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ENAE483: Principles of Space Systems Design Power Propulsion Thermal Design: Team B2

Preliminary Design Review

Michael Hamilton Kenneth Murphy

Thomas Noyes Christopher OHare

November 9th, 2012

ENAE483 Power, Propulsion, and Thermal Project

Objectives
To design a thermal regulation system for the stated spacecraft and mission To design a power system to fully power a crewed spacecraft on a 13 day lunar mission To design a 6-DOF propulsion system for the stated spacecraft and mission

ENAE483 Power, Propulsion, and Thermal Project

Overview

ENAE483 Power, Propulsion, and Thermal Project

Crew Capsule Choice


Team Diameter Half Angle Mass Power Req. A3 3.47 m 25 deg 1331 kg 330 W A6 3.47 m 25 deg 1157 kg 116 W A9 3.47 m 25deg 900 kg 1460 W A4 3.47 m 25 deg 1303 kg 1130 W

A number of considerations went into choosing a design Comprehensiveness of subsystems modeled Realism and conservatism of power requirements and total mass Strength of team member recommendation Based on the above criteria, design A4 was selected.
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Thermal System

ENAE483 Power, Propulsion, and Thermal Project

Thermal - Outline
1. 2. 3. 4. 5. 6. 7. 8. Requirements Solar exposure Cabin heat generation Mission scenario definitions Passive regulation Active cooling Active heating Final design specs

ENAE483 Power, Propulsion, and Thermal Project

Thermal - Requirements
Cabin temperature is based on the following factors Internal heat production crew, electronics, avionics Exposure to solar flux Heat radiation to the surrounding environment
Cabin must be maintained within a comfortable range for the crew across specified environmental scenarios Design will target an optimum cabin temperature of 294 K (21 degC)

Acceptable Cabin Temp Range

Nominal Active/Emergency

292-300 K 289-303 K

ENAE483 Power, Propulsion, and Thermal Project

Thermal Solar Exposure


Assume constant solar flux at 1 AU 1394 W/m^2 Capsule area exposed to solar flux is a function of solar angle from the axis of symmetry Exposure areas considered in both space and lunar heat calculations

ENAE483 Power, Propulsion, and Thermal Project

Thermal Solar Exposure

Minimum exposure when = 25 deg (cone half-angle) Maximum exposure when = 117 deg
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Thermal Solar Exposure

Considerations for differing surface materials on the heat shield


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Thermal Cabin Heat Generation


Crew will generate varying heat based on activity levels 1630 W heat from electronics 1130 W crew systems 500 W avionics

Action (at 21 degC)


Sleep Light work

Watts Per person (W)


67.2 92.0

Total Watts - Total w/ 3 ppl (W) elec (W)


201.6 276 1801.6 1876

Moderate work
Heavy work

95.0
97.9

285
293.7

1885
1893.7

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Thermal - Scenarios
Surrounding environment will affect amount of heat radiated from capsule Capsule must be able to maintain target internal temp at every indicated scenario
Scenario Space min exposure & activity Space max exposure & activity Moon Polar Moon Mid latitude Moon Local Midnight Moon Equatorial Noon Moon Eclipse orbiting Moon Dawn Moon Dusk Environment Temp (K) 4 4 180 215 120 380 N/A 100 390 ENAE483 Power, Propulsion, and Thermal Project Solar angle to capsule (deg) 25 117 88 45 N/A 0 N/A N/A 90
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Thermal Passive Regulation


For simplicity of construction, any surface material is assumed to cover the entire capsule

We want to minimize cabin temperature fluctuation across the space and lunar environment scenarios This will minimize need for active temperature regulation

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Thermal Passive Regulation

+ = + 4

Generally, temp fluctuations are minimized by materials with low emissivity ( ) and low absorptivity ( ) Consideration of two surface materials: white paint typical surface, acts as reference material 6x Mylar low emissivity and absorptivity
White paint
0.2 0.8

6x Mylar
0.164 0.03
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ENAE483 Power, Propulsion, and Thermal Project

Thermal - Calculations
Space Transit

+ = 4 4
(In instances of eclipse, Is= 0)

