Thermal Control System Status Report

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Thermal Control System Status Report

• J. Burger, H. Hofer,
• L. Cheng, M. Molina

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AMS02 Thermal System

• J. Burger Introduction (Organization, Quality
  Control and Schedule)
• L. Q. Wang Shandong University Responsibilities
• M. Molina Technical Update

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AMS02 Thermal Organization
AMS Overall Thermal System Coordinators ETH H.
Hofer, MIT J. Burger, SDU L. Cheng, NSPO J.R.
Tsai CGS M. Molina, OHB R. Schlitt
Subsystem Thermal Organized by Subsystem
Coordinators
AMS Collaboration Spokesman S.C.C. Ting
Electronics M. Capell CGS M. Molina NSPO J.R. Tsai
TRD S. Schael, K. Lübelsmeyer OHB R. Schlitt
Magnet Cryocoolers H. Hofer GSC S. Breon
RICH G. Laurenti CGS G. Sardo
Subdetector Thermal Groups
Tracker R. Battiston, M. Pohl NLR M. Brouwer
J. van Es NIKHEF B. Verlaat Zhongshan U. Z. He
TRD Gas System U. Becker LMSO C. Clark CGS M.
Molina
ECAL F. Cervelli CGS M. Cova
ToF G. Laurenti CGS C. Vettore
Thermal Subsystem Safety and Interface to ISS and
STS Organized by subsystem coordinators and
reviewed every three months by NASA MMO at KSC,
JSC or CERN
NASA MMO LMSO C. Clark USS2, Vacuum Case And
Safety
NASA MMO Mission Manager S. Porter
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AMS Overall Thermal Control System Organization
PM H. Hofer (ETH-Z) Technical Responsibles J.
Burger (MIT) L. Cheng (SDU) J.R. Tsai (NSPO)
AMS Experiment
Thermal Contractor Carlo Gavazzi Space
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OHB System, Bremen Design and Manufacturing
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QUALITY ASSURANCE / PRODUCT ASSURANCE

• For cost reasons, we have included a limited set
  of quality assurance documentaion in the contract
  with CGS, which is sufficient to assure us of the
  safety and reliability of the thermal control
  system

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AMS-02 Thermal testing
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Structural tests

• An STA of the radiatorscrates will be delivered
  to LMSO/NASA for static and modal testing.

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SDU visit to CGS-Milano26th April 2004

• Prof. CHENG Lin
• Prof. LI Kang

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Areas of collaboration between SDU and CGS

• Presented by Prof. L. Q. WANG
• Shandong University

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Thermal activities

• Wenjing DU and Gongming XIN have come to CERN for
  a three-year period.
• They will translate the Thermal Mathematical
  Model of the Large Solar Simulator (provided by
  ESA in ESATAN format) to the standard format for
  AMS thermal modelling SINDA.
• Together with CGS they will develop test plans
  and test predictions for the AMS Thermal-Vacuum
  test.

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Mechanical design

• A mechanical engineer, starting Fall 2004, will
  support the design of
• Structural Test Article (making simpler the
  original Radiators crates design)
• Together with CGS
• Support Stand for Thermal Vacuum Test at ESTEC
• Together with R. Becker

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STA manufacturing

• In order to test the data exchange between CGS
  and SDU, a 3-D CAD model of an upper bracket of
  the radiators has been sent to SDU in various
  formats.
• Manufacturing drawings have been sent as well

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MAIN RADIATOR UPPER BRACKETS
UPPER BRACKET
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• First specimen of the upper bracket is delivered
  to CGS for dimensional and tolerances control.
• Next step will be getting certified Alumimum
  alloy bare material for building a flight-like
  bracket.

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Loop Heat Pipe Life Test

• SDU will perform a long-duration test of the LHP
  with one quarter of the Zenith radiator.
• Performances of the LHP will be monitored over a
  2 years timeframe.

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A short break influence of initial condition and
disturbances
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Temporal periodic oscillation
Typical secondary flow patterns in one period of
temporal periodic oscillation from solution at
Dk 300 on A1-1
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• 5300 lt Dk ? 7400

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AMS TCSTechnical report

• M. Molina

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TV/TB test _at_ ESTEC
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AMS-02 level TV Test objectives

• Functional performance verification under thermal
  vacuum conditions
• Magnet charge and discharge phases
• Functional performance at room temperature is
  already tested during assembly
• Verification that no degradation occurs during
  and after test
• Verification of the Thermal Control System H/W
  performance
• heaters power consumption (i.e. duty cycles) and
  thermistors/thermostats settings
• radiators effective heat rejection capability
• Loop Heat Pipe performance
• Tracker Thermal Control System Performance
• Partial verification/validation of the AMS-02
  thermal mathematical model
• Verification of the thermal interfaces
• Optical properties validation
• Validation of the (thermal) hardware workmanship
• MLI effective emittance
• Thermal filler

