Download as pdf or txt
Download as pdf or txt
You are on page 1of 18

Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

SAE TECHNICAL
PAPER SERIES 2008-01-2001

Thermal Design of the Mars Science Laboratory


Powered Descent Vehicle
Anthony D. Paris, Melanie L. Fisher, Frank P. Kelly, Brenda J. Hernandez,
Brenda A. Dudik, Robert J. Krylo, and Pradeep Bhandari
Jet Propulsion Laboratory, California Institute of Technology

38th International Conference


on Environmental Systems
San Francisco, California
June 29-July 2, 2008

400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-0790 Web: www.sae.org
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

By mandate of the Engineering Meetings Board, this paper has been approved for SAE publication upon
completion of a peer review process by a minimum of three (3) industry experts under the supervision of
the session organizer.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of SAE.

For permission and licensing requests contact:

SAE Permissions
400 Commonwealth Drive
Warrendale, PA 15096-0001-USA
Email: permissions@sae.org
Tel: 724-772-4028
Fax: 724-776-3036

For multiple print copies contact:

SAE Customer Service


Tel: 877-606-7323 (inside USA and Canada)
Tel: 724-776-4970 (outside USA)
Fax: 724-776-0790
Email: CustomerService@sae.org

ISSN 0148-7191
Copyright © 2008 SAE International
Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE.
The author is solely responsible for the content of the paper. A process is available by which discussions
will be printed with the paper if it is published in SAE Transactions.

Persons wishing to submit papers to be considered for presentation or publication by SAE should send the
manuscript or a 300 word abstract of a proposed manuscript to: Secretary, Engineering Meetings Board, SAE.

Printed in USA
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

2008-01-2001

Thermal Design of the Mars Science Laboratory


Powered Descent Vehicle
Anthony D. Paris, Melanie L. Fisher, Frank P. Kelly, Brenda J. Hernandez, Brenda A. Dudik,
Robert J. Krylo and Pradeep Bhandari
Jet Propulsion Laboratory, California Institute of Technology

Copyright © 2008 SAE International

ABSTRACT delivery of the MSL Rover vehicle to the surface of the


planet.
NASA’s Mars Science Laboratory mission will use a
Powered Descent Vehicle to accurately and safely land This paper will present an overview of just a portion of
a roving, robotic laboratory on the surface of Mars. The the Mars Science Laboratory spacecraft thermal
precision landing systems employed on this vehicle are design—specifically, that which concerns the hardware
exposed to a wide range of mission environments from systems responsible for the touchdown landing of the
deep space cruise to atmospheric descent and require a spacecraft on Mars. Collectively, these landing systems
robust and adaptable thermal design. This paper are referred to as the MSL Powered Descent Vehicle.
discusses the overall thermal design philosophy of the The thermal design of those systems and components
MSL Powered Descent Vehicle and presents analysis of designed specifically for other mission phases (such as
the active and passive elements comprising the Cruise, the Cruise Stage module, Aeroshell, or Rover) are
Entry, Descent, and Landing thermal control systems. beyond the present scope of this paper and will be
presented elsewhere. Although the critical operational
INTRODUCTION phases for the MSL Powered Descent Vehicle are the
Mars exo-atmospheric and atmospheric entry phases,
Scheduled for launch in September 2009, NASA’s Mars the thermal control of these components throughout
Science Laboratory (MSL) mission is the latest in a each mission phase will be discussed.
series of mobile robotic probes dedicated to traversing
the planet Mars and seeking past signs of water and The thermal design of the MSL Entry, Descent, and
possible life. NASA’s two preceding rover missions, Landing systems is complicated by the fact that these
Mars Pathfinder and the twin Mars Exploration Rovers, components are exposed to a wide range of
demonstrated a landing technique which used an environmental conditions throughout the course of the
encapsulating aeroshell, supersonic parachute, solid mission. At various points in time, the hardware will be
rocket engines, and airbags to slow the descent of the exposed to a free-convection dominated terrestrial
spacecraft through the atmosphere and cushion the atmospheric environment (pre-launch), a radiation
impact of landing. The present Mars Science Laboratory dominated high vacuum environment (cruise), and a
mission strives to land a rover in excess of 900 kg within forced convection dominated Mars atmospheric
a tighter landing ellipse than the previous missions and environment (EDL). While optimal operation of the
these requirements have resulted in an Entry, Descent, Powered Descent Vehicle systems is required only
and Landing (EDL) approach with marked differences during the descent and landing phases, the thermal
from preceding landed exploration missions .
[1] design of the spacecraft must be robust to all modes of
thermal energy transport and severity of environmental
The Mars Science Laboratory mission has six distinct temperatures.
phases: pre-launch, launch, deep space cruise, Mars
exo-atmospheric entry, atmospheric entry, and surface THERMAL DESIGN REQUIREMENTS
operations. During the first three phases of the
mission—throughout which the MSL spacecraft resides VEHICLE DESCRIPTION - As with previous NASA Mars
in its cruise configuration—the primary mission objective landed missions, the Mars Science Laboratory
is to deliver the entry vehicle and science payload to the spacecraft features a collection of components
vicinity of Mars. The two phases defining the Entry, cocooned within larger structures. Depictions of the
Descent, and Landing portion of the mission (exo- stacked nature of the MSL spacecraft during the launch
atmospheric and atmospheric entry) involve a process of and cruise phases of the mission are found in figures 1
shedding and deploying hardware that results in the safe and 2. At the center of the stack is the MSL rover with
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

its mobility systems and other deployable components the Descent Stage by six pyro-separation bolts but
stowed to occupy minimum volume. The MSL rover is otherwise makes no physical contact with the DS or
powered by a Multi-Mission Radioisotope Thermoelectric Rover. Due to seals which prevent the inflow of
Generator (MMRTG) located at the back end of the superheated gases during atmospheric entry, the
Rover chassis opposite the suite of science instruments. Aeroshell also serves to completely encapsulate the
The Rover is attached to the primary structure of the vehicle during the launch and cruise phases of the
MSL Descent Stage (DS) via three hard mounts mission. In the pre-launch environment, waste heat
equipped with pyrotechnic separation devices and three from the MMRTG must be removed from within the
bridle attachment locations. The bridle serves as a sealed Aeroshell interior while the spacecraft resides in
mechanical tether to control the separation of the the launch payload faring.
Descent Stage and Rover during final deployment on the
Mars Surface. When co-joined, the Rover and Descent The Descent Stage is a structural platform which hosts
Stage are referred to collectively as the Powered an integrated monopropellant (Hydrazine) chemical
Descent Vehicle (see figure 3). propulsion system and distributed components
comprising the guidance and navigation, power, and
avionics subsystems. The purpose of this hardware is to
reduce the velocity of the Powered Descent Vehicle from
approximately 160 m/s to less than 1 m/s while
exercising closed-loop guidance control. After
deployment of the MSL Rover at touchdown, the
Descent Stage will undertake a flyaway maneuver to
safely dispose of the excess EDL hardware and allow
the landing site to remain undisturbed.