Lunar Surface + = 4 4 + [0.6389 4 4 + 0.3611 4 4 ] (Assumes the moon radiates back at the cone at angle below the horizon)
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Thermal Passive Regulation


Scenario Space min exposure/activity Space max exposure/activity Moon Polar Moon Mid latitude Moon Local Midnight Cabin Temp (K) white Cabin Temp (K) 6x paint mylar 232.4 275.1 275.0 284.6 194.1 292.4 313.3 314.2 320.3 283.7

Moon Equatorial Noon


Moon Eclipse orbiting Moon Dawn Moon Dusk

347.7
187.9 190.0 365.2

372.2
279.3 279.9 384.5

Temperature Range

177.3

100.8

(Temperatures based on a medium crew activity level during sun exposure and sleep during no sun)

Mylar layers provide an acceptable temperature range. The numbers in red are the most extreme cabin temperatures experienced, and must be altered using active thermal regulation. ENAE483 Power, Propulsion, and Thermal Project

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Thermal Active Cooling


In order to lower the cabin temperature, must add external radiators Since high passive temps exist only on the lunar scenarios, external radiators need only to be deployed upon landing, and can be abandoned upon liftoff Radiators are static after deployment to minimize system complication Double layer upper highly emissive material, lower insulator Upper Optical Surface Reflector Lower 6xMylar OSR 0.8 0.05 6xMylar 0.03 0.164
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Thermal Active Cooling


Radiator adds the following numbers to the lunar surface equation = cos() = 4 4 + 4 4 Calculation of required area of radiators for max temp scenarios provides design radiator area:

Design panel size: 14 m^2

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Thermal Active Heating


During low temp scenarios, need to provide active heating Simple heater can increase electronic power heat contribution Can provide variable heat to adjust to different scenario needs

Design heater: 500 W (Extra power as margin)

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Thermal Final Design


Aspect
Target Cabin Temp Capsule surface Radiator

Design specs
Target maintenance temp of 294 K Acceptable range of 292-300 K 6x Mylar Covers entire surface Dual layer panels Upper - Optical Surface Reflectors Lower 6x Mylar 2 2 x 3.5 m panels 14 m^2 total area Deployable on Lunar landing Jettisoned on Lunar launch 500 W electric heater Variable heat production
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Heater

Power System

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Power Requirements
System
C02 Scrubbing Trace Contaminates Control Water Distillation Dehumidifier O2, N2, H2 Storage Avionics Heater

Power (W)
300 150 156 500 20.6 500 500

Duration
13 days 13 days 13 days 13 days 13 days 13 days 13 days

Total Power and Energy

2130 Watts

665 kWh
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ENAE483 Power, Propulsion, and Thermal Project

Power Trade Study


After defining the power requirements for the capsule, the following energy sources were considered:
Fuel Cells Nuclear Solar Arrays and Fuel Cell Combination

The power supply must be able to support 2.1kilowatts without requiring excessive mass or volume. Our power supply must also be able to supply 646kWh. The primary constraint will be mass for this trade study and volume restrictions will only be checked for the chosen power source.
If the most mass efficient resource reasonably fits in the capsule, it will be chosen for the mission.

Overall feasibility will be considered for each design system.


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Fuel Cell
Mission duration and mass are linearly related with this method. This can be advantageous for shorter missions, but the mass accumulates, so it adds significant weight. Using a fuel cell with a higher specific energy and specific power will require less mass. Based on NASA study (Burke) the best solid fuel cell options for this mission would be ArO-Zn or high power Lithium-Ion.
Both of these will be analyzed in the trade study (see graph-next slide) A Hydrogen-Oxygen combustion fuel cell will also be considered.

