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Stretching The Operational Envelope of The PPS X000 Plasma Thruster
Stretching The Operational Envelope of The PPS X000 Plasma Thruster
Stretching The Operational Envelope of The PPS X000 Plasma Thruster
Denis Estublier§
ESA / ESTEC, Keplerlaan 1, Postbus 299, 2200 AG Noordwijk, The Netherlands
and
Franck Darnon**
CNES, Centre Spatial de Toulouse, 18 avenue Édouard Belin, 31401 Toulouse Cedex 4, France
Nomenclature
F = thrust
Id = discharge current
Idosc = discharge current oscillation amplitude
Im = magnet current (subscript 1 for internal coil, subscript 2 for external coils)
Isp = specific impulse
m& a = main (anode) mass flow rate
m& c = cathode mass flow rate
Pd = discharge power
pe = thrust-specific power
Pvac = background gas pressure
UCRP = cathode coupling voltage, or cathode reference potential
Ud = discharge voltage
η = efficiency
I. Introduction
Electric propulsion systems based on plasma (or Hall-effect) thrusters are now widely recognized as a key
technology for many Earth-orbiting satellite applications as well as space exploration missions. In addition to the
*
R&D Engineer, Plasma Propulsion Section, Space Propulsion Division. AIAA Member.
†
Former supervisor, Plasma Propulsion Section, Space Propulsion Division.
‡
Supervisor, Plasma Propulsion Section, Space Propulsion Division.
§
Member of Technical Staff, ESTEC/TOS.
**
Propulsion Engineer, Pyrotechnics and Propulsion Section, CNES.
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Copyright © 2004 by copyrightSnecma Moteurs, ESA and CNES. Published by the American Institute of Aeronautics and Astronautics, Inc., with permission.
extensive flight heritage accumulated aboard Russian spacecraft, plasma propulsion technology is now entering
service on board western spacecraft as well. First, the Astra 1K and Stentor satellites, although not successfully
launched, contributed significantly in terms of systems and flight hardware experience.1 More recently, the
successful launch and on-going Earth-orbit raising operations of the ESA Smart-1 mission2 demonstrate solar-
electric propulsion combined with gravity-assist maneuvers for the first time. At the time of writing, the single
PPS®1350 engine powering Smart-1 has logged over 2600 hours of operation. Commercial spacecraft launched this
year include the Space Systems/Loral-built MBSAT broadcast communications satellite (launched in March), which
incorporates SPT-100 thrusters, and the Astrium-built Intelsat-X-02 satellite (launched in June), which uses Snecma
Moteurs-built plasma propulsion modules featuring the same thrusters.
The benefits of plasma propulsion, however, are still not fully utilized on commercial platforms because such
systems are currently limited to station-keeping duties and have to include 3 years of chemical propulsion
redundancy. Bi-modal propulsion systems, which can be throttled to efficiently perform orbit transfer or
repositioning as well as station-keeping maneuvers, are therefore currently being considered both in the US3 and in
Europe.4 The demands placed on the propulsion system differ significantly for these two tasks: while orbit transfer
generally places a maximum time constraint on the maneuver, so that thrust-specific power pe (in kW/N) must be
minimized, station-keeping on the contrary demands that propellant mass savings (or Isp, which is proportional to
pe) be maximized. The growing need for versatility of performance in propulsion systems, for Earth orbit as well as
space exploration missions, is also exemplified by the current activities conducted on hybrid (coupled plasma/ion)
propulsion systems5 as well as dual-stage Hall thrusters.6 Since thruster requirements for station-keeping keep
driving the Isp up while the need for orbit transfer capability is also becoming clearer,7 the operating points at which
high efficiency is desired are being drawn further apart. Figure 1 shows the operational envelope of a typical (single
stage) Hall thruster, based on a performance model. The main physical as well as practical limitations that bound the
domain are also indicated.
Thermal limits
- PPU
400
300 V - Available power
275 V
340 V Region of
20 A
380 V interest for
Discharge
350 420 V
station
460 V
stability 18 A 500 V keeping
540 V
300 580 V
620 V
16 A 660 V
Thrust /mN
700 V
740 V
780 V
250 800 V
14 A
6000 W
12 A 5500 W
200
5000 W
10 A
4500 W
8A
150
4000 W
- Electronics/PPU
Region of interest 6A
5A
3500 W
- Lifetime
for orbit topping 4A
3000 W - discharge stability
100
1500 1700 1900 2100 2300 2500 2700
I SP /s
Discharge stability
Figure 1. Typical operating envelope of a Hall thruster with physical or practical boundaries.
