X CDH/MACE H/P bend 145 +X CDH/MACE H/P bend FLX7-5 CDH1 Watts

FLX7-6 CDH2 Watts FLX7-7 MACE1 Watts FLX7-8 MACE2 Watts

Avionics A Surv Power Avionics B Surv Power

Cryopanelat -85 °C Cryopanelat -128 °CCryopanelat -100 °C

Heat Pipes operate essentially isothermally throughout test

MACE/C&DH Transport Pipes Start-Up

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0

40

80

120

160

200

240

280

320

-10

-8

-6

-4

-2

0

2

4

6

11/13/11 19:00 11/13/11 19:30 11/13/11 20:00 11/13/11 20:30 11/13/11 21:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

112 +X MACE/CDH HP Condnsr 113 -X MACE/CDH HP Evap MACE B 114 -X MACE/CDH HP Evap CDH B

115 +X MACE/CDH HP Evap MACE A 116 +X MACE/CDH HP Evap CDH A 119 -X MACE/CDH HP Condensr

142 -X CDH/MACE H/P bend 145 +X CDH/MACE H/P bend FLX7-5 CDH1 Watts

FLX7-6 CDH2 Watts FLX7-7 MACE1 Watts FLX7-8 MACE2 Watts

Avionics A Surv Power Avionics B Surv Power

PSE Transport Pipes

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0

50

100

150

200

250

300

350

400

450

-15

-10

-5

0

5

10

15

20

25

30

11/13/11 17:00 11/14/11 11:00 11/15/11 5:00 11/15/11 23:00 11/16/11 17:00 11/17/11 11:00 11/18/11 5:00 11/18/11 23:00 11/19/11 17:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

76 PSE +X HP condenser 108 PSE -X HP condenser 117 +X PSE HP Evap 118 -X PSE HP Evap

140 +X PSE H/P adia 154 -X PSE H/P adia FLX7-1 PSE Watts FLX9-3 PSE HP Heater A

FLX9-4 PSE HP Heater B Total MACE/CDH/AV Power

Cryopanelat -85 °C Cryopanelat -128 °CCryopanelat -100 °C

Heat Pipes operate essentially isothermally throughout test

PSE Transport Pipes Start-Up

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0

50

100

150

200

250

300

350

400

-5

-4

-3

-2

-1

0

1

2

3

4

5

11/13/11 19:00 11/13/11 19:30 11/13/11 20:00 11/13/11 20:30 11/13/11 21:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

76 PSE +X HP condenser 108 PSE -X HP condenser 117 +X PSE HP Evap 118 -X PSE HP Evap

140 +X PSE H/P adia 154 -X PSE H/P adia FLX7-1 PSE Watts FLX9-3 PSE HP Heater A

FLX9-4 PSE HP Heater B Total MACE/CDH/AV Power

Heat Pipes start as soon as power is applied

L-Shaped Spreader Pipes 1-5

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0

50

100

150

200

250

300

350

400

450

-15

-10

-5

0

5

10

15

20

25

30

11/13/11 17:00 11/14/11 11:00 11/15/11 5:00 11/15/11 23:00 11/16/11 17:00 11/17/11 11:00 11/18/11 5:00 11/18/11 23:00 11/19/11 17:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

56 AV Rad L pipe 1 Evap 325 Av Rad L Pipe 1 Cond 101 Av Rad L pipe 2 Evap 41 AV Rad L-pipe 2 Cond

42 AV Rad L-pipe 3 Evap 102 Av Rad L pipe 3 Cond 327 Av Rad L Pipe 4 Evap 58 AV Rad L pipe 4 Cond

43 AV Rad L-pipe 5 Evap 103 Av Rad L pipe 5 Cond Total PSE Power Total MACE/CDH/AV Power

Cryopanelat -128 °CCryopanelat -100 °CCryopanelat -85 °C

Due to the tight network of pipes, it is difficult to determine which are operating and which may not be.