From the NASA study (graph on next slide), the solid fuel cell details are listed below:
ArO-Zn Average results 200W/kg and 135 Wh/kg Li-Ion (High Energy) Average results 100W/kg and 170 Wh/kg
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Solid Fuel Cell Specific Power and Energy

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Fuel Cells
Hydrogen-Oxygen combustion fuel cell: End Result = 1088Wh/kg + 36kg reactor (derivation below)
H2+(1/2)O2 = H20 + 242kJ (242kJ=67.22Wh) Total mass for this reaction for 1 mol H20 yield = 2g+16g = 18g With efficiency of 50% for conservatism (most cells are ~60% US Department of Energy), that makes the specific energy density 67.22Wh/.018kg = 1850Wh/kg total reactants Must add tank mass of 0.7kg/kg liquid in tank (from crew systems project) yields 1850Wh/1.7kg = 1088Wh/kg system + Reactor Reactor = 255lbs*(2.1kw/7kw) to kg = 36kg*** Volume = 0.15m^3(2.1kw/7kw) = rough dimensions of 0.4mxx0.4mx0.3m*** *** Reactor assumed to be proportional to the shuttles in W/m^3 and kg/W

Tank Sizes
For 543kg O2, tank must be 0.476m^3 Dimensions: Sphere r=0.484m For 68kg H2, tank must be 1 m^3 Dimensions: Sphere: r=0.62m
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Solar Panels
Solar panels must be used in combination with a method of storing energy because they cannot be guaranteed to produce power at all times.
Highly efficient solid fuel cells can be used (Li-Ion)

Solar panels considered will be AEC-Able Ultraflex (net results: 42W/kg plus 149kg for fuel cells and specific energy isnt applicable since there is constant energy absorption while the arrays are in sunlight).
Specific power of 140W/kg. The panels deployed during ~75% of the trip (excludes orbital maneuvers) For a conservative estimate, the panels can be assumed to receive 40% of the solar energy because of imperfect angles (Griffin 487).

Rechargeable fuel cells will have to be added with enough capacity for 12 hours worth of energy so there will a buffer available for fluxes in wattage from the cells.
25kWh Lithium-Ion fuel cell weighs 149kg Approximate dimensions are .5mx.5mx.5m
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Solar Panels
Based on the necessary wattage, 2100W, the solar panel area needed is: 6.6m^2
GaAs is better than Si, with a 23% efficiency yielding 320W/m^2. Considering the efficiency and percentage or sunlight, the power per area is: 100W/m^2

To achieve that area with 2 solar panels, each one would have to have a diameter of 3.73m. This is approximately as large as the capsule, which proportionally is Complicates system because the arrays must be deployed and retracted during any orbital maneuvers so they will not be damaged. The actuators needed to deploy and retract the solar arrays will be light and used only a few times so the power and mass requirements are negligible.
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Nuclear Power
High energy power source, but may not be mass or volume efficient for a 13-day mission. Pu-238 produces power for a long duration of time, but does not have the power for 2.1kW for this mission unless you use multiple RTGs. We would need more than double the RTGs that the Cassini assembly used to generate 2.1kW of power.
This requires 7/3* the volume of the Cassini RTG system which yields to cylinders approximately 1.3m in length and .4m in diameter. These will certainly not fit in our small capsule.***

The mass is not limited by specific energy, so even with a specific power of ~15W/kg, the total systems mass does not exceed 156kg. Also note that the publics perception of nuclear power is not positive, so gathering funding for a project will be difficult. This method will be more desirable if no other means can parallel its efficiency.
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Selecting a Power Supply


For each power source, either specific energy or specific power will require a minimum mass to power the capsule. For each source, the limiting factor was used to determine minimum mass necessary for the system.
Power Supplys by Mass
2000 1800 1600 Kg of Power System 1400 1200 1000 800 600 400 200 0 0 5 10 15 Days of Mission 20 25 RTGs Oxygen Hydrogen Combustion

Solid Fuel Cell - ArO-Zn

13 days
Solid Fuel Cell - Li-Ion

Solar Panels

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Power Supply Chosen


Although the nuclear reactor was slightly more mass efficient and saved 50kg, the volume of the systems was far too large and would not fit in our capsule. Because of this, we decided to go with the second option. After analyzing the mass efficiency of the power sources, the solar arrays with a fuel cell with power for 12 hours package is the best option @ 196kg.
There are a few complexities with the solar array package, but they are still preferable to the extra mass for the fuel cells. Additionally, the tanks required for the O2-H2 fuel cell could not fit in the capsule with all of the other systems. The internal volume requirement is only 0.5x0.5x0.5m for the fuel cell.