After developing the PPS®1350, Snecma Moteurs recognized the promise of bi-modal capability for the next
generation of satellites, and in 1999 started pre-development activities on a 5-kW class Hall thruster, the PPS®5000,8
designed to the specifications of the European @bus program.4 A technological demonstrator model, dubbed
PPS®X000 (pronounced X-thousand) and shown in Fig. 2, was first built and underwent initial characterization at
discharge voltages up to 580 V. The results of this first testing campaign are discussed in Ref. 9, with maximum
reported thrust and total Isp of 335 mN and 2480 s, respectively.
Because Snecma Moteurs was committed to further pursuing and understanding high specific impulse operating
conditions for the station-keeping mode, characterization tests were later extended to discharge voltages up to
1000 V. This paper presents the results of this second, high voltage characterization testing campaign. An overview
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of the performance and stability issues at high voltage has been given in Ref 10. This paper provides a more
extensive presentation of the test results, including low-voltage discharge characteristics.
II. Apparatus
The tests were carried out in the LEEP 2 (Large European
Electric Propulsion) facility at QinetiQ, Farnborough, UK.
The test facility has been described in great detail in
References 9 and 11. We mention here only the general
experimental setup and relevant upgrades that are specific to
this test.
A. Vacuum Chamber
The vacuum chamber is 3.8 meters in diameter in its
widest section, which is 4 meter long, and has a total length
of 10 meters. High vacuum is achieved using 2×600 mm
diameter cryogenic pumps assisted by a large xenon
®
Figure 2: The PPS X000: a technological cryogenic pumping array. The effective pumping speed of
®
demonstrator model for the PPS 5000. The xenon with the thruster operating at a discharge power of
thruster is shown mounted on its mechanical 5 kW was found to be better than 30000 l/s. This ensured a
interface, with a single QinetiQ cathode. background pressure lower than 5×105 hPa or Torr (measured
with a nitrogen-calibrated gauge) under all flow conditions
for discharge voltages Ud above 650 V, i.e., a total mass flow rate lower than 8.73 mg/s (89.35 sccm for xenon) at
5 kW of discharge power. No attempts were thus made in the results to correct for possible effects of the background
pressure, since the ingested xenon would then represent less than 1.6% of the anode mass flow rate and the mean
free path for beam ions in the background xenon would be on the order of a meter.
B. Facility Configuration
The general test configuration was similar to the one used previously9, as shown in Fig. 3. Briefly, the flow was
metered and controlled via a facility propellant supply system (PSS). The power processing rack (PPR) delivered the
required currents and voltages to the cathode heater and ignitor, electromagnet coils, flow valves and controllers,
and anode. A bench filter-unit (BFU) was
placed on the anode line to facilitate PPR DACS Thruster
Power
discharge ignition12 and to decouple the BFU
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mechanical drift, and low
Gas discharge
frequency vibration. Its output is
+
subtracted from the output of the I (magnet 1) Magnet 1 Magnet
balance carrying the thruster. As Voltage source
+
in previous tests, the (mA) analog
I (magnet 2) Magnet 2 Current source
output ran alongside the thruster
Current flow
power cables to the vacuum Lf 2 BFU
chamber feedthrough, after which Diode
+
the signal was converted and V (anode)
Cf 2
Rf 2 Anode
amplified. Thus, the signal in the CRP Thruster
discharge
tests reported in this paper was + I (heater)
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The performance characterization included magnet current optimization, magnet current balance optimization,
cathode flow rate variations and vacuum pressure variations. In addition to this, a constant flow rate voltage sweep
from 300 V to 1 kV was performed, as well as a thermal characterization at points A1 and E. The thermal
characterization consisted of data collection from a total of seven thermocouples while the thruster was allowed to
achieve complete thermal equilibrium. Finally, the low plasma density limit was sought for Ud =1 kV. This was
achieved by progressively decreasing the anode current towards point I after the engine had stabilized at point H
(Ud =1 kV and Pd =5 kW) for 15 minutes.