L-Shaped Spreader Pipes 6-10

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0

50

100

150

200

250

300

350

400

450

-15

-10

-5

0

5

10

15

20

25

30

11/13/11 17:00 11/14/11 11:00 11/15/11 5:00 11/15/11 23:00 11/16/11 17:00 11/17/11 11:00 11/18/11 5:00 11/18/11 23:00 11/19/11 17:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

104 Av Rad L pipe 6 Evap 44 AV Rad L-pipe 6 Cond 57 AV Rad L pipe 7 Evap 326 Av Rad L Pipe 7 Cond

105 Av Rad L pipe 8 Evap 45 AV Rad L-pipe 8 Cond 46 AV Rad L-pipe 9 Evap 106 Av Rad L pipe 9 Cond

328 Av Rad L Pipe 10 Evap 59 AV Rad L pipe 10 Cond Total PSE Power Total MACE/CDH/AV Power

Cryopanelat -128 °CCryopanelat -100 °CCryopanelat -85 °C

L-Shaped Spreader Pipes 1-5 Start-Up

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0

50

100

150

200

250

300

-10

-5

0

5

10

15

20

11/13/11 19:00 11/13/11 21:00 11/13/11 23:00 11/14/11 1:00 11/14/11 3:00 11/14/11 5:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

56 AV Rad L pipe 1 Evap 325 Av Rad L Pipe 1 Cond 101 Av Rad L pipe 2 Evap 41 AV Rad L-pipe 2 Cond

42 AV Rad L-pipe 3 Evap 102 Av Rad L pipe 3 Cond 327 Av Rad L Pipe 4 Evap 58 AV Rad L pipe 4 Cond

43 AV Rad L-pipe 5 Evap 103 Av Rad L pipe 5 Cond Total PSE Power Total MACE/CDH/AV Power

Pipe start-ups are staggered over a number of hours. Some temperature changes may be due to neighbor pipes starting.

L-Shaped Spreader Pipes 6-10 Start-Up

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0

50

100

150

200

250

300

-10

-5

0

5

10

15

20

11/13/11 19:00 11/13/11 21:00 11/13/11 23:00 11/14/11 1:00 11/14/11 3:00 11/14/11 5:00

Pow

er (W

)

Tem

pera

ture

(°C)

Date Time

104 Av Rad L pipe 6 Evap 44 AV Rad L-pipe 6 Cond 57 AV Rad L pipe 7 Evap 326 Av Rad L Pipe 7 Cond

105 Av Rad L pipe 8 Evap 45 AV Rad L-pipe 8 Cond 46 AV Rad L-pipe 9 Evap 106 Av Rad L pipe 9 Cond

328 Av Rad L Pipe 10 Evap 59 AV Rad L pipe 10 Cond Total PSE Power Total MACE/CDH/AV Power

Start-up of pipes 7 and 8? These two pipes are not directly connected to transport pipes.

L-Shaped Spreader Pipes Start-Up Delta Ts

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0

20

40

60

80

100

120

140

160

180

200

-2

-1

0

1

2

3

4

5

6

7

8

11/13/11 19:00 11/13/11 22:00 11/14/11 1:00 11/14/11 4:00 11/14/11 7:00 11/14/11 10:00

Pow

er (W

)

Evap

orat

or T

empe

ratu

re -

Cond

ense

r Te

mpe

ratu

re (°

C)

Date Time

Pipe 1 Delta T Pipe 2 Delta T Pipe 3 Delta T Pipe 4 Delta T Pipe 5 Delta T Pipe 6 Delta T

Pipe 7 Delta T Pipe 8 Delta T Pipe 9 Delta T Pipe 10 Delta T Total PSE Power

Thermistor Data Drop-Out

Start-up of one or more pipes.

Unclear what happened here. (No changes to test conditions)

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0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

20.0

22.0

24.0

26.0

28.0

30.0

32.0

34.0

36.0

38.0

40.0

0.0 500.0 1000.0 1500.0 2000.0 2500.0 3000.0 3500.0 4000.0 4500.0 5000.0

Pow

er (W

)

Tem

pera

ture

(°C)

Time (Sec)

Reflux Start-Up Test, L-Pipe S/N 009 (Radiator Pipe 5), 22 July 2011 Stand-Alone Test, pre-delivery

E1 E2 E3 E4 E5 A1 A2 C1 C2 C3 C4 C5 Ambient Power

Start-Up

Typical start-up of short evaporator heat pipe tested in reflux configuration (with fully flooded evaporator).

Conclusions • Horizontal pipes (all transport pipes, straight spreaders in radiator)

operated as expected – Started as soon as power was applied – Operated nearly isothermally throughout test

• Small heat pipes (operating in reflux mode) did not start immediately – This was consistent with previous testing of these pipes in this

configuration and with testing of similar pipes on another program – Delayed start-up believed to be due to fully flooded evaporator and low

power available to initiate nucleate boiling • Simulator temperatures were well within temperature predictions

and the system as a whole met all thermal requirements • Inaccuracies in thermocouple measurements make comparisons

between pipes and calculations of conductances difficult, if not impossible

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