Deployed solar arrays on lunar surface and during transfer between Earth and the moon
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Fuel Cell in Capsule

Lithium-Ion fuel cell easily fits without inconveniencing the crew

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Propulsion Subsystem Selection and Sizing


Propulsion Subsystem Selection and Sizing Process*
Step 1: Determine spacecraft propulsion functions (orbit insertion, orbit maintenance, attitude control, reentry) Step 2: Determine budget and thrust level constraints for orbit insertion and maintenance Step 3: Determine total impulse for attitude control, thrust levels for control authority, duty cycles, and mission life requirements Step 4: Determine propulsion system options: - Combined or separate propulsion systems for orbit and attitude control - High vs. low thrust - Liquid vs. solid vs. electric propulsion technology
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Propulsion Subsystem Selection and Sizing


Propulsion Subsystem Selection and Sizing Process*
Step 5: Estimate key parameters for each option - Effective Isp for orbit and attitude control - Propellant mass - Propellant and pressurant volume - Configure the subsystem and create equipment list Step 6: Estimate total mass and power for each option Step 7: Establish baseline propulsion subsystem Step 8: Document results and iterate as required *From J. R. Wertz and W. J. Larson, Space Mission Analysis and Design (3rd ed.) Microcosm Press, 2010
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Propulsion Subsystem Selection and Sizing


Step 1: Determine spacecraft propulsion functions (orbit insertion, orbit maintenance, attitude control, reentry) Attitude Control during Earth-return and reentry phases Orbit Maintenance during Earth-return phase Step 2: Determine budget and thrust level constraints for orbit insertion and maintenance The budget for orbit maintenance is given as a requirement of 50 m/s.

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Propulsion Subsystem Selection and Sizing


Step 3: Determine total impulse for attitude control, thrust levels for control authority, duty cycles, and mission life requirements Capsule Parameters Capsule gross mass = 4,795 kg Outer radius of capsule base = 1.785 m Wall thickness of capsule = 0.1 m Half-cone angle of capsule = 25o Height of capsule = 3.83 m

Center of Mass Calculation

Capsule is modeled as a 2-D isosceles triangle to determine centroid Center of mass is assumed to be on centerline of capsule at the vertical centroid due to geometric symmetry Radius at center of mass = 1.1906 m
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Propulsion Subsystem Selection and Sizing


Step 3: Determine total impulse for attitude control, thrust levels for control authority, duty cycles, and mission life requirements Moments of Inertia Mass modeled as being contained solely on capsule walls , = = =
3 5 1 2

2
2 2 4 +

, = , = 2 , = , = 13,233 2 , = 7,639 2
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Propulsion Subsystem Selection and Sizing


Step 3: Determine total impulse for attitude control, thrust levels for control authority, duty cycles, and mission life requirements Yaw and Pitch Requirements Must withstand 500 N-m in pitch and yaw during reentry ,, = , = 420 ...
420 2

,, =

= 210 (with 2 thrusters)

Due to capsule geometry, yaw and pitch moments about the x and y axes are symmetric Since bottom thruster angled due to capsule geometry: ,, = sin 65 = 231 and ,, = 210 (necessary of angled thrusters to meet yaw/pitch requirements)
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210

Propulsion Subsystem Selection and Sizing


Step 3: Determine total impulse for attitude control, thrust levels for control authority, duty cycles, and mission life requirements Roll Requirements Must be able to spin capsule 180 in 30 seconds Must accelerate and then decelerate to not be continuously spinning after the 30 seconds Area under the vs. t graph must equal pi radians (180). h represents _max and t/2 = 15 seconds Area under curve = h*(t/2) _max = pi/15 rad/s
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Propulsion Subsystem Selection and Sizing


Step 3: Determine total impulse for attitude control, thrust levels for control authority, duty cycles, and mission life requirements Roll Requirements =