Separated
Backshell

Powered
Descent Vehicle

Figure 1. Mars Science Laboratory spacecraft


component stack (Cruise phase configuration)

Figure 3. Powered Descent Vehicle, depicted during


final descent to Mars with visualization of thruster
exhaust plumes (from Reference 1).

The topmost component in the spacecraft stack is the


Cruise Stage. Similar in purpose to the Descent Stage,
the Cruise Stage is essentially a propulsion and
guidance module that conveys the Aeroshell and
Powered Descent Vehicle stack from Earth to Mars.
Figure 2. Mars Science Laboratory spacecraft The Cruise Stage is attached to both the Aeroshell and
(Cruise phase configuration) the launch vehicle by an adapter structure that has
pyrotechnic separation bolts on both sides of the
To both survive aerothermal heating effects from interface. At the end of launch phase, one set of
atmospheric entry and slow the entry body to subsonic separation mechanisms frees the spacecraft from the
speeds, the Powered Descent Vehicle is surrounded by Launch vehicle, while the second set separates the
an aeroshell subsystem equipped with a supersonic Cruise Stage from the Aeroshell just prior to Mars exo-
parachute. The Aeroshell is hard mounted to the top of atmospheric entry.
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

Figure 4. Entry, Descent and Landing worst case angles (with respect to the spacecraft’s solar array) from
timeline assumptions for purposes of thermal 0 to 80 degrees. The combination of minimum solar
design distance and maximum solar flux establish the worst
case hot conditions for the spacecraft during the cruise
Figure 4 shows an annotated timeline of the Entry, phase. A worst case solar flux of 1440 W/m2 can range
Descent, and Landing phase, complete with graphical from fully incident upon the Cruise Stage solar array
representations of when each component is employed (zero degree off-sun) to normal with the exposed portion
and discarded. The actual timeline for EDL that will be of the Aeroshell (fifty-three degrees off-sun). Due to the
followed during flight will depend upon a number of extreme permissible off-sun angle range in early Cruise,
factors yet to be determined (such as the particular the first sixty days of the mission also contain the worst
landing site). The timeline shown in figure 4 is a case cold conditions for the Cruise Stage solar array and
representative bounding timeline for the thermal design the Aeroshell’s parachute hardware. This set of worst
as it maximizes exposure to several extreme thermal case cold conditions occurs at a solar range of 1.075
boundary conditions. A.U. and an off-sun angle of 80 degrees.

SPACECRAFT ENVIRONMENTS - The thermal After the first sixty days post-launch, the permissible off-
environment of the Powered Descent Vehicle is largely sun angles are constrained to between 0 and 45
defined by the Cruise and EDL phases of the mission. degrees off-sun. The worst cold case for the majority of
Although the pre-launch environment presents several the Powered Descent Vehicle components occurs very
challenges from a thermal management perspective, a late in the cruise phase when the solar flux is weakest.
ground-based thermal environmental control system will The maximum solar range requirement for the thermal
maintain the spacecraft components within allowable design is 1.63 A.U. and this corresponds to a minimum
2
flight temperature ranges. A detailed discussion of the incident solar flux of approximately 516 W/m . Due to
design and performance of these ground-based thermal variations in launch vehicle performance and uncertainty
control systems is reserved for other publications as the in spacecraft mass, there are a range of possible arrival
focus in this paper is the performance of the spacecraft dates at Mars for the MSL mission. The minimum solar
thermal design in flight. range requirement associated with Mars arrival is 1.5
A.U. and this establishes the worst case hot conditions
Cruise Phase - The cruise phase of the MSL mission just prior to Entry, Descent, and Landing. Figure 5
does not have an Earth orbiting or inner planet gravity shows the variation in the solar range of the spacecraft
assist trajectory, thus the majority of cruise is spent for three predicted arrival dates at Mars. It should be
traveling away from the sun. For the first sixty days of noted that mission plans do not call for a nominal twelve
cruise, the spacecraft may be as close as 0.975 A.U. month cruise phase, but rather extreme trajectories were
from the sun and will have a range of permissible off-sun
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

chosen to determine bounding thermal design and exposure timeline were selected as a basis for
requirements. design requirements (see figure 6).

Although atmospheric thermophysical properties do


influence the trajectory during the Descent phase, for the
Spacecraft to Sun Range (A.U.)

purposes of bounding the thermal design requirements,


0-45q off-sun
maximum values were assumed for CO2 density (0.02
3
Cruise/EDL Worst kg/m ) and thermal conductivity ( 0.007 W/m˜K) and a
Cold Case
EDL Worst
minimum value was assumed for temperature (-100qC).
Hot Case Both the maximum velocity and maximum exposure
timelines assume the same values for these properties.
Cruise Worst Cold Case
0-80q off-sun
For Parachute Hardware

Cruise Worst Hot Case 200

Entry Vehicle Velocity (m/s)


Maximum Velocity Profile
2 4 6 8 10 12
150
Cruise Duration (months)

100
Figure 5. Worst case solar range assumptions for
Maximum Timeline Profile
the cruise phase thermal design
50
Entry, Descent, and Landing Phase - Prior to the EDL
phase, the MSL spacecraft will jettison the Cruise Stage
and perform a final turn-to-entry maneuver (see figure 0
0 50 100 150 200 250 300
4). The maximum off-sun angle for this final turn-to-
Time After Heatshield Separation (seconds)
entry has been established as 76 degrees from the
spacecraft’s +Z axis. The maximum timeline Figure 6. Worst case atmospheric descent velocity
requirement from Cruise Stage jettison to touchdown is profiles used in the PDV thermal design
25 minutes and this duration constrains all transient
thermal events on the entry body. During Entry, TEMPERATURE REQUIREMENTS - Due to the size
Descent, and Landing, the spacecraft encounters an and complexity of the MSL Powered Descent Vehicle,
environmental heating load on the external surfaces of there are a large number of individual hardware
the Aeroshell which can subsist for upwards of 140 components with unique allowable flight temperature
seconds. The Aeroshell is equipped with both ablative (AFT) requirements. Maximum and minimum Allowable
and non-ablative protective coatings to survive this Flight Temperatures for each component are derived by
heating event. For readers interested in the design of adding margin to the temperature range over which the
the Aeroshell thermal protection system, reference [2] components have been qualified for performance. As
summarizes the aerothermodynamic definition analysis standard practice, 15qC is added and 20qC is subtracted
and TPS development for the MSL project. For the from the minimum and maximum qualification
purposes of evaluating the Powered Descent Vehicle temperatures, respectively, to arrive at a more narrow
thermal design, the performance of the Aeroshell TPS is allowable flight temperature range. Rather than
assumed to meet its minimum design requirements and consider each component in detail, this paper will focus
maintain the Aeroshell interior surface below +150qC. on common groupings of components which share
similar AFT ranges. Figure 7 shows an annotated view
Following the aerothermal heating event, the entry body of the Descent Stage with callouts for propulsion,
parachute is deployed and the vehicle is reduced to a avionics, telecommunication, and guidance and
subsonic velocity. Upon activation of a mach trigger, navigation subsystems. The Descent Stage propulsion
the forebody of the Aeroshell (i.e. the Heatshield) is system can be divided into six general components:
jettisoned. At this point in the descent phase, the propellant tanks, pressurant tanks, pressurant lines,
Powered Descent Vehicle is exposed to the cold Martian propellant lines, propellant control plates, and thrusters.
atmosphere for the first time and some forced A simplified propulsion system schematic is shown in
convective cooling can occur. Worst cold case analyses figure 8 for clarity. Figure 9 shows a similar annotated
must assume a combination of vehicle velocity, view for the Rover, with callouts for components that are
atmospheric thermophysical properties, and exposure of interest during the Cruise and EDL phases.
time to assess the maximum heat loss due to forced
convection. To properly bound the environmental Table 1 lists the minimum and maximum allowable flight
requirements for this phase of the mission, EDL temperatures for a subset of the Powered Descent
performance simulations for various candidate landing Vehicle components. Of these components, the
sites were conducted by the Flight System design team propulsion system has the highest minimum allowable
and worst case descent trajectories for vehicle velocity temperatures. All wetted propulsion components are
required to remain well above the freezing point of the
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

