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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
Overview
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.
ENAE483 Power, Propulsion, and Thermal Project 4
Thermal System
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
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)
Nominal Active/Emergency
292-300 K 289-303 K
Minimum exposure when = 25 deg (cone half-angle) Maximum exposure when = 117 deg
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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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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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+ = + 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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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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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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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
2130 Watts
665 kWh
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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.
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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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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13 days
Solid Fuel Cell - Li-Ion
Solar Panels
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Deployed solar arrays on lunar surface and during transfer between Earth and the moon
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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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2
2 2 4 +
, = , = 2 , = , = 13,233 2 , = 7,639 2
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,, =
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
= = 107
107 ,,, = 1.19 = 89.9
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Hybrid Rocket AMPAC SV14 Cold Gas Thruster TRW MRE-5 Monopropellant Thruster
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Propellant
N2,NH3, Freon, Helium Organic polymer
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
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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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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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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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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Design Considerations: Must be able to maintain attitude hold in dead band for 3 days
Spacecraft is allowed a maximum drift angle of 5
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= 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
= 0.26
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= ln
=
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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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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