Magnet current optimization meant that once the thruster had been throttled to the desired operating point, both
inner and outer magnet currents were adjusted in order to 1) stabilize the thruster if applicable; and 2) minimize the
discharge current, i.e., optimize discharge efficiency. Magnet current balance optimization meant that, from the
setting obtained in the magnet current optimization, the outer electromagnet coil current Im2 was varied by ±15%
while the inner coil current Im1 was held constant.
Cathode flow-rate variations were carried out at the optimized setpoint to establish the sensitivity of cathode
coupling potential (or cathode reference potential, CRP) to cathode flow rate. Another parameter that was monitored
was the discharge current oscillation amplitude. In this part, cathode flow rate was varied within ±15% of its initial
setting, which corresponded to 5% of the anode mass flow rate.
Finally, the xenon background pressure in the facility was increased by leaking neutral Xe through the loadlock
in the upper part of the vacuum chamber via a spare feed line and flow controller in the PSS. This was carried out in
order to experimentally establish the sensitivity of thruster performance and stability to background gas pressure.
The vacuum pressure was allowed to progressively increase by 50%.
The control parameters varied during the characterization were always changed in small steps. The thruster was
then allowed to stabilize for a minimum of 5 minutes between changes, except for cathode flow variations where a
minimum of 10 minutes were given between each 5% step.
A. Current-Voltage Characteristics
The first part of the characterization consisted of constant mass-flow-rate voltage sweeps to establish the current-
voltage characteristic, so
that a preliminary 8 6
assessment of the
discharge voltage range 7
5
for stable thruster
operations might be 6
Idosc /App
discharge current to 6 A
4 3
for 300 V of discharge
voltage (anode mass flow
3
rate m& a =6.8 mg/s) and 2
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sweep was performed once up to 800 V, and was then repeated up to 1 kV (Fig. 6). Since an increase in discharge
current was observed toward the upper end of the voltage range, anode flow rate was slightly reduced from its initial
value at 900 V in order not to exceed a discharge current greatly above the initial target of 6 A at 1 kV.
18
Id /A
16
14
12
10
6
ma=6.9mg/s - Im=20A
ma=6.9mg/s - Im=16A
4 ma=6.9mg/s - Im=12A
ma=11.6mg/s - Im=20A
ma=11.6mg/s - Im=16A
ma=11.6mg/s - Im=12A
2
ma=14.0mg/s - Im=20A
ma=14.0mg/s - Im=16A
ma=14.0mg/s - Im=12A
0
80 110 140 170 200 230 260 290
Ud /V
Figure 7. Families of low-voltage discharge I-V characteristics for varying anode mass
flow-rates (ma) and magnet currents (Im).
12
Idosc /App
10
ma=6.9mg/s - Im=20
ma=6.9mg/s - Im=16A
ma=6.9mg/s - Im=12A
8 ma=11.6mg/s - Im=20A
ma=11.6mg/s - Im=16A
ma=11.6mg/s - Im=12A
ma=14.0mg/s - Im=20A
ma=14.0mg/s - Im=16A
6 ma=14.0mg/s - Im=12A
0
80 110 140 170 200 230 260 290
Ud /V
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yet higher voltage.15 The current-voltage characteristic itself remains flat up to about 700 V, and then rises very
slightly with voltage. It is not known which of the possible mechanisms dominates (creation of multiply charged
ions vs. turbulence-induced electron-mobility enhancement) as the charge states in the ion beam were not studied.
An additional effect on the measurements could come from unfiltered AC components when the oscillations are
large, which in particular is believed to cause the small but noticeable change in discharge current that can be
observed at the mode transition near 425 V.
The behavior at low voltage is shown in Fig. 7, where I-V discharge characteristics for Ud ≤ 300 V are shown for
several values of ma and Im. The data were collected over a progressive decrease of Ud starting at 300 V, with a few
minutes stabilization every 25 V. Note that the data corresponding to the highest flow rate is truncated at Id = 16 A
because of the anode supply limitation. The classical “negative impedance” knee can be observed, where the onset
of high-amplitude oscillations (fluctuating mode) coincides with an increase in Id at low values of Ud (Fig. 8). This
most likely is due to a turbulence-induced enhancement of electron mobility in the axial direction of the discharge
chamber. For larger values of Im, the oscillation amplitude decreases and so does the discharge current Id.