Hydrazine fuel (+2qC), and the +15qC minimum In addition to allowable flight temperature ranges,
requirement provides adequate margin (albeit slightly several components have additional temperature
less that standard practice would dictate). The Mars constraints. The Descent Inertial Measurement Unit has
Lander Engines used on the Descent Stage are qualified a temperature ramp rate requirement of 1qC/min or less
to operate with fuel temperatures as low as +10qC, so of temperature drift during operation. For the Descent
the minimum allowable temperature limit was raised to Stage propellant tanks, an internal diaphragm separates
+25qC. The Rover external components have an the pressurized gas (Helium) from the fuel, and in order
allowable minimum limit of -128qC, owing to the fact that to minimize propellant migration through this diaphragm
the Mars atmosphere on the surface can reach these over the nine months of cruise a temperature gradient is
low temperatures during winter nights. required upon the tank surface. The ullage (i.e. gas-
side) is required to maintain, on average, a temperature
10qC warmer than the fuel side of the tank.

Table 1. Allowable Flight Temperatures for selected


PDV components

AFT Range (qC)


Component Min Max
Telecom
Travelling Wave Tube Amplifier -20 +55
Small Deep Space Transponder -35 +50
Avionics -40 +50
GNC
Figure 7. Descent Stage Components
Terminal Descent Sensor -30 +50
Descent Inertial Measurement Unit -9 +35

Pressurant Control Assy


Power
Thermal Batteries -40 +35
Baseload Resistor Assembly -50 +60
Propulsion
Fuel Control Assy Pyrovalve Plate Pyrovalve
Plate Fuel Tanks +25 +45
MLE Lines/Plates/Thruster Valves +25 +45
RCS Lines/Plates/Thruster Valves +15 +50
Reaction Control System (RCS) Mars Lander Engines (MLE)

Pressurant Tanks/Lines +15 +50


Rover
Figure 8. Descent Stage propulsion schematic
External Components -128 +50
MMRTG +65 +185

POWER DISSIPATION – A majority of the avionics and


Guidance, Navigation, and Control components used
during the EDL phase are dormant for the vast majority
of cruise. As discussed previously, the EDL phase lasts
for mere minutes and afterwards the Descent Stage
hardware is discarded and no longer used during
surface operations. Thus, these components are either
unpowered or minimally powered for months of cruise
and then experience a brief period of intense activity
during EDL. Table 2 lists the power dissipation
requirements for the PDV components for both the
Cruise and EDL phases and also details the minimum
Figure 9. Rover Components component masses assumed in our thermal analysis.
For the components that have a variable power
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

dissipation during EDL, the values in the table represent external environments that are either not well
a time-weighted average consistent with total energy characterized or are known to vary widely during the
dissipation. The actual power dissipation profile for course of the mission. Where passive thermal control
these components during EDL is shown in figure 10. could not be employed, redundancy of active thermal
elements was required. Both passive and active thermal
Table 2. Component power dissipation hardware was integrated into the total system design.
requirements and minimum mass assumptions Survival heaters were sized with 20% excess capacity to
ensure that operation duty cycles do not eclipse 80% on-
Component Mass Cruise EDL time. Finally, when assessing temperature margins from
(kg) (Watts) (Watts) allowable flight temperatures, thermal environments
were stacked to produce worst case analyzes. In
Avionics
addition to these general principles, there were three
Power and Analog Module, A 5 43 45 (avg) significant design constraints which shaped the overall
Power and Analog Module, B 5 34 34 thermal design of the MSL Powered Descent Vehicle.
Motor Controller Assembly 10 13 48 (avg)
MMRTG THERMAL MANAGEMENT While
Power Assembly 4 32 92 (avg) Radioisotope Thermoelectric Generators have flown on
Baseload Resistor Assembly 1.5 0 105 several previous deep space exploration missions, most
Guidance, Navigation, & Control
of the previous spacecraft have used direct or indirect
views to deep space to radiate away waste heat. For
Descent Inertial Measurement 2.5 0 34 landed missions such as MSL and NASA’s Viking
Unit missions of the mid-1970s, the RTG power sources are
Terminal Descent Radar, Digital 1.9 0 21 (avg) shaded from direct views to space by the presence of
the protective Aeroshells designed to shield against
Terminal Descent Radar, RF 2.5 0 18 (avg)
aerothermal heat loads upon entry. The thermal design
Telecom of the Viking Landers did allow for rejection of the waste
Travelling Wave Tube Amplifier 1.6 85 85 heat from their RTGs by passively radiating the heat
through their Aeroshell, largely because the waste heat
Small Deep Space Transponder 1.5 17 17 load was modest (1350 Watts total) and distributed (two
[3]
Rover RTGs, each on opposite sides of the spacecraft bus) .
Rover Internals 128 150 156 A passive thermal approach for MMRTG waste heat
MMRTG 20 2000 2000 removal cannot be employed on the MSL mission
because the RTG waste heat load is large at 2000 Watts
and concentrated in a single unit. The effective view
90 270 blockage provided by the Powered Descent Vehicle
DPAM A
240
within the Aeroshell creates a concentrated radiative
Power (W) DMCA and DPA ONLY

75
DPAM B
TDS Digital
heat flux on the Aeroshell and Descent Stage in the
Cruise Stage 210
TDS RF
Separation Event
vicinity of the MMRTG and can produce high
60
DPA
DMCA Entry
180 temperatures on the MMRTG housing and a large
Power (W)

Entry
Event
Event 150
spatial temperature gradient on the Aeroshell. Utilizing
45 thermal conduction paths through the spacecraft
120
structure to reject the waste heat was also not possible,
30 90 since the MMRTG must be thermally isolated from the
60
Rover chassis to maintain internal Rover components
15 within a moderate temperature range. Based on these
30
design constraints, it was concluded that active thermal
0 0:00 0:01 0:02 0:03 0:04 0:05 0:06 0:07 0:08 0:09 0:10 0:11 0:12 0:13 0:14 0:15 0:16 0:17 0:18 0:19 0:20 0:21 0:22 0:23 0:24 0:25 0:26 0:27 0:28 0:29 0:30 0:31
0 control elements were necessary to remove waste heat
0 5 10 15 20 25 30
Time (Minutes) from the MMRTG and transfer it to the Cruise Stage
where it can be rejected to space.