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General thermal test requirements

• AMS-02 shall follow a complete test program,
  including
• Thermal Vacuum
• Thermal Balance with Solar Simulator 
• Shroud temperature range from -170C to 50C
  TBC
• Working Pressure 10-5 torr
• Need for a dedicated line for the He venting

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Test sequence - schedule

• Installation and check-out 3 weeks
• Estimated duration of the test 6 weeks
• De-installation and visual inspection 1 week
• Shipment 1 week
• 3 months are allocated in total, 1.5 of which
  inside the LSS

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Input needed from ESA to the AMS Collaboration

• Mechanical I/F to the LSS, for appropriate MGSE
  design
• (DELIVERED 3rd July 2003)
• Thermal LSS model for test prediction
• Support for thermal model use, during test
  predictions.
• Preparation to start in 2004

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Cryocoolersand Zenith Radiator
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LHP Zenith radiator system
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• Zenith Radiator- sandwich layout

• face sheet 1 t1,8mm Al core t10mm Rohacell
  51WF
• face sheet 2 t0,3mm Al

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TYPICAL ORBIT, SILVERED TEFLON

• Beta 25 is the typical orbit for
  cryocoolers
• It is the orbit that represents the averaged
  temperature over the year
• Silvered Teflon coating was considered on
  radiator to enhance its thermal performance.

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Beta -25 (TYPICAL)
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AMS-02 Thermal analysis

• M. Cova, C. Vettore

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Launch to Activation SequenceAnalysis

• STS free flying
• AMS-02 in Cargo Bay with STS docked to the ISS
• AMS-02 in Hand-off position with STS docked to
  the ISS
• AMS-02 on ISS truss

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1. STS free flying
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2. AMS-02 in Cargo Bay with STS docked to the
ISS
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3. AMS-02 in hand-off position with STS docked
to the ISS
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4. AMS-02 on ISS truss
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Orbits Analyzed
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Power Profiles
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Heaters
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More heaters needed

• HV Bricks
• E-crate
• ECAL, RICH, LOWER TOF
• TRD

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LTA (Launch-To-Activation)Temperature
distributions
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1. STS free flying
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STS free flying
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2. AMS-02 in Cargo Bay with STS docked to the
ISS
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AMS in Cargo Bay, STS docked
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3. AMS-02 in hand-off position with STS docked
to the ISS
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AMS in Hand-off position (2 hours OFF)
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AMS in Hand-off position (6 hours partially ON)
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4. AMS-02 on ISS truss
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Power Outage Scenario
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Configuration

• AMS-02 mounted on the ISS
• AMS-02 power completely OFF
• Initial conditions for the transient
• Steady state solution with AMS-02 powered

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Orbital cases for cooling down

• Worst cold orbit for the detectors

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Results
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HIGH VOLTAGE BRICKS

• A. Franzoso

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The Brick (prototype from INFN -PI)
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Introduction

• 6 Ecal bricks (EHV) mounted on the lower USS
• 4 Rich bricks (RHV) mounted on the lower USS
• 4 Tof bricks (SHV) mounted on the main radiators

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Bricks location and numbering (1/2)
SHV
RAM
WAKE
2
4
1
3
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Bricks location and numbering (2/2)
RHV EHV
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Temperature requirements

• Operational -20C 60C
• Non operational -40C 70C

Power dissipation

• EHV 6.45 W
• RHV 4.35 W
• SHV 5.8 W

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Preliminary mechanical design
Mechanics weight 1.2 kg ( bolts)
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Exploded views
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Accommodation on lower USS
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Thermal control concept

• Bricks insulated from USS by means of Zirconium
  oxide washers
• Rationale USS too cold in worst cold cases
• Bricks thermal control by radiation
• White painted aluminum radiator 1.5 mm thick,
  green in the picture
• Side walls (orange in the picture) auxiliary
  radiators
• Locally applied MLI, depending on the HVbrick
  location

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Analysis worst cases

• STS free flying Beta 60, -Z solar inertial
• STS docked B0 and 60, YPR0,0,0
• Transfer B60, YPR0,0,0
• Switch on B0, YPR0,0,0
• Cold operational on ISS B0, YPR0,0,0
• Hot operational on ISS B-75, YPR-15,0,0
• Heaters failure B-75, YPR-15,0,0
• Cooling down (power outage) B 0, YPR0,0,0

