STARLight Thermal Tahir Rashid STARLight Mechanical Engineer 734

STARLight Thermal Tahir Rashid STARLight Mechanical Engineer (734) 764 -7210 trashid@umich. edu STARLight PDR 3 Oct ‘ 01 G. 1. 1 Rashid

Thermal Requirements STARLight • Thermal Requirements – During 1. 5 second integration period, thermal stability across one receiver module must be < 11 m. K – Thermal stability across one AD module must be < 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 STARLight PDR 3 Oct ‘ 01 G. 1. 2 Rashid

Thermal Model Development STARLight • Objective: – Does this design meet requirements for thermal stability? – How well does system meet control setpoint? – Estimate of time constant (in-flight & onground) STARLight PDR 3 Oct ‘ 01 G. 1. 3 Rashid

Thermal Model Development STARLight • Thermal Network STARLight PDR 3 Oct ‘ 01 G. 1. 4 Rashid

Time Constants & Stability STARLight – Estimate of Time Constants & Stability once setpoint is achieved. STARLight PDR 3 Oct ‘ 01 G. 1. 5 Rashid

Time Constants & Stability STARLight – Def’n - Amount of time to reach setpoint value depends on: Ø Is temperature within tolerance range of Setpoint: 0. 1 C Ø Is stability per requirements when within the setpoint range ? Unstable STARLight PDR 3 Oct ‘ 01 G. 1. 6 Rashid

Time Constants & Stability STARLight – 1 C Temperature Change during Flight Conditions (0. 02 W) Ø For Receiver Plate - 5 minutes to reach setpoint 20 C Ø For Thermal Plate – 17. 5 minutes to reach setpoint 20 C STARLight PDR 3 Oct ‘ 01 G. 1. 7 Rashid

Time Constants & Stability STARLight PDR 3 Oct ‘ 01 G. 1. 8 Rashid

Time Constants & Stability STARLight – 10 C Temperature Change during Ground Conditions (0. 2 W Required) Ø For Receiver Plate - 10 minutes to reach setpoint -30 C Ø For Thermal Plate - 34 minutes to reach setpoint -30 C STARLight PDR 3 Oct ‘ 01 G. 1. 9 Rashid

Time Constants & Stability STARLight PDR 3 Oct ‘ 01 G. 1. 10 Rashid

Time Constants & Stability STARLight – Temperature Change during Ground Conditions (9 W) Ø For Receiver Plate - 12 seconds to reach setpoint of -30 C Ø For Thermal Plate - 36 seconds to reach setpoint of -30 C STARLight PDR 3 Oct ‘ 01 G. 1. 11 Rashid

Time Constants & Stability STARLight PDR 3 Oct ‘ 01 G. 1. 12 Rashid

Model Summary STARLight – 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 STARLight PDR 3 Oct ‘ 01 G. 1. 13 Rashid

Thermal Control System (Mechanical) STARLight • (Dwg#: 086 -0075 X 2) STARLight PDR 3 Oct ‘ 01 G. 1. 14 Rashid

Thermal Control System (Mechanical) Plate Setpoint Temp LNA (0. 5 W) + LNA (0. 5 W) Ma. Com LNA(0. 5 W)+Switch(0. 288 W) Miteq LNA (1. 2 W) STARLight Fluid Temp (0. 09 gpm) Fluid Temp (0. 18 gpm) STARLight PDR 3 Oct ‘ 01 G. 1. 15 Rashid

Thermal Control System (Mechanical) STARLight DAC (1. 12 W) 16 -Bit A/D (0. 08 W) Delay Line (0. 132 W) Op Amp (0. 594 W) 6 -Bit A/D (4 W) Plate Setpoint Temp Fluid Temp (0. 09 gpm) Fluid Temp (0. 18 gpm) STARLight PDR 3 Oct ‘ 01 G. 1. 16 Rashid

Thermal Control System (Electrical) STARLight PDR 3 Oct ‘ 01 G. 1. 17 Rashid

Thermal Control System (Electrical) STARLight • Design meets criteria of Aircraft power < 100 W STARLight PDR 3 Oct ‘ 01 G. 1. 18 Rashid

Thermal Control System Summary STARLight • 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 100 W STARLight PDR 3 Oct ‘ 01 G. 1. 19 Rashid

Prototype Testing STARLight • Perform a Refrigeration Unit Test • Objectives – Verify Manufacturer’s Power Ratings under various ambient conditions – Estimate Heat that can be dissipated by the Refrigeration System under extreme ambient conditions(-30 C to 40 C) – Examine Effects of Antifreeze on Cold Evaporator Plates STARLight PDR 3 Oct ‘ 01 G. 1. 20 Rashid

Prototype Testing STARLight PDR 3 Oct ‘ 01 G. 1. 21 Rashid

Prototype Testing STARLight • 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. STARLight PDR 3 Oct ‘ 01 G. 1. 22 Rashid

Schedule (Efforts to CDR) STARLight • Test refrigeration unit (10/26/01) – Nova. Kool Refrigeration Unit (Arrived 09/26/01) – Test Procedure (086 -0085 x 1) 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) STARLight PDR 3 Oct ‘ 01 G. 1. 23 Rashid

Schedule (Efforts to CDR) STARLight • Manufacture 2 -channel prototype hardware – Long-lead item is Aluminum Y-thermal plate (11/09/01) Ø Dwg 086 -0078 completed and provided for quotes – Reservoir Ø Dwg to be complete by (10/12/01) Ø Manufactured in-house (10/24/01) – Test stand Ø Dwg to be complete by (10/26/01) Ø Manufactured in-house (11/05/01) STARLight PDR 3 Oct ‘ 01 G. 1. 24 Rashid

Schedule (Efforts to CDR) STARLight • 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) STARLight PDR 3 Oct ‘ 01 G. 1. 25 Rashid