Figure 10. EDL power dissipation profiles for EDL THERMAL TRANSIENT – The EDL phase of the
Descent Stage avionics and GN&C components. mission presents not only widely varying thermal
environments for the MSL spacecraft, but also entails
THERMAL DESIGN APPROACH the largest power dissipation from active components.
The one aspect of EDL that is favorable for the thermal
In developing the overall thermal control design for the design is that it occurs quickly (less than 25 minutes).
MSL Powered Descent Vehicle, a few overarching Rather than attempt to actively compensate for changes
design principles were observed in accordance with in environments and power dissipation levels, the
institutional best practices. In terms of overall design approach of the EDL Transient thermal design is to
philosophy, a passive thermal design was preferred with minimize design complexity by relying on thermal mass
an emphasis on minimizing temperature sensitivity to
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

to moderate temperature excursions during this phase of environment, directed flows of cooled air onto these
the mission. radiators afford similar amounts of heat rejection. An
integrated mechanical pump assembly is located on the
ELECTRICAL SURVIVAL HEATER POWER - As Cruise Stage and produces a flow rate of up to 1.5 liters
previously described, the Descent Stage propulsion per minute within the loop. The cooled fluid exiting the
system is very large and has minimum allowable last radiator is routed to a series of heat exchanger
temperature requirements more stringent than most plates on the Cruise Stage, Descent Stage, and Rover
other components on the spacecraft. As a result, the to remove waste heat from components that are
largest share of survival heater power on the spacecraft powered during the cruise phase of the mission. For the
is devoted to this system. The simplest thermal design Powered Descent Vehicle, these components include
implementation for the propulsion system as a whole the Descent Stage Traveling Wave Tube Amplifier
would be to use the MSL Aeroshell as a thermal cavity (TWTA), Small Deep Space Transponder (SDST),
and maintain the entire PDV at a temperature within the Descent Power and Analog Modules (DPAMs), and
range required by the propulsion components. Descent Power Assembly (DPA).
However, the size of the MSL Aeroshell (4.5 meters in
diameter) and the thermally conductive mechanical
1
connections to the Cruise Stage preclude this approach
from being feasible. It was determined that over 500 Integrated Pump
Watts of survival heater power would be needed at the Assembly
end of the Cruise phase to maintain temperatures above
+25qC throughout the Aeroshell cavity. Instead, the
direction of the thermal design for the Descent Stage
propulsion system was to minimize survival heater
power by thermally isolating the propulsion components
from the Descent Stage structure and applying direct
local heating to component surfaces.

THERMAL DESIGN DESCRIPTION


Cruise
Stage
CRUISE HEAT REJECTION SYSTEM - In order to Radiators
MMRTG Heat
reject the waste heat from the MSL Rover MMRTG Exchanger
Heat
during the cruise phase of the mission, a single-phase Exchanger
mechanically-pumped cooling loop was designed and Tubing Runs
implemented. Similar in concept to the cooling loops Figure 11. Cruise Heat Rejection System (CHRS)
employed on NASA’s Mars Pathfinder[4] and Mars components
Exploration Rover[5,6] missions, the loop circulates liquid
CFC-11 between heat exchangers near thermally The CHRS interface with the Rover occurs on the
dissipating components within the Aeroshell and radiator MMRTG Heat Exchanger plates which flank the sides of
panels populating the Cruise Stage. The heat rejection the MMRTG. Their primary purpose is to capture
system allows for removal of several hundreds of watts radiative waste heat from the MMRTG during the
of steady-state waste heat during both the launch and Surface phase of the mission and use it to warm the
cruise phases. At the onset of the Entry, Descent, and Rover internals. The MSL Rover has a separate
Landing phase, the CFC-11 is vented to space and the mechanically-pumped fluid loop (Surface Heat Rejection
evacuated aluminum tubing running between the Cruise System) to transfer heat from the MMRTG Heat
Stage and PDV is cut prior to the separation of the Exchangers to the Rover. During the cruise phase of
Cruise stage from the entry vehicle. A description of the the mission, the Surface Heat Rejection system serves
preliminary design and development of the Cruise HRS the dual purpose of moving waste heat from the inside of
system may be found in references [7] and [8]. The the Rover to these plates. Thus, the MMRTG heat
discussion here is limited to the form and functionality of exchanger plates effectively serve as another heat load
the mechanically-pumped loop system. on the CHRS system during cruise. Figure 12 shows a
picture of the Cruise and Surface HRS tubing running
Figure 11 shows an exposed view of the approximately side-by-side on the Rover MMRTG Heat Exchanger
40 meters of Cruise HRS tubing on the MSL spacecraft. Plates.
A series of ten radiator panels—painted white and with
double passes of tubing on the backside—ring the The overall capacity of the CHRS system to reject waste
circumference of the Cruise Stage and provide an heat at the designed operational temperature range is
unobstructed view to deep space. In the launch pad approximately 3000 Watts. The 2000 Watts of steady
heat load from MMRTG dominates this capacity with
1
The separation fittings between the Cruise Stage and environmental back loading from solar absorption on the
Descent Stage constitute primary mechanical load paths CHRS radiators contributing up to 400 Watts and
for the spacecraft and are not amenable to thermally spacecraft loads contributing less than 710 Watts. As a
isolating materials or structural design
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

result, the fluid temperatures within the CHRS vary by As previously described, each of the active components
only a moderate amount (less than 50qC) as the MSL on the Powered Descent Vehicle experiences an
spacecraft journeys from Earth to Mars. Figure 13 elevated or maximum power dissipation during the EDL
shows the predicted changes in fluid temperatures at phase of the mission. To complicate matters, the Cruise
various locations in the CHRS loop. HRS system is vented prior to EDL and components that
were once cooled by this system can experience an
accelerated rise in temperature.

The majority of the power dissipating components on the


Descent Stage and Rover also have appreciable mass.
A simple isolated lumped-mass analysis (using full
component masses) indicates that the majority of the
components would experience a temperature ramp rate
of less than 1qC per minute. These include the DPAMs,
the DPA, DMCA, TDS, SDST and the Rover internals.
Since each component is bolted to primary or secondary
structure, additional thermal mass is available to
moderate the temperature rise to some degree.
Likewise, for the brief exposure period to the Mars
atmosphere, the mass of the components and their own
internal dissipation greatly decrease the probability of
Figure 12. Rover Heat Exchanger Plates. Tubing sharp temperature decreases due to convective cooling.
from both the Cruise and Surface Heat Rejection For each of these components, the thermal design is
Systems run side-by-side on the exterior surfaces. passive and relies solely upon thermal mass to
moderate temperature changes. Another detail of the
thermal design for the Descent Stage avionics suite
located directly above the MMRTG is that a MLI blanket
is used to block radiative heating from the MMRTG to
Cruise HRS Radiators the avionics. Due to the large amount of waste heat, the
MMRTG does rapidly warm during EDL. However, its
large maximum allowable AFT (+185qC) allows even a
Min: +32qC Min: -20qC
large temperature rise to occur without violating its
Max: +80qC Max: +21qC
requirement.