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STS free flying
Coldest brick RHV 3 Minimum
temperature -37.7C HEATERS APPLIED 5W
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STS Docked
Coldest brick RHV 3 Minimum
temperature -29.4C HEATERS APPLIED 5W
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Transfer
Coldest brick EHV 5 Minimum
temperature -32.8C HEATERS APPLIED 7W, then 0W
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Switch ON on ISS truss
Coldest brick EHV 4 Minimum
temperature -20.0C (avg.) HEATERS APPLIED 7W
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Cold operational (RHV)
Coldest brick RHV 3 Minimum
temperature -18.9C Nominal dissipation 4.35W
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Cold operational (EHV)
Coldest brick EHV 6 Minimum
temperature -18.0C Nominal dissipation 6.45W
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HOT operational (RHV)
Hottest brick RHV 4 Maximum
temperature 53.8C Nominal dissipation 4.35W
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HOT operational (EHV)
Hottest brick EHV 4 Maximum
temperature 57.9C Nominal dissipation 6.45W
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Cooling down (power off)
Coldest brick EHV 6 Minimum
temperature -35.1C No heaters,No internal
dissipation
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CAB thermal design status
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CONCLUSIONS FROM THE MEETING AT CRISA (30/7/2004)

• CRISA refined Thermal reduced model, providing
  one node on the baseplate per module
• CAB has a single Thermal interface the
  baseplate, to be kept below 50C

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CAB Thermal CONCEPT
3 (TBC) HPs connected to the CAB baseplate and on
the radiative side of the WAKE radiator (6WK-1)
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New reduced model

• Delivered 5 July 2004
• Model debug
• definition of dissipation profile
• ? Integration of debugged model 14 July 2004
• Number of nodes used
• NEW model 19 nodes for each external box side
• OLD model 1 node for each external box side

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CAB RAMP UP power profile
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CAB Thermal NEXT STEPS

• Number of HPs to be defined
• Heat pipes length
• Conceptual Thermal Design will be completed mid
  September
• When Thermal will be OK
• Structural analysis
• Thermal analysis on CRISA detailed model

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Structural analysis
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Design and test procedure of glued sandwich
inserts.
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Insert Design
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Test Plan
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Shearing Tests Set Up
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Tension Tests Set Up
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Shearing Tests Results
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Tension Test Results
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MAIN RADIATORS FE MODEL
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WAKE RADIATOR
Radiator Panel ROHACELL Al 2024 T81
BOLTS (A286 160 KSI)
Upper bracket (Al 7075 T7351)
XPD (Al 7075 T7351) (FR4)
Mid bracket (Al 7075 T7351)
Links (Al 7075 T7351)
Lower Rod (Al 7075 T7351) (steel)
CRATE (Al 7075 T7351) (FR4)
PDS (Al 7075 T7351) (FR4)
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RAM RADIATOR
Radiator Panel ROHACELL Al 2024 T81
BOLTS (A286 160 KSI)
XPD (Al 7075 T7351) (FR4)
Upper bracket (Al 7075 T7351)
Links (Al 7075 T7351)
Mid bracket (Al 7075 T7351)
CRATE (Al 7075 T7351) (FR4)
Lower Rod (Al 7075 T7351) (steel)
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RAM Radiator mode 1 at 26.64 Hz
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RAM Radiator mode 2 at 34.67 Hz
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Deformation Load case 1023
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Static Analysis
Top bracket plate
Load Case 4032, Layer Z1
Load Case 4032, Layer Z1- detail
MoSu0.07
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Static Analysis
Mid bracket plate
Load Case 4042, Layer Z1
Load Case 4042, Layer Z1 - detail
MoSu0.17
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Static Analysis
Lower bracket plate
Load Case 4012, Layer Z2 - detail
Load Case 4012, Layer Z2
MoSu1.85
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Static Analysis
Crate structure plate
Load Case 4042, Layer Z1 detail
Load Case 4042, Layer Z1
MoSu0.67
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Static Analysis
XPD structure plate
Load Case 4009, Layer Z1 - no lug - detail
MoSu1.91
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Structural analysis closed actions

• Updated analysis using new loads
• Bolt analysis corrected as requested
• Buckling analysis updated
• Fail safe analysis

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Conclusions

• Main Radiator Structure is compliant with the
  requirements
• The 1st natural frequency of the RAM Radiator is
  26.66 Hz
• The 1st natural frequency of the WAKE Radiator is
  25.76 Hz
• All MoS are positive for all applied loads
• The lowest MoS is 0.07 on the top bracket
• Stress verification performed
• Joints verification, both nominal and fail safe
  configuration, performed
• No buckling is present under applied loads.
• EVA induced loads lead to negative MoS on Zenith
  radiator

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IMPORTANT DATA needed for the Delta Thermal CDR

• Tracker Thermal Control System analysis
  (RE-)START
• CAB mid September
• LOWER TOF Thermal design
• ICD issue 4 End September