= = 107
107 ,,, = 1.19 = 89.9

,,, = 89.9 4 = 22.5 (4 )

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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: - Combined or separate propulsion systems for orbit and attitude control - High vs. low thrust - Liquid vs. solid vs. electric propulsion technology Design will use a reaction control system which provides both orbit maintenance and attitude control Propulsion system type will be determined through trade studies

Hybrid Rocket AMPAC SV14 Cold Gas Thruster TRW MRE-5 Monopropellant Thruster

EADS S400-01 Bipropellant Thruster

NASA NSTAR Ion Thruster

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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options:
Type Cold Gas Solid Motor
Liquid Monopropellant Liquid Bipropellant

Propellant
N2,NH3, Freon, Helium Organic polymer

Energy High Pressure Chemical


Exothermic decomposition

Vacuum Isp (sec) 50-75 280-300 150-225 300-340 330 225 150-700 2000-6000 2000

Thrust Range (N) 0.05-200 50-5x106 0.05-2669 5-5x106 3-200 225-3.5x105 0.005-0.5 5x10-6-0.5 25-200
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H2O2, N2H4 N2O4 & MMH N2O4 & N2H4 O2 & Rubber N2,NH3,N2H4, H2 Hg/A/Xe/Cs Argon

Chemical Chemical Chemical Resistive heating Electrostatic Magnetic

Dual Mode Hybrid Resistojet Ion MPD

ENAE483 Power, Propulsion, and Thermal Project

Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: Determine Optimum Propulsion System

Given: Yaw and pitch control requires thrusters capable of 210 N and 231 N Roll control requires thrusters capable of 22.5 N Minimize power requirements eliminates electrothermal, electrostatic, and electromagnetic options Must be able to restart eliminates solid and hybrid options Maximize Isp eliminates cold gas option Minimize complexity, mass, and volume eliminates liquid bipropellant
System selected: liquid monopropellant, specifically monopropellant hydrazine thrusters
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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: Yaw and Pitch Thrusters

Monopropellant hydrazine thrusters Produced by Olin/RRC, TRW companies Flight-qualified Parameters: Thrust = 222 N Mass = 1.8 kg Isp = 245 sec Total Impulse = 200x103 N-s

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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: Yaw and Pitch Thrusters

Design Considerations: Thrusters pointed in the aft direction do not provide the full 231 N required in the negative z-direction due to the capsule geometry (provide only 222 N, a deficit of 9 N). However, thrusters pointed in the forward direction are only required to provide 210 N in the positive z-direction. The selected thrusters provide 222 N, a surplus of 12 N.
Since firing of the thrusters is coupled for yaw and pitch maneuvers, the design will exceed requirements by 3 N (12 N surplus minus 9 N deficit). Translational motion in the positive x-direction caused by the angled thrusters pointing in the aft direction will be canceled by firing the roll thrusters pointing in the negative x-direction.
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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: Yaw and Pitch Thrusters Angling

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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: Roll Thrusters

Monopropellant hydrazine thrusters Produced by Olin/RRC, TRW, Marquardt, and HAC companies Flight-qualified Parameters: Thrust = 22-36 N Mass = 0.2-0.3 kg Isp = 215-240 sec Total Impulse = 40-1100x103 N-s

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Propulsion Subsystem Selection and Sizing


Step 4: Determine propulsion system options: Roll Thrusters

Design Considerations: Must be able to maintain attitude hold in dead band for 3 days
Spacecraft is allowed a maximum drift angle of 5

RCS thrusters controlled by high-speed solenoid with response time of 10ms


Initial burn to place spacecraft in attitude hold is considered negligible for fuel calculations

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Propulsion Subsystem Selection and Sizing


Step 5: Estimate key parameters for each option Determine fuel necessary to maintain spacecraft roll within dead band

= 2

= 22.5 2 1.19 = 53.6 = 3.5051 106 = 0.1745 3.5051 106 = 49794 = 13.83

72 = 6 13.83
= 0.938

= 0.938 0.001 6 = 0.0056


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Propulsion Subsystem Selection and Sizing