There are three active components on the Descent


Min: -10qC Stage (DIMU, BLRA, and TWTA) that do not have
Rover Heat CS/DS Heat
Max: +43qC enough thermal mass from their packaging to remain
Exchanger Exchangers
within their allowable temperature range during EDL.
~1200 Watts ~700 Watts The Baseload Resistor Assembly (BLRA) is used to
stabilize the power bus by drawing a constant load
which grows to be a sizable heat source (105 Watts)
MMRTG ~800 Watts Parasitic during EDL. This component is located on one of the
main structural panels used to hold the Mars Lander
Figure 13. Predicted CHRS fluid temperatures Engines. Due to the mass of this panel (4 kg of
during the cruise phase of the mission. Heat loads aluminum) and the fact that no other power dissipating
are for worst hot case conditions. components are nearby, the effective thermal mass of
the coupling is large enough to moderate the
EDL TRANSIENT THERMAL MASS - The primary temperature rise of the BLRA.
objective of the Powered Descent Vehicle thermal
design for the EDL phase of the mission is to use The DIMU is also located on one of these structural
existing or added thermal mass to dampen thermal panels (see figure 7) and has a lower power dissipation
transients. The relatively short durations of the EDL than the BLRA. However, this component must be
sequence (less than 25 minutes), aerothermal heating operated for hours before the onset of EDL to allow time
event (60 to 145 seconds), and exposure to convection for calibration. It was determined that the operational
within the Mars atmosphere (75 to 260 seconds) serve time for the DIMU required a steady-state thermal
to constrain large temperature swings to only those design and the structural panel was painted white to
components with either large self-heating rates or a serve as a radiator. To ensure the DIMU is kept above
combination of large exposed surface area and low its minimum allowable temperature even when powered
mass. For components that meet these criteria, the down, survival heaters and mechanical thermostats
goal of the thermal design is to shield these components were installed on the structural panel to maintain the
from the environment where possible and add additional interface temperature. In addition to the AFT range, the
mass to their mounting interfaces. DIMU also has a temperature ramp rate requirement of
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

1qC per minute or less. Although not an issue during plates, sixteen thruster engines, and over 30 meters of
cruise, this requirement is problematic for the worst cold fuel line length. The thermal design approach chosen
case environmental conditions during atmospheric for the PDV propulsion system is similar to the design
descent. To isolate the structural panel and DIMU employed on the Mars Exploration Rover Cruise Stage
housing from convection during descent, the front and propulsion system and has four major aspects:
back sides of the structural panel will be covered with a
single layer of reinforced black Kapton sheeting. A 1. Thermal isolation of all propulsion components from
structural covering or “cowl” has also been designed to the spacecraft structure via low thermal
encapsulate the DIMU housing and serve as a conductance mounts
windbreaker. The purpose of both material additions is
to create a thermally isolating gas gap between the 2. Encapsulation of all tanks, plates, and lines with
surfaces of the panel and DIMU and the cold airstream. multi-layer insulation
Both of these materials are designed to have high
emissivity so that radiative heat exchange can still occur 3. Use of film heaters and layers of heat spreading
during cruise. To summarize, the final design (shown in aluminum tape to apply survival heating directly to
figure 14) uses radiation to dump heat, a gas gap to propulsion components
insulate against convection, and thermal mass to
modulate temperature transients. 4. Grouping of components into discrete control zones
with dedicated temperature sensors

The MSL Descent Stage propulsion system is divided


into thirty-four heater zones: eight tank zones, five plate
zones, and twenty-one propellant line zones. The only
zones that are controlled by mechanical thermostats are
White Paint
two of the tank zones (the Helium pressurant tanks) and
one of the plate zones. The remainder use flight
Platinum Resistance Thermometer (PRT)
Kapton Film measurements and flight software commands to control
Heaters
Outrigger the heater circuits. Although flight software control
Panel heaters require more system resources (each zone has
redundant temperature sensors, cabling, and power
switches), the advantage of this approach is the
DIMU
flexibility afforded by thermal control set points that may
be altered after system testing or during the mission.

Thermostats

TWTA Power
Supply

Figure 14. Descent Inertial Measurement Unit


thermal design depiction (with Kapton sheets and
wind cowl removed).

The Travelling Wave Tube Amplifier (TWTA) is a


telecom component which is mounted to a Cruise HRS
heat exchanger plate located on the Descent Stage (see
figure 15). During cruise, the 85 W of waste heat from SDST
the TWTA is managed capably by the CHRS, but once
the system is vented, the TWTA rises sharply in TWTA
temperature. To mitigate this rise, approximately 1 kg of
high specific heat material was installed on the backside
of this plate. The additional thermal mass serves to Figure 15. Descent Stage Telecom Plate
spread the heat from the high heat flux collector head of
the TWTA as well as directly absorb thermal energy. Eight thermal control zones are used to control the five
propellant tanks on the MSL Powered Descent Vehicle.
DESCENT STAGE PROPULSION - Aside from the The three Hydrazine propellant tanks each have two
Cruise and Surface Heat Rejection Systems, the largest separate thermal control zones—one to control the
and most complex thermal control system on the MSL wetted bottom half of the tank and the other to control
Spacecraft belongs to the propulsion subsystem. The the top ullage half. Figure 16 shows a representation of
Powered Descent Vehicle contains the majority of the a Descent Stage propellant tank with film heaters and
propulsion hardware on the spacecraft with three PRT sensors for each zone.
propellant tanks, two pressurant tanks, four component
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

line zones is as follows: six for Mars Lander Engine


feed lines, five for fuel tank interconnects, five for
Mount Ullage Heater Inner Struts Outer Reaction Control System thruster feed lines, two for
Heater Struts pressurant feed lines, and three for service fill and drain
lines. Figure 18 shows the location of each propellant
line zone within a top down view of the Descent Stage
structure.

Film Heaters

Flow control
components
Ullage PRT

Fuel Heaters Fuel PRT


Figure 16. Descent Stage Propellant Tank with
thermal hardware

The DS propellant tanks are attached to the primary


structure through three mounting tabs and a series of
inner and outer struts. The longer inner struts are made
of stainless steel while the shorter outer struts are PRTs
mainly a titanium alloy to afford greater thermal isolation.
The entire surface of the tank will be covered with a Figure 17. Descent Stage Fuel Control Assembly
multi-layer insulation blanket. The outer struts and the Plate with thermal hardware
first few inches of the inner struts will also be blanketed
to reduce parasitic heat leaks. The thermal design for
the DS pressurant tanks is similar, but there is only one
thermal control zone per tank and the heaters are
controlled by mechanical thermostats located near the
mounting strut locations. 1 2
12 13
8 # MLE Lines
The thermal design for the various Descent Stage
20 21 5
propulsion flow control components (valves, filters, 19 # Fuel Inter-
11 connect
pressure transducers, pressure regulators) is divided
10 RCS Lines
into five thermal control zones—one for each of the 18 #
17
Pressurant Control Assembly, Fuel Control Assembly, 7 # Pressurant
16 Lines
Fill and Drain Assembly, and the two Pyrovalve plates.
9 # Service
Each of the plates is thermally isolated from the Descent Lines
Stage primary structure with spacers made from low 6
thermal conductivity materials (polyamide-imide resins
and titanium). Rather than size individual film heaters 14
for each component, two or three film heaters are 15 4 3

