"Mars Science Laboratory Rover System Thermal
110225987
Mars Science Laboratory Rover System Thermal Test
On November 26, 2011, NASA launched a large (900 kg) rover as part of the Mars Science Laboratory (MSL) mission to Mars. The MSL rover is scheduled to land on Mars on August 5, 2012. Prior to launch, the Rover was successfully operated in simulated mission extreme environments during a 16 day long Rover System Thermal Test (STT) This paper describes the MSL Rover STT, test planning, test execution, test results, thermal model correlation and flight predictions. The rover was tested in the JPL 25 Foot Diameter Space Simulator Facility at the Jet Propulsion Laboratory (JPL) The Rover operated in simulated Cruise (vacuum) and Mars Surface environments (8 Torr nitrogen gas) with mission extreme hot and cold boundary conditions. A Xenon lamp solar simulator was used to impose simulated solar loads on the rover during a bounding hot case and during a simulated Mars diurnal test case. All thermal hardware was exercised and performed nominally. The Rover Heat Rejection System, a liquid phase fluid loop used to transport heat in and out of the electronics boxes inside the rover chassis, performed better than predicted. Steady state and transient data were collected to allow correlation of analytical thermal models. These thermal models were subsequently used to predict rover thermal performance for the MSL Gale Crater landing site. Models predict that critical hardware temperatures will be maintained within allowable flight limits over the entire 669 Sol surface mission.
Keith S Novak Joshua E Kempenaar Yuanming Liu Pradeep Bhandari Brenda A Dudik
127700075
Summary of Mars Science Laboratory Rover System Thermal Test
Keith S Novak Joshua E Kempenaar Yuanming Liu Brenda A Dudik
110028971
From Concept to Flight: An Active Active Fluid Loop Based Thermal Control System for Mars Science Laboratory Rover
The Mars Science Laboratory (MSL) rover, Curiosity, which was launched on November 26, 2011, incorporates a novel active thermal control system to keep the sensitive electronics and science instruments at safe operating and survival temperatures. While the diurnal temperature variations on the Mars surface range from 120 C to +30 C, the sensitive equipment are kept within 40 C to +50 C. The active thermal control system is based on a single phase mechanically pumped fluid loop (MPFL) system which removes or recovers excess waste heat and manages it to maintain the sensitive equipment inside the rover at safe temperatures. This paper will describe the entire process of developing this active thermal control system for the MSL rover from concept to flight implementation. The development of the rover thermal control system during its architecture, design, fabrication, integration, testing, and launch is described.
Gajanana C Birur Pradeep Bhandari David P Bame Paul B Karlmann Arthur Mastropietro Yuanming Liu Jennifer Miller Michael T Pauken Jacqueline Lyra
129417832
Performance of the Mechanically Pumped Fluid Loop Rover Heat Rejection System Used for Thermal Control of the Mars Science Laboratory Curiosity Rover on the Surface of Mars
The challenging range of landing sites for which the Mars Science Laboratory Rover was designed, required a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as 123C and as warm as 38C, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) Rover Heat Rejection System (RHRS) and external radiators to maintain the temperature of sensitive electronics and science instruments within a 40C to +50C range. The RHRS harnesses some of the waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG) for use as survival heat for the rover during cold conditions. The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Heat exchanger plates (hot plates) positioned close to the MMRTG pick up this survival heat from it by radiative heat transfer and supply it to the rover. This design is the first instance of use of a RHRS for thermal control of a rover or lander on the surface of a planet. After an extremely successful landing on Mars (August 5) the rover and the RHRS have performed flawlessly for close to an earth year (half the nominal mission life) This paper will share the performance of the RHRS on the Martian surface as well as compare it to its predictions.