Step 5: Estimate key parameters for each option Determine fuel necessary to maintain spacecraft pitch and yaw within dead band = 523.6 = 1.978 105 = 8822 = 2.45 29
= 9.06

= 0.26

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Propulsion Subsystem Selection and Sizing


Step 5: Estimate key parameters for each option Determine fuel necessary for required translational of 50 m/sec

= ln
=

Z-direction: = 4696 = 98.9 X/Y-direction: = 4689 = 96.9


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Propulsion Subsystem Selection and Sizing


Step 5: Estimate key parameters for each option Propellant storage

Total propellant mass = 293 kg Hydrazine density = 1000 kg/m3 Tank volume = 293/1000 = 0.293 m3 Tank mass = 10 kg (using bare tank MER)

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Propulsion Subsystem Selection and Sizing


Step 6: Estimate total mass and power Total mass = Thruster mass + propellant mass + tank mass Total mass = (8)(1.8) + (8)(0.3) + 293 + 10 = 319.8 kg External power requirement is negligible (propellant will be pressure fed with no pumps) Propellant pressure feed system will use an internal rubber diaphragm to facilitate the displacement of the propellant from the storage tank. A rubber diaphragm is optimum due to its low weight, proven design, high expulsion efficiency, and no limitations on cycling.

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Propulsion Subsystem Selection and Sizing


Step 7: Establish baseline propulsion subsystem Baseline propulsion system summary: Eight yaw/pitch thrusters providing 222 N of thrust Eight roll thrusters providing 22.5 N of thrust Total propellant mass = 293 kg Hydrazine density = 1000 kg/m3 Tank volume = 293/1000 = 0.293 m3 Tank mass = 10 kg (using bare tank MER) Total mass = 319.8 kg Step 8: Document results and iterate as required Future iterations can explore modifying the thruster parameters such as throat area, nozzle exit area, and propellant type

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Mass/Power Budget
System
Crew Systems Radiator Panels Heater Capsule surface coating Thrusters Thruster prop. tanks Power - Battery Power Solar Arrays Total

Mass (kg)
1303 300 5 30 16.8 302.9 146 50 2153.7

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Thermal References
Pennell, S., and J. Deignan. "Computing the Projected Area of a Cone." SIAM Review 31.2 (1989): 299. Print. Ungar, Eugene K. "Modeling of Multi-Layer Insulation Layups with Transmissive Outer Layers." Tfaws.nasa.gov. NASA/Johnson Space Center, Aug. 2002. Web. Oct. 2012.

Batterson, S., H. Benson, and D. Gault. "Lunar Surface Models." NASA Space Vehicle Design Criteria (1969): n. pag. Print.
Fortescue, Peter W., John Stark, and Graham Swinerd. Spacecraft Systems Engineering. Hoboken, NJ: Wiley, 2011. Print. "Man-Systems Integration Standards (MSIS)." Man-Systems Integration Standards (MSIS). NASA, n.d. Web. 08 Nov. 2012. <http://msis.jsc.nasa.gov/>.

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Power References
AIAA 2003-5938, Fuel Cells for Space Science Applications, Burke, K. A., November 2003 "Fuel Cell Technologies Program." U.S. Department of Energy. N.p., n.d. Web. 2 Nov. 2012. <www1.eere.energy.gov/hydrogenandfuelcells/pdfs/fct_h2_fuelcell_factsheet.pdf >. Griffin, Michael D., and James R. French. Space vehicle design. 2nd ed. Reston, VA: American Institute of Aeronautics and Astronautics, 2004. Print.

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Propulsion Subsystem Selection and Sizing


Citations [1] High Speed Solenoids. Ledex, n.d. Web. 8 Nov. 2012. <http://www.ledex.com/high-speed-solenoids/high-speedsolenoids.html>. [2] Wertz, James Richard., and Wiley J. Larson. Space Mission Analysis and Design. Hawthorne, CA: Microcosm, 2010. Print. [3] Akin, Dave. Lecture 8 SYS/Mass Estimating Relations, 2012 [4] Akin, Dave. Lecture 14 PPT/Rocket Propulsion, 2012

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