attached to the plates along with redundant flight PRTs


to maintain the entire plate assembly above the
minimum allowable flight temperature of any flow control Figure 18. Descent Stage Propellant Lines –
component. The plates are aluminum with a minimum Thermal Zones
thickness of two millimeters and black anodized to
ensure that the survival heat from the film heaters is
The thermal design for each of the line control zones is
distributed along the plates and can both conduct and
similar. The lines are thermally isolated from the
radiate from the plates to the components. The entire
Descent Stage primary structure with structural mounts
front and back side of the plates is covered with MLI to
made from titanium alloy and polyamide-imide resin
create an insulated enclosure and minimize thermal
materials and are individually wrapped with conformal
gradients between components. Figure 17 shows a
MLI blankets. The DS propulsion lines vary in outer
depiction of the Fuel Control Assembly Plate with
diameter (the largest being approximately 32 mm) and
locations for the three plate film heaters and PRTs.
many of the lines have welded in-place elbow or three-
way fittings. The majority of the tubes are thin-walled
A majority of the thermal control zones on the Descent (less than one millimeter thick), stainless-steel tubing,
Stage are used for the thermal design of the Propulsion although some small lengths have thicker walls. The
lines. The apportionment of the twenty-one propellant
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

average line length within a single thermal control zone performance of the thermal control system for the MSL
is approximately one meter in length and all zones have PDV.
at least one line mount tied to structure. As an example,
figure 19 shows the propulsion tubing, fittings, and
mounts of the ninth thermal control zone.

The combination of large radiative surface area, discrete


locations for parasitic losses (i.e. mount locations), and
low axial thermal conductance due to the thin-walled
stainless steel tubing creates a potential problem of
excessive thermal gradients within a given line zone.
Large thermal gradients can lead to over sizing survival
heater power and complicate the task of locating a a) b)
temperature control sensor within a zone. To minimize
potential axial temperature gradients, an approach is
taken to increase axial conductance as well as apply low
heat flux survival heating over the majority of the line
surface area. Prior to application of the heaters, the
tube portions of the line zones will be covered with two
layers of aluminum tape totaling 0.25 mm in thickness.
For a typical 19 mm outer diameter stainless steel tube,
the aluminum tape will increase the axial conductance
by more than a factor of three. The survival heaters will c) d)
be hot-formed, spiral-wound Kapton film heaters which
vary in width from 6 to 16 mm and in pitch from 14 to 42
Figure 20. Descent Stage Propellant Line Thermal
mm, depending on the line diameter size. Due to the
presence of tube fittings and the need for higher heat Hardware: a) bare tubing, b) Aluminum tape, c) heaters
fluxes near mount locations, each propulsion line and PRTs d) MLI wrapping
thermal control zone will consist of multiple film heaters
wired in a combination of series and parallel MSL Spacecraft Cruise Subsystem
configurations. Figure 20 shows photographs of a
mocked-up propulsion line thermal control zone at
various stages of this process.

Descent Rover
Maximum
Predicted
Temperature

PRT
Location

Figure 21. MSL System Level Thermal Model

SYSTEM LEVEL THERMAL MODELING - A system


Figure 19. Example Descent Stage Propellant Line level thermal model of the Cruise and EDL configuration
Thermal Control Zone of the MSL spacecraft was created to assess the
performance of the thermal design in the deep space
DESIGN PERFORMANCE environment. The geometric model of the Powered
Descent Vehicle was created with the Siemens AG NX I-
Assessment of the performance of the MSL Powered deas software package and is shown in figure 21. The
Descent Vehicle thermal design has been achieved by thermal solver used in conjunction with this element
engineering analysis and thermal modeling. The mesh was the TMG Thermal code from MAYA Heat
performance of the flight system will be unique to the Transfer Technologies, Ltd.
final assembly of hardware, and empirical validation of
the overall thermal system design will not be possible Although an attempt was made to simplify the number of
until system level thermal balance tests (scheduled for geometric elements wherever possible, the cruise
late 2008). The following paragraphs describe the configuration spacecraft model is quite large with over
analytical techniques used to assess the designed 10,000 individual elements. While certain areas of the
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

model, such as the Rover chassis and mobility systems, representation of the Descent Stage propellant tanks
do not require high spatial resolution due to small and heaters along with worst case cold temperature
potential for thermal gradients during cruise, other areas predictions.
like the MMRTG, CHRS radiators, and Descent Stage
Propulsion systems were given a larger apportionment
of elements. The characteristic length of the elements
on the PDV model range from 5 to 25 cm and allow for +28°C
resolution of spatial temperature gradients of as high as +50°C
2.5 qC/cm on the MMRTG and 0.5 qC/cm on the
+30°C
remainder of the spacecraft.

In addition to the previously described environmental


parameters, a number of assumptions were made in
construction of the system thermal model in order to +30°C
define the stack-up of worst hot and cold case
+38°C
conditions. For the worst cold case, all external white
painted surfaces were assumed to possess beginning-
of-life properties (0.1 to 0.3 solar absorptance, 0.8 to 0.9 +35°C
infrared emissivity) throughout the mission. Additionally,
separation fittings between the Descent and Cruise
Stages and bolted joints at component interfaces were
assumed to have thermal conductances at the upper
range of expected values (1.5 W/qC). MLI blankets were -25°C
assumed to have effective emittances (H*) at the upper
expected range (0.05 for large blankets, up to 0.15 for Figure 22. Worst hot case Powered Descent Vehicle
Prop line blankets). A similar stack up was performed temperature predictions (early Cruise, 0.975 A.U.,
for the worst hot cases, with optical properties biased to propulsion tanks shown with MLI covering)
induce greatest environmental heat loading and large
conductive couplings to high temperature sinks. For
power dissipating components, a low value of thermal
conductance (0 to 1 W/qC) was used for pinned or bolted -27°C
joints to bound the temperature rise due to self-heating. +50°C