Pradeep Bhandari Gajanana C Birur David P Bame Arthur Mastropietro Jennifer Miller Paul B Karlmann Yuanming Liu Kevin R Anderson
126438202
From concept to flight an active thermal control system for Mars Science Laboratory Rover
Gajanana C Birur
109418744
Design and Preliminary Thermal Performance of the Mars Science Laboratory Rover Heat Exchangers
The challenging range of proposed landing sites for the Mars Science Laboratory Rover requires a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as 123 degrees Centigrade and as warm as 38 degrees Centigrade, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) and external radiators to maintain the temperature of sensitive electronics and science instruments within a 40 degrees Centigrade to 50 degrees Centigrade range. The MPFL also manages significant waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG) The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Two similar Heat Exchanger (HX) assemblies were designed to both acquire the heat from the MMRTG and radiate waste heat from the onboard electronics to the surrounding Martian environment. Heat acquisition is accomplished on the interior surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the MPFL to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in plane thermal conductivity and extremely low through thickness thermal conductivity by using aerogel as an insulator inside composite honeycomb sandwich panels. A complex assembly of hand welded and uniquely bent aluminum tubes are bonded onto the HX panels and were specifically designed to be easily mated and demated to the rest of the Rover Heat Recovery and Rejection System (RHRS) in order to ease the integration effort. During the cruise phase to Mars, the HX assemblies serve the additional function of transferring heat from the Rover MPFL to the separate Cruise Stage MPFL so that heat generated deep inside the Rover can be dissipated via the Cruise Stage radiators. Significant fabrication challenges had to be overcome in order to make the HX design a reality. The cruise phase thermal performance of the Rover HXs was verified in the cruise phase system level thermal vacuum test that was performed at JPL in January of 2009. The Rover HXs were modeled in I DEAS TMG and predictions are compared to actual data from the test.
Arthur Mastropietro John S Beatty Frank P Kelly Gajanana C Birur Pradeep Bhandari Michael T Pauken Peter M Illsley Yuanming Liu David P Bame Jennifer Miller
106586443
Mars Science Laboratory Rover Integrated Pump Assembly Bellows Jamming Failure
The Mars Science Laboratory rover and spacecraft utilize two mechanically pumped fluid loops for heat transfer to and from the internal electronics assemblies and the Radioisotope Thermo Electric Generator (RTG) The heat transfer fluid is Freon R 11 (CFC 11) which has a large coefficient of thermal expansion. The Freon within the heat transfer system must have a volume for safe expansion of the fluid as the system temperature rises. The device used for this function is a gas over liquid accumulator. The accumulator uses a metal bellows to separate the fluid and gas sections. During expansion and contraction of the fluid in the system, the bellows extends and retracts to provide the needed volume change. During final testing of a spare unit, the bellows would not extend the full distance required to provide the needed expansion volume. Increasing the fluid pressure did not loosen the jammed bellows either. No amount of stroking the bellows back and forth would get it to pass the jamming point. This type of failure, if it occurred during flight, would result in significant overpressure of the heat transfer system leading to a burst failure at some point in the system piping. A loss of the Freon fluid would soon result in a loss of the mission. The determination of the source of the jamming of the bellows was quite elusive, leading to an extensive series of tests and analyses. The testing and analyses did indicate the root cause of the failure, qualitatively. The results did not provide a set of dimensional limits for the existing hardware design that would guarantee proper operation of the accumulator. In the end, a new design was developed that relied on good engineering judgment combined with the test results to select a reliable enough solution that still met other physical constraints of the hardware, the schedule, and the rover system.
