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STARLight Thermal

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STARLight Thermal Tahir Rashid STARLight Mechanical Engineer (734) 764-7210 trashid_at_umich.edu – PowerPoint PPT presentation

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Title: STARLight Thermal


1
STARLight Thermal
  • Tahir Rashid
  • STARLight Mechanical Engineer
  • (734) 764-7210
  • trashid_at_umich.edu

2
Thermal Requirements
  • Thermal Requirements
  • During 1.5 second integration period, thermal
    stability across one receiver module must be lt
    11mK
  • Thermal stability across one AD module must be lt
    1 K
  • Temperature can vary between adjacent modules
  • Ambient temperatures -30?C to 40 ?C
  • Thermal control system to use less than 100 W
    Aircraft Power
  • Simple and cost-effective
  • Setpoint Operational Conditions
  • Y-Thermal Plate Setpoint Values -20?C to 30
    ?C
  • Receiver Thermal Plate Setpoint Values 2?C
    higher than Y-Plate
  • Tolerance Range of Setpoint ? 0.1 ?C
  • Fluid Setpoint 1?C lower than Y-plate setpoint

3
Thermal Model Development
  • Objective
  • Does this design meet requirements for thermal
    stability?
  • How well does system meet control setpoint?
  • Estimate of time constant (in-flight on-ground)

4
Thermal Model Development
  • Thermal Network

5
Time Constants Stability
  • Estimate of Time Constants Stability once
    setpoint is achieved.

6
Time Constants Stability
  • Defn - Amount of time to reach setpoint value
    depends on
  • Is temperature within tolerance range of
    Setpoint ? 0.1 ?C
  • Is stability per requirements when within the
    setpoint range ?

Unstable
7
Time Constants Stability
  • 1?C Temperature Change during Flight Conditions
    (0.02 W)
  • For Receiver Plate - 5 minutes to reach setpoint
    20?C
  • For Thermal Plate 17.5 minutes to reach
    setpoint 20?C

8
Time Constants Stability
9
Time Constants Stability
  • 10?C Temperature Change during Ground Conditions
    (0.2 W Required)
  • For Receiver Plate - 10 minutes to reach setpoint
    -30?C
  • For Thermal Plate - 34 minutes to reach setpoint
    -30?C

10
Time Constants Stability
11
Time Constants Stability
  • Temperature Change during Ground Conditions (9 W)
  • For Receiver Plate - 12 seconds to reach setpoint
    of -30?C
  • For Thermal Plate - 36 seconds to reach setpoint
    of -30?C

12
Time Constants Stability
13
Model Summary
  • Thermal stability requirement is achievable
  • Since sensor module is a sealed-system, no
    external power will be required during ground
    operation. Turning on electronics will heat the
    sensor module very rapidly
  • Operational Note Turn cooling system on prior to
    turning on electronics

14
Thermal Control System (Mechanical)
  • (Dwg 086-0075 X2)

15
Thermal Control System (Mechanical)
Plate Setpoint Temp
MaCom LNA(0.5W)Switch(0.288W)
LNA (0.5W) LNA (0.5W)
Miteq LNA (1.2W)
Fluid Temp (0.09 gpm)
Fluid Temp (0.18 gpm)
16
Thermal Control System (Mechanical)
Plate Setpoint Temp
Delay Line (0.132W)
16-Bit A/D (0.08W)
DAC (1.12W)
Fluid Temp (0.09 gpm)
Op Amp (0.594W)
6-Bit A/D (4W)
Fluid Temp (0.18 gpm)
17
Thermal Control System (Electrical)
18
Thermal Control System (Electrical)
  • Design meets criteria of Aircraft power lt 100W

19
Thermal Control System Summary
  • Design consists of mostly off-the-shelf
    components (simple cost-effective)
  • A reduction in flow by ½ across the electronic
    modules will not affect the required heat
    transfer
  • Design meets criteria of Aircraft power
    consumption less than 100W

20
Prototype Testing
  • Perform a Refrigeration Unit Test
  • Objectives
  • Verify Manufacturers Power Ratings under various
    ambient conditions
  • Estimate Heat that can be dissipated by the
    Refrigeration System under extreme ambient
    conditions(-30?C to40 ?C)
  • Examine Effects of Antifreeze on Cold Evaporator
    Plates
  •  

21
Prototype Testing
22
Prototype Testing
  • Perform 2-Channel Prototype Test by using
    simulated heat loads
  • Objectives
  • Provide valuable insight into integration of
    sensor assembly mechanical design, refrigeration
    unit, and remainder of thermal control components
  • Determine thermal time constants.
  • Verify thermal stability at various ambient
    conditions, including extremes.
  • Verify thermal stability during sudden ambient
    changes (thermal shock)
  • Determine power consumption at various ambients.

23
Schedule (Efforts to CDR)
  • Test refrigeration unit (10/26/01)
  • NovaKool Refrigeration Unit (Arrived 09/26/01)
  • Test Procedure (086-0085x1) complete (10/12/01)
  • Status of Other Off-the-Shelf Components
  • Circulation Pump (Arrived 09/21/01)
  • Filter In stock (Delivery by 10/10/01)
  • Fittings, Tubing,Check Valves, Quick
    Disconnects,etc In stock (Deliver by 10/12/01)
  • Strip Heaters In stock (Deliver by 10/11/01)

24
Schedule (Efforts to CDR)
  • Manufacture 2-channel prototype hardware
  • Long-lead item is Aluminum Y-thermal plate
    (11/09/01)
  • Dwg 086-0078 completed and provided for quotes
  • Reservoir
  • Dwg to be complete by (10/12/01)
  • Manufactured in-house (10/24/01)
  • Test stand
  • Dwg to be complete by (10/26/01)
  • Manufactured in-house (11/05/01)

25
Schedule (Efforts to CDR)
  • Perform testing of prototype in thermal chamber
  • Test Procedure Complete by 11/02/01
  • Start test using simulated loads (11/12/01)
    Finish (12/07/01)
  • Analyze test results (12/14/01)
  • Update Thermal ICD (Doc 086-0017) (02/08/01)
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