-5°C
CRUISE PHASE TEMPERATURE PREDICTIONS -
Figures 22 and 23 show annotated temperature contour
maps of the worst hot and cold modeling cases,
respectively, for the Powered Descent Vehicle. The
temperature gradient along the structure is primarily due
-15°C
to the approximately 800 W of waste heat radiating from +0°C
the MMRTG. For the worst hot case, few of the Descent
Stage avionics components are dissipating power in
early cruise, so these results reflect a steady-state -11°C
thermal balance between the Cruise Stage and
Aeroshell (warmed by the sun) and the Descent Stage.
In this hot case, the Cruise HRS fluid varies between
+21 and +80 qC, and both the telecom plate and
avionics plate are maintained in the +30 to +35qC range. -50°C
The worst cold case shows a greater thermal gradient
due to the falloff in absorbed solar energy on the
spacecraft. The primary sources of heat within the Figure 23. Worst cold case Powered Descent
Aeroshell are the waste heat from the MMRTG and the Vehicle temperature predictions (late Cruise, 1.63
survival heater power from the propulsion thermal A.U., propulsion tanks shown without MLI covering)
control system. The Cruise HRS fluid varies between -
20 and +32qC, and both the telecom plate and avionics Temperature predictions for selected PDV components
plate are maintained between -10 and -15qC. are listed in Table 3. Each shows at least three degrees
of temperature margin from the minimum or maximum
allowable requirement. The Rover externals show a
In addition to providing predictions for an overall thermal
balance, the system level thermal model was also used large degree of margin (over 80qC) from the minimum
to size the propulsion system survival heaters and locate requirement. As mentioned previously, the Mars surface
the placement of the temperature control sensors for environment is the thermal design driver for the MSL
each zone. Figure 24 shows the system model Rover and the cruise environment is benign to the extent
that finely detailed thermal analysis was not necessary.
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

40.3 C Max 1. Cruise HRS Venting: All thermal links between the
Film CHRS fluid were disconnected, simulating the
Heater
Elements venting of the fluid from the system

2. Cruise Stage Separation: The spacecraft model


spin rotation was set to zero (down from 2 rpm
during cruise) and the elements belonging to the
31.2 C Min Cruise Stage were removed from the model solution.
a)
The solar vector was changed to reflect the
b)
maximum 76 degree off-sun angle post turn-to-entry
maneuver with the direction pointing on the MMRTG
Figure 24. Worst cold case DS Propellant Tank side of the Aeroshell.
temperature predictions (late Cruise, 1.63 A.U.): a)
location of film heater model elements b) prediction of 3. Aerothermal Heating: Rather than model the
tank surface temperature gradients absorption of the aerothermal heat flux and ablation
of the TPS, maximum Aeroshell bondline
Table 3. Cruise phase temperature predictions for temperature requirements were assumed to bound
worst hot and cold analysis cases the analysis. The Heatshield (+250qC), Backshell
(+150qC), and Parachute Cone (+185qC) maximum
Component Cruise/EDL WCC Cruise WCH AFTs were all set as imposed temperature boundary
conditions.
Min Predict Max Predict
AFT AFT
4. Post-Aerothermal Heating Phase: Imposed
Telecom Aeroshell temperature boundary conditions were
TWTA -20 -15 +55 +37 removed from the model and the Aeroshell
temperature was allowed to relax during the
SDST -35 -14 +50 +30 remainder of the transient run.
Avionics
5. Heatshield Separation: To bound the worst hot case
DMCA -40 -24 +50 +38
temperature warm-up, convective cooling was
DPAM -40 -12 +50 +42 neglected. Instead, the Heatshield (facing the DS
DPA -40 -14 +50 +41 and Rover) was set to -30qC to reflect a maximum
Mars atmospheric temperature radiative heat sink
BLRA -50 -31 +60 +26 and effectively remove the Heatshield from the
Guidance, Navigation, & Control model.
TDS RF/HW Stack -30 -27 +50 +28
Figure 25 shows a predicted temperature contour map
DIMU -9 -5 +35 +20 of the Powered Descent Vehicle at the end of the EDL
Propulsion transient analysis. Interface temperatures for most of
the Descent Stage avionics and GN&C components
Fuel Tanks +25 +31 +50 +41
remain well below their maximum allowable flight
MLE Lines +25 +31 +45 +34 temperature limit (+50qC). The thermal mass beneath
Rover the TWTA was sized to meet requirements (+55qC max
AFT) under a stack-up of worst case conditions, so no
Rover External -128 -34 +50 +40
excess margin is present in that design.
MMRTG +65 +111 +185 +148
FORCED CONVECTION ANALYSIS – The system level
EDL TEMPERATURE PREDICTIONS – The system thermal model was not used to predict temperature
level thermal model was also used to asses the drops due to exposure to the Mars atmosphere during
temperature rise in components during the EDL phase. the final portion of Descent and Landing. Due to the
The model was first run in a steady-state mode to very short duration of atmospheric exposure, large scale
determine the worst hot case thermal balance at the system level effects are insignificant when compared to
start of EDL. Model parameters for this run were biased local changes in temperature. Instead, the requirements
in the same manner as the Cruise worst case hot and assumptions for the fluid flow in the atmospheric
analysis but the solar flux was reduced to reflect the 1.5 environment were used with empirical correlations to
A.U. solar range. arrive at convective heat transfer coefficients pertaining
to individual components. These coefficients were then
To reflect the changing EDL thermal environment as used with simple thermal mass models or geometric
depicted in figure 4, a sequence of changes were made sub-models to bound the maximum expected
to the system level model during the transient solution. temperature decrease on a component-by-component
They were as follows: basis.
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

TDS: 10°C propulsion components. The small margins for these


DIMU: BLRA:
+60°C components owe more to the control set points of the
29°C 29°C propulsion survival heaters than any large effect from
convective cooling. The large mass of Hydrazine
propellant (over 380 kg divided between the three tanks)
and the high flow rates through the Propellant lines
during powered descent overpower all convection
Telecom losses.
Plate: 33°C

+25°C

TWTA: DIMU Wind Cowl


55°C DIMU

Structural
DMCA: Single Kapton layer
Panel
46°C DPAM:
35°C
-15°C

Figure 25. Worst hot case Powered Descent Vehicle


temperature predictions (end of EDL, 1.5 A.U.)

The empirical correlation for an averaged convective


heat transfer coefficient is of the form[9]:

hd # C*k/d*(Red)m*(P*Cp/k)1/3
Figure 26. Thermal sub-model of the Descent
where d is a characteristic length for the exposed Inertial Measurement Unit with wind shielding
component, Red is the Reynolds number based upon a thermal hardware.
characteristic length, and viscosity, P; specific heat, Cp;
and thermal conductivity, k are evaluated for the carbon Table 4. Temperature predictions accounting for
dioxide atmosphere at temperature. The empirical convection in the Mars atmosphere during descent.
coefficients C and m are selected based upon the Both possible bounding trajectories (maximum timeline
general planform shape of each component (cylindrical, and maximum initial velocity) are presented.
rectangular, planar, etc.) and the average expected flow
direction (parallel or cross-flow). The resultant average
Component Min AFT Max Max
heat transfer coefficients range from moderately low
qC Time Velocity
(~15 W/m2˜K or commensurate with free convection on
Earth) to very low (less than 1 W/m2˜K just prior to Predict Predict
qC qC
Landing). Thermal analysts for the Mars Viking[3] and
Phoenix[10] missions used convective heat transfer DIMU -9 -5 -4
coefficients in the range of 0.5 to 8 W/m2˜K for their
DIMU – Temp Gradient -1 C/min -0.5 -1 C/min
atmospheric convection analysis which is consistent with C/min
our approach.
DMCA -40 -8 -5
For the Descent Inertial Measurement unit, a more BLRA -50 -13 -11
detailed analysis approach was used to refine the
DPAM/DPA -40 -1 0
design. A geometric sub-model (see figure 26) was
created for the structural mounting panel, the DIMU TDS Digital/RF -30 -10 -7
component, and the shielding provided by the Kapton Telecom Plate -20 -1 +1
film layers and wind cowl. The model was run in
transient mode with distinct heat transfer coefficients MLE Lines +25 +25 +27
applied to the Kapton layers and the wind cowl. The DS Fuel Tanks +25 +31 +31
temperature ramp rate requirement applies at the
mounting interface of the DIMU, so this model was used
to predict the change in the structural panel temperature The intent of the modeling and analysis of the Powered
just below the DIMU mount. Descent Vehicle thermal design was to assess the
robustness of the thermal control system. At this stage
Table 4 shows a summary of the temperature in the design process, this level of verification shows that
predictions based on this convection analysis. A there are no major issues with the overall design
majority of the components show robust margins from approach and all temperature requirements are being
their minimum AFTs with an exception being the met. It is expected that the forthcoming system level
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