Mitchell R Johnson Joel Johnson Gajanana C Birur Pradeep Bhandari Paul B Karlmann
107095387
Multi Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover
The addition of the Multi Mission Radioisotope Thermoelectric Generator (MMRTG) to the Mars Science Laboratory (MSL) Rover requires an advanced thermal control system that is able to both recover and reject the waste heat from the MMRTG as needed in order to maintain the onboard electronics at benign temperatures despite the extreme and widely varying environmental conditions experienced both on the way to Mars and on the Martian surface. Based on the previously successful Mars landed mission thermal control schemes, a mechanically pumped fluid loop (MPFL) architecture was selected as the most robust and efficient means for meeting the MSL thermal requirements. The MSL heat recovery and rejection system (HRS) is comprised of two Freon (CFC 11) MPFLs that interact closely with one another to provide comprehensive thermal management throughout all mission phases. The first loop, called the Rover HRS (RHRS) consists of a set of pumps, thermal control valves, and heat exchangers (HXs) that enables the transport of heat from the MMRTG to the rover electronics during cold conditions or from the electronics straight to the environment for immediate heat rejection during warm conditions. The second loop, called the Cruise HRS (CHRS) is thermally coupled to the RHRS during the cruise to Mars, and provides a means for dissipating the waste heat more directly from the MMRTG as well as from both the cruise stage and rover avionics by promoting circulation to the cruise stage radiators. A multifunctional structure was developed that is capable of both collecting waste heat from the MMRTG and rejecting the waste heat to the surrounding environment. It consists of a pair of honeycomb core sandwich panels with HRS tubes bonded to both sides. Two similar HX assemblies were designed to surround the MMRTG on the aft end of the rover. Heat acquisition is accomplished on the interior (MMRTG facing) surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the fluid loops to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in plane thermal conductivity and extremely low through thickness thermal conductivity by using aluminum facesheets and aerogel as insulation inside a composite honeycomb core. Complex assemblies of hand welded and uniquely bent aluminum tubes are bonded onto each side of the HX panels, and are specifically designed to be easily mated and demated to the rest of the RHRS in order to ease the integration effort.
Arthur Mastropietro John S Beatty Frank P Kelly Pradeep Bhandari David P Bame Yuanming Liu Gajanana C Birux Jennifer Miller Michael T Pauken Peter M Illsley
109561270
Post flight Analysis of Mars Science Laboratory Entry Aerothermal Environment and Thermal Protection System Response
The Mars Science Laboratory rover landed at Gale Crater on August 5 th 2012. The rover was protected from the extreme heating environments of Martian atmospheric entry by an ablative heatshield. This tiled Phenolic Impregnated Carbon Ablator heatshield was instrumented with a suite of sensors that monitored the in depth ablator temperature response and the surface pressure at discrete locations. This paper presents a comparison of the flight data with post entry analysis at the discrete sensor locations. From the flight data, we postulate that the heatshield experienced roughness induced turbulent transition due to roughness elements around the heatshield tile and sensor plugs. We find that the analytical ablator material model performs well and can be used directly with the in depth temperature data. Finally, we assess the performance of the ablation sensors, and predict the bondline temperature rise. The flight data from the instrumentation, along with the successful landing of the rover, confirms the performance of the heatshield and the conservative heatshield design and margins process.
Todd R White Milad Mahazari Deepak Bose Jose A Santos
129760774
Inverse Estimation of the Mars Science Laboratory Entry Aerothermal Environment and Thermal Protection System Response
The Mars Science Laboratory entry vehicle successfully landed the Curiosity rover on the Martian surface on August 5, 2012. A phenolic impregnated carbon ablator heatshield was used to protect the spacecraft against the severe aeroheating environments of atmospheric entry. This heatshield was instrumented with a comprehensive set of pressure and temperature sensors. The objective of this paper is to perform an inverse estimation of the entry vehicle's surface heating and heatshield material properties. The surface heating is estimated using the flight temperature data from the shallowest thermocouple. The sensitivity of the estimated surface heating profile to estimation tuning parameters, measurement errors, recession uncertainty and material property uncertainty is investigated. A Monte Carlo analysis is conducted to quantify the uncertainty bounds associated with the nominal estimated surface heating. Additionally, a thermocouple driver approach is employed to estimate heatshield material properties using the flight data from the deeper thermocouples while applying the shallowest thermocouple temperature as the surface boundary condition.
Milad Mahzari Robert D Braun Todd R White Deepak Bose