4
behavior shows a sensitivity of the 14
10
PPS®X000 demonstrator shows Id pt. E 2.5
6
current does not become significant Id pt. G 1.5
until 19 – 20 A. This suggests that 4
the magnetic circuit of the Id osc pt. F
1
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regime transitions. This will be the subject of further studies.
|Ucrp| /V
20
mc was varied by 15% and the thruster was left to
stabilize for 10 minutes at each step. This 18
explains the multiple values of UCRP stacked 16
together in correspondence with each step of mc
14
variation. The optimization of mc is a trade-off
between high cathode tip temperatures, 12
detrimental to cathode life, and Isp : a larger flow- 10
rate decreases |UCRP | and therefore cathode tip 0,3 0,35 0,4 0,45 0,5
temperature, but increases the “cold flow” loss of mc /[mg/s]
xenon through the cathode. Setting the cathode
mass flow rate equal to 5.5% of the anode mass Figure 10. Cathode coupling voltage UCRP vs. cathode
flow rate for all operating points provided a good mass flow rate mc.
compromise.
F. Thruster performance
7,98 1
Finally, the propulsive performance is
7,96 summarized in Figures 12 and 13, where the
0,9
previous characterization points are
7,94 represented for completeness. The error bars
translate the ±10 mN thrust uncertainty
0,8
7,92
mentioned in Part 2.2, which was found to
0,7
Idosc /App
7,88
data reported here include cathode mass flow
0,6
rate. In addition, electromagnet coil power and
7,86 power dissipated in the cabling have als been
0,5
taken into account, so that the input power
7,84 Id
Idosc considered in the efficiency is the total thruster
0,4
7,82 input power. The thrust efficiency reaches a
maximum near 2700 s of Isp, (700 V of
7,8 0,3
discharge voltage) at 5 kW of discharge power.
5,0E-05 5,5E-05 6,0E-05 6,5E-05 7,0E-05 7,5E-05 8,0E-05
This behavior is consistent with both the fact
Pvac /hPa (or Torr)
that the beam current and/or plasma density are
approaching their lower limits, and that the
Figure 11. Discharge current Id and discharge current magnetic circuit begins to saturate at operating
oscillation amplitude Idosc vs. background xenon pressure conditions near 800 V. The overall
Pvac. Presented data is for Point E (5 kW / 650 V). performance is consistent with other published
results (References 17, 18, 22, 23, and 24).
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400
350
A
A-
A1
300
B
C
250 D+
D E
F H+
F/mN
G
200
H
150
OG H-
100
50
0
1200 1700 2200 2700 3200
Total Isp /s
Figure 12. Thrust vs. Isp. Extra points correspond to the following discharge
conditions: 300 V / 5.5 kW for A-; 1 kV / 6.3 kW for H+; and 1 kV / 4 kW for H-.
70
60 E
A1
F G
D+
C H+
50 OG
B D H-
A-
Thrust efficiency η (%)
A H
40
30
20
10
0
1200 1700 2200 2700 3200
Total Isp /s
Figure 13. Thrust efficiency vs. Isp. Extra points correspond to the following
discharge conditions: 300 V / 5.5 kW for A-; 1 kV / 6.3 kW for H+; and 1 kV / 4 kW for H-.
V. Conclusion
The technological demonstrator PPS®X000 is the precursor thruster for the flight-design PPS®5000, and is
shown operating in Fig. 14. Extensive characterization testing has been completed up to a total thruster power of
6.5 kW and a discharge voltage of 1 kV, with a maximum total specific impulse of 3240 s. A maximum thrust
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efficiency of 58% was obtained at 5 kW / 650 V. The
maximum demonstrated thrust was 335 mN at 6 kW /
300 V, corresponding to a minimum thrust-specific power
of 18.3 kW/N.
This high-voltage characterization campaign was
successful not only in demonstrating performance levels
well above the state of the art, but also in identifying the
functional limits of the present design at high discharge
voltage. In particular, steady-state operation was
demonstrated for order-of-magnitude variations of the
discharge voltage (100 – 1000 V) and power (360 –
6300 W).
References
1
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