thermal vacuum tests will allow an opportunity to refine 2. Edquist, K.T., et al., ”Mars Science Laboratory Entry
and correlate the system level model and verify the Capsule Aerothermodynamics and Thermal
functionality of the implemented thermal hardware. Protection System,” Aerospace Conference, 2007
IEEE, Big Sky, MT, pp. 1-13, March 3-10, 2007.
CONCLUSION 3. Tracey, T.R. and Morey, T.F., “Thermal Design of
th
the Viking Lander Capsule,” AIAA 12 Aerospace
This paper presented an overview of the thermal design Sciences Meeting, Washington D.C., January 30-
philosophy of the MSL Powered Descent Vehicle and February 1, 1974.
described in detail only a limited number of components 4. Bhandari, P., Birur, G.C., and Gram, M.B.,
involved in the Cruise and Entry, Descent, and Landing “Mechanical Pumped Cooling Loop for Spacecraft
phases of the mission. The precision landing systems Thermal Control,” SAE Technical Paper No. 961488,
employed on the MSL spacecraft will be exposed to a 26th International Conference on Environmental
wide range of mission environments from deep space Systems, Monterey, California, July 8-11, 1996.
cruise to atmospheric descent. The main objectives of 5. Ganapathi, G.B, et al., “Active Heat Rejection
the MSL Powered Descent Vehicle thermal design are to System on Mars Exploration Rover – Design
manage large amounts of component waste heat,
Changes from Mars Pathfinder”, Space Technology
minimize electrical survival heater power, and safeguard
Applications International Forum 2003, Albuquerque,
hardware against harsh and somewhat unpredictable
NM, February 2-5, 2003.
thermal environments. The resulting design utilizes and
adapts thermal control technologies and analysis 6. Tsuyuki, G., et al., “The Hardware Challenges for
methodologies from previous Mars landed missions with the Mars Exploration Rover Heat Rejection System,”
the additional technical challenge of extending this AIP Conference Proceedings, Vol 699(1), pp. 59-70.
thermal design over a much larger, more complex, and February 4, 2004.
more integrated spacecraft system. The results of 7. Bhandari, P., Birur G., Prina, M., Ramirez, B., Paris,
system level thermal modeling and analysis indicate a A.D., Novak, K., Pauken, M., “Pumped Fluid Loop
robust thermal design approach and it is expected that Heat Rejection & Recovery Systems for Thermal
the Mars Science Laboratory Powered Descent Vehicle Control of the Mars Science Laboratory,” 17th
will possess a thermal control system capable of Spacecraft Thermal Control Workshop, El Segundo,
maintaining all spacecraft components within allowable CA, March 16, 2006.
temperature ranges. 8. Bhandari P., Birur G., Pauken, M., Paris, A.D.,
Novak, K., Prina, M., Ramirez, B., and Bame, D.,
ACKNOWLEDGMENTS “Mars Science Laboratory Thermal Control
Architecture,” Proc. of 35th International Conference
The work described in this paper was performed at the on Environmental Systems (ICES), Rome, Italy, July
Jet Propulsion Laboratory, California Institute of 11-15, 2005.
Technology, under a contract with the National 9. Incropera, F.P. and DeWitt, D.P., “Introduction to
nd
Aeronautics and Space Administration. The authors Heat Transfer,” 2 ed., John Wiley & Sons, New
wish to acknowledge the many engineers and scientists York, 1990.
collaboratively working on the Mars Science Laboratory 10. Bennington, J. et al., “Phoenix Flight System
project, of which the thermal subsystem is only a part of Thermal Control,” Critical Design Review Document,
the greater whole. Specific acknowledgement is Lockheed Martin Aerospace, November 29, 2005.
extended to members of the MSL Thermal, Mechanical,
Propulsion, and Flight System teams who contributed in
many ways to the work presented here: Jackie Lyra,
CONTACT
Gaj Birur, Mark Duran, Keith Novak, Gordy Cucullu,
Rebecca Mikhalov, Brian Carroll, Jamie Piacentine,
Dr. Anthony D. Paris
Dave Bame, Dan Klein, Tom Rivellini, Ben Thoma, Andy
Jet Propulsion Laboratory
Etters, Mark Rober, Dan Coatta, Robert Usiskin, Carl
M/S 125-109
Guernsey, Morgan Parker, Frank Picha, Ray Baker, Ron
4800 Oak Grove Blvd
Carlson, Al Chen, Beth Dewell, Keith Comeaux, among
Pasadena, CA 91109-8099
others. Gary Kinsella and Siu-Chun Lee are specially
Phone: (818) 393-6732
acknowledged for their diligent and detailed work on the
Fax: (818) 393-6682
integrated thermal design of the MSL Reaction Control
E-mail: Anthony.D.Paris@jpl.nasa.gov
Thruster interface.

REFERENCES
DEFINITIONS, ACRONYMS, ABBREVIATIONS
1. Prakash, R. et al., “Mars Science Laboratory Entry,
Descent, and Landing System Overview”, IEEE AFT: Allowable Flight Temperature
BLRA: Baseload Resistor Assembly
Aerospace Conference, Big Sky, MT, March 1-8,
BUD: Bridle Umbilical Device
2008.
CHRS: Cruise Heat Rejection System
Downloaded from SAE International by Swinburne Univ Of Technology, Thursday, August 09, 2018

DIMU: Descent Inertial Measurement Unit PDV: Powered Descent Vehicle


DMCA: Descent Motor Controller Assembly PRT: Platinum Resistance Thermometer
DPA: Descent Power Assembly RCS: Reaction Control System
DPAM: Descent Power and Analog Module Rover: Mars Science Laboratory Rover
DS: Descent Stage SDST: Small Deep Space Transponder
EDL: Entry, Descent, and Landing SHRS: Surface Heat Rejection System
GN&C: Guidance, Navigation, and Control TDS: Terminal Descent Sensor radar
MLE: Mars Lander Engine TPS: Thermal Protection System
MLI: Multi-layer Insulation TWTA: Travelling Wave Tube Amplifier
MMRTG: Multi-Mission Radioisotope Thermoelectric
Generator
MSL: Mars Science Laboratory
NASA: National Aeronautics and Space Administration

You might also like