STARLight PDR 3 Oct ‘01 G.1.1 Rashid STARLight STARLight Thermal Tahir Rashid STARLight Mechanical Engineer (734)

STARLight PDR 3 Oct ‘01 G.1.2 Rashid STARLight Thermal Requirements – During 1.5 second integration period, thermal stability across one receiver module must be < 11mK – Thermal stability across one AD module must be < 1 K – Temperature can vary between adjacent modules – Ambient temperatures -30  C to 40  C – Thermal control system to use less than 100 W Aircraft Power – Simple and cost-effective Setpoint Operational Conditions – Y-Thermal Plate Setpoint Values: -20  C to 30  C – Receiver Thermal Plate Setpoint Values: 2  C higher than Y-Plate – Tolerance Range of Setpoint:  0.1  C – Fluid Setpoint 1  C lower than Y-plate setpoint

STARLight PDR 3 Oct ‘01 G.1.3 Rashid STARLight Thermal Model Development Objective: – Does this design meet requirements for thermal stability? – How well does system meet control setpoint? – Estimate of time constant (in-flight & on- ground)

STARLight PDR 3 Oct ‘01 G.1.4 Rashid STARLight Thermal Model Development Thermal Network

STARLight PDR 3 Oct ‘01 G.1.5 Rashid STARLight Time Constants & Stability – Estimate of Time Constants & Stability once setpoint is achieved.

STARLight PDR 3 Oct ‘01 G.1.6 Rashid STARLight Time Constants & Stability – Def’n - Amount of time to reach setpoint value depends on:  Is temperature within tolerance range of Setpoint:  0.1  C  Is stability per requirements when within the setpoint range ? Unstable

STARLight PDR 3 Oct ‘01 G.1.7 Rashid STARLight Time Constants & Stability – 1  C Temperature Change during Flight Conditions (0.02 W)  For Receiver Plate - 5 minutes to reach setpoint 20  C  For Thermal Plate – 17.5 minutes to reach setpoint 20  C

STARLight PDR 3 Oct ‘01 G.1.8 Rashid STARLight Time Constants & Stability

STARLight PDR 3 Oct ‘01 G.1.9 Rashid STARLight Time Constants & Stability – 10  C Temperature Change during Ground Conditions (0.2 W Required)  For Receiver Plate - 10 minutes to reach setpoint -30  C  For Thermal Plate - 34 minutes to reach setpoint -30  C

STARLight PDR 3 Oct ‘01 G.1.10 Rashid STARLight Time Constants & Stability

STARLight PDR 3 Oct ‘01 G.1.11 Rashid STARLight Time Constants & Stability – Temperature Change during Ground Conditions (9 W)  For Receiver Plate - 12 seconds to reach setpoint of -30  C  For Thermal Plate - 36 seconds to reach setpoint of -30  C

STARLight PDR 3 Oct ‘01 G.1.12 Rashid STARLight Time Constants & Stability

STARLight PDR 3 Oct ‘01 G.1.13 Rashid STARLight Model Summary – Thermal stability requirement is achievable – Since sensor module is a sealed-system, no external power will be required during ground operation. Turning on electronics will heat the sensor module very rapidly – Operational Note: Turn cooling system on prior to turning on electronics

STARLight PDR 3 Oct ‘01 G.1.14 Rashid STARLight Thermal Control System (Mechanical) (Dwg#: X2)

STARLight PDR 3 Oct ‘01 G.1.15 Rashid STARLight Thermal Control System (Mechanical) MaCom LNA(0.5W)+Switch(0.288W)LNA (0.5W) + LNA (0.5W) Miteq LNA (1.2W) Plate Setpoint Temp Fluid Temp (0.09 gpm) Fluid Temp (0.18 gpm)

STARLight PDR 3 Oct ‘01 G.1.16 Rashid STARLight Thermal Control System (Mechanical) Op Amp (0.594W) Delay Line (0.132W) 6-Bit A/D (4W) Plate Setpoint Temp Fluid Temp (0.09 gpm) Fluid Temp (0.18 gpm) 16-Bit A/D (0.08W) DAC (1.12W)

STARLight PDR 3 Oct ‘01 G.1.17 Rashid STARLight Thermal Control System (Electrical)

STARLight PDR 3 Oct ‘01 G.1.18 Rashid STARLight Thermal Control System (Electrical) Design meets criteria of Aircraft power < 100W

STARLight PDR 3 Oct ‘01 G.1.19 Rashid STARLight Thermal Control System Summary Design consists of mostly off-the-shelf components (simple & cost-effective) A reduction in flow by ½ across the electronic modules will not affect the required heat transfer Design meets criteria of Aircraft power consumption less than 100W

STARLight PDR 3 Oct ‘01 G.1.20 Rashid STARLight Prototype Testing Perform a Refrigeration Unit Test Objectives – Verify Manufacturer’s Power Ratings under various ambient conditions – Estimate Heat that can be dissipated by the Refrigeration System under extreme ambient conditions(-30  C to40  C) – Examine Effects of Antifreeze on Cold Evaporator Plates

STARLight PDR 3 Oct ‘01 G.1.21 Rashid STARLight Prototype Testing

STARLight PDR 3 Oct ‘01 G.1.22 Rashid STARLight Prototype Testing Perform 2-Channel Prototype Test by using simulated heat loads Objectives – Provide valuable insight into integration of sensor assembly mechanical design, refrigeration unit, and remainder of thermal control components – Determine thermal time constants. – Verify thermal stability at various ambient conditions, including extremes. – Verify thermal stability during sudden ambient changes (thermal shock) – Determine power consumption at various ambients.

STARLight PDR 3 Oct ‘01 G.1.23 Rashid STARLight Schedule (Efforts to CDR) Test refrigeration unit (10/26/01) – NovaKool Refrigeration Unit (Arrived 09/26/01) – Test Procedure ( x1) complete (10/12/01) Status of Other Off-the-Shelf Components – Circulation Pump (Arrived 09/21/01) – Filter – In stock (Delivery by 10/10/01) – Fittings, Tubing,Check Valves, Quick Disconnects,etc – In stock (Deliver by 10/12/01) – Strip Heaters – In stock (Deliver by 10/11/01)

STARLight PDR 3 Oct ‘01 G.1.24 Rashid STARLight Schedule (Efforts to CDR) Manufacture 2-channel prototype hardware – Long-lead item is Aluminum Y-thermal plate (11/09/01)  Dwg completed and provided for quotes – Reservoir  Dwg to be complete by (10/12/01)  Manufactured in-house (10/24/01) – Test stand  Dwg to be complete by (10/26/01)  Manufactured in-house (11/05/01)

STARLight PDR 3 Oct ‘01 G.1.25 Rashid STARLight Schedule (Efforts to CDR) Perform testing of prototype in thermal chamber – Test Procedure Complete by 11/02/01 – Start test using simulated loads (11/12/01) Finish (12/07/01) – Analyze test results (12/14/01) Update Thermal ICD (Doc#: ) (02/08/01)