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AMS Thermal Control System (TCS): A Status Report

AMS Thermal Control System (TCS): A Status Report. Group Leaders: Drj Sun – AIDC, M. Molina – CGS, J. Burger – MIT, J.-R. Tsai – NSPO, L. Cheng – SDU Presented by M. Molina, T.Luan, DrjSun. AMS TCS - main components. TCS Mass budget. Target mass for the TCS = 274 Kg.

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AMS Thermal Control System (TCS): A Status Report

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  1. AMS Thermal Control System (TCS): A Status Report Group Leaders: Drj Sun – AIDC, M. Molina – CGS, J. Burger – MIT, J.-R. Tsai – NSPO, L. Cheng – SDU Presented by M. Molina, T.Luan, DrjSun

  2. AMS TCS - main components

  3. TCS Mass budget Target mass for the TCS = 274 Kg

  4. Gemini structure(radiator backbone)

  5. Main radiators • They provide the sink to most of the electronic units • The wake one provides the sink to the CAB LHP

  6. Radiator cross section

  7. CAB LHP is to be fixed outside the WAKE radiator

  8. Integration jig

  9. Tracker radiators • They provide the sink to the TTCS

  10. Tracker radiator assembly

  11. Zenith radiators • They provide the sink to the Cryocoolers LHP

  12. 4 zenith radiator quadrants

  13. Activities since last TIM (Oct 2006) • STA structural analysis • Inserts specimen construction • TWG activities • test review • Thermal analysis • TCS STA Integration • Work with AIDC • Integration Jig • Test coupon design

  14. STA structural analysis • STA will undergo • Static test with 5 load cases • Modal survey test • JS provided CGS/SDU the load cases and a new model of the USS to be used

  15. First vibration mode, Wake radiator 23 Hz

  16. Max tension force on inserts Main radiator

  17. TENSION TEST 1792 N

  18. Max shear force on inserts Main radiator

  19. SHEAR TEST 5375 N

  20. Max tension force on inserts Tracker radiator

  21. Max shear force on inserts Tracker radiator

  22. 60 samples sent to NASA for testing

  23. Rupture Test Load [Nmm/mm] 34.21 154.61 36.27 27.33 Drum peel test

  24. Rupture Test Load [Kg] 64.61 68.43 54.01 156 65.51 54.21 Flat wise test

  25. Lap shear

  26. Flight loads analysis • When subjected to FM loads inserts will show • Positive margin to tension • Positive margin to shear ONLY with an improved configuration (heavier, i.e. with more glue) • No problem for the STA, because loads are lower • Need of a stronger glue = HOT BONDING

  27. RADIATOR INSERT SPECIMEN TENSION TESTS (Summary Table) CGS Sample Identification Number PLYFORM Sample Identification Number Ultimate Test Load [N] Analysis Limit Load [N] MoS [SF 1.4] Remarks 1 T 06023 ISO1 1841.55 600 600 1.19 2 T 06023 ISO2 1792.78 1.13 3 T 06031 ISO1 2217.25 1.63 4 T 06031 ISO2 2356.70 1.8 5 T 06031 ISO3 2410.88 1.87

  28. RADIATOR INSERT SPECIMEN SHEAR TESTS (Summary Table) CGS Sample Identification Number PLYFORM Sample Identification Number Ultimate Test Load [N] Analysis Limit Load [N] MoS [SF 1.4] Remarks 1 T 06028 ST01 4301.94 3526 -0.12 2 T 06028 ST02 5375.96 3526 -0.088 3 T 06028 ST03 5457.32 3526 -0.1 4 T 06028 ST04 7967.05 3526 0.62 5 T 06028 ST05 6887.25 3526 0.39

  29. Conclusion on inserts testing • A first set of samples has been tested in Italy • OK for the STA • OK for the FM with an improved (heavier) configuration • SOLUTION = Hot bonding process • Cold bonded samples have been sent to NASA for testing and SWG approval • Hot bonded samples will be built and tested by AIDC

  30. Test coupon

  31. Aim of test coupon • Establish and test CGS-AIDC data exchange • Set-up Rohacell sandwich panel technology • Inserts precise positioning • Heat pipes bending and gluing • Skin joining

  32. Inserts • Built by AIDC

  33. Skins joint

  34. Heat pipe • Filled with Ammonia, straight and bent • Profiles only, to be machined at AIDC

  35. Test spec. for the test coupon • Document „AMS-PR-CGS-002“ has been issued and delivered to AIDC • DISTRUCTIVE TESTS ON SPECIMENS • NON DISTRUCTIVE TESTS ON THE TWO TEST COUPONS • Mechanical tests • Thermal tests

  36. Distructive test (1) • The specimens shall be manufactured in according to the following requirements: • Same item materials, coming from the same production lot. • Same surface treatment (according to the Test Coupon Engineering Drawing). • Same item manufacturing procedures. • Same vacuum bag. • Same curing cycle.

  37. Test Type Test Requirement Specimens Quantity INSERT TENSILE ≥ 2350 [N] 15 (TBC) INSERT SHEAR ≥ 7500 [N] 15 (TBC) DRUM PEEL ≥ 5.5 [Nxmm/mm] 5 FLAT-WISE ≥ 610 [N] 5 LAP SHEAR ≥ 37 [N/mm2] 5 Distructive test (2) Reference values

  38. Non-distructive tests • Visual inspection • CMM measurement • Inserts position • Geometrical Tolerances

  39. Thermal test at NSPO • Scope • Determine suitable heat conductance between radiator skin and heat pipes • Details are to be defined by NSPO • Concept: IR Lamp one side, IR camera on the opposite

  40. FM schedule • Integration jig and crate links Jul 2007 • All radiators, brackets and rods Jan 2008 (TBC with AIDC) • Zenith radiator delivery Jun 2008

  41. FM schedule • MLI Mar 2008 • CAB LHP Apr 2008

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