THF-15 Satellite Critical Design Review Team Having Fun THF-15 Satellite Matt Chapin1, Nick Wackel1, Olon Pierce1 The University of Alabama, Tuscaloosa, AL 35487 This report details a critical design proposal for replacing, on orbit, the Thermal Infrared Sensor onboard Landsat 8 to extend its mission design life. Landsat 8 is an American Earth observation satellite developed by NASA Goddard Space Flight Center and the United States Geological Survey. The purpose of this report is to present a feasible design of the propulsion, power, and thermal subsystems for Critical Design Review. I. Overview Landsat 8 is an American Earth observation satellite launched on February 11, 2013. It is a collaboration between NASA and the United States Geological Survey (USGS) with the underlying goal of “monitoring, understanding, and managing the resources needed for human sustainment such as food, water and forests” [1]. Landsat 8 collects multispectral images of Earth’s land surface and Polar Regions. Instrumental in the collection of this data, the Thermal Infrared Sensor (TIRS) conducts thermal imaging of two long-wavelength infrared bands. TIRS was a late addition to Landsat 8 and thus had a relaxed design-life of three years. In order to extend the life of the Landsat 8 mission, NASA and USGS have developed a robot capable of removing and replacing the sensor and request TIRS be retrofitted on orbit. A. Mission Objective The primary objective of the THF-15 satellite is to deliver the robot developed by NASA and USGS to Landsat 8 and ensure successful completion of the TIRS repair. THF-15’s mission will be considered a success if the following criteria are met: 1. 2. 3. THF-15 intercepts Landsat 8 on orbit without severely altering its orbital trajectory and causing structural or electronics damage. THF-15 deploys the repair robot and installs the new TIRS on Landsat 8. THF-15 detaches from Landsat 8 and performs a maneuver to enter a parking orbit. Secondary objectives could be potential consequences of the THF-15 satellite project. For example, successful completion of the primary objective will demonstrate lifespan-extension capabilities for the Landsat project. The Landsat 8 satellite has a lifespan of five to ten years and therefore will require an additional Thermal Infrared Sensor to remain fully operational for the remaining third of its lifespan. B. Schedule The existing TIRS on Landsat 8 will expire in early 2016. Launch of the THF-15 satellite must occur by the end of 2016 to minimize the interruption in Landsat observations. Traditionally, the baseline for minor satellite missions is an operational timeline of less than five years. THF-15 uses this model to estimate time budgets for each phase of the operational timeline. The Conceptual Development Phase will focus on securing government funding by conducting research and performing cost feasibility analysis. A Preliminary Design Review will take place, and upon approval, THF-15 will proceed to the Detailed Development Phase. This phase includes detailed mission design, technology development, and risk mitigation. With most of the necessary technology (i.e. the repair robot and spare TIRS) already developed by NASA and the USGS, THF-15 can reduce the amount of time spent in this phase. The project will then undergo a Critical Design Review, and pending approval, will enter Production and Deployment. This phase contains the manufacturing of the satellite, launch segment, and operational 1 check once THF-15 reaches the target orbit. The THF-15 satellite will then be operated by the USGS until its retirement. Table 1. THF-15 Operational Timeline Phase Description Time Budget Conceptual Development Marketing Research 2 months 4 months Detailed Development Production/Deployment Tech Development/Risk Mitigation Detailed Design Production Launch Ops Check on Orbit 4 months 8 months 5 months 1 month 10 days Operation USGS Control 5 years Retirement Orbit Transfer 1 month As shown above in Table 1, THF-15 will have initial operating capability within two years. This fulfills the requirement of replacing the Thermal Infrared Sensor by the end of 2016. C. Payload The payload of THF-15 is critical to mission success. It consists of two entities: the repair robot and spare Thermal Infrared Sensor, both developed by NASA and the USGS. Each item has a mass and volume associated with it, and these measurements will affect the design of the bus The repair robot is an autonomous device that will remove the existing TIRS from Landsat 8 and install the new one. It will deploy after THF-15 establishes a secure connection to Landsat 8. The robot is designed to be send mission data continuously to the ground station until successful completion of the mission is confirmed. Following completion, the robot with retract into the bus of THF-15 and await further command. The mass of the repair robot given by NASA and the USGS is 100 kilograms. The volume is assumed to be 0.5 cubic meters. The Thermal Infrared Sensor (Fig. 1), one of two sensors utilized by Landsat 8, measures Earth’s surface temperature in two thermal bands. The TIRS uses GaAs Quantum Well Infrared Photodetector arrays, a lower-cost alternative to conventional infrared technology, to detect thermal infrared wavelengths of light. 2 Figure 1. Thermal Infrared Sensor (TIRS) The mass of TIRS is 225 kilograms, and its volume is 2.89 cubic meters. The dimensions are given as 2 x 0.76 x 1.9 meters. D. Bus The THF-15 satellite houses the mission payload, propulsion system, and communications structure. This qualifies it as the bus of the mission architecture. Based on the combined volumes of both payload components, THF-15 is projected to have a volume of 9 cubic meters. The dimensions are given as 2.2 x 1 x 2.1 meters. In order to safely intercept Landsat 8 and attach to the satellite structure, the deployment face of THF-15 must be in the direction of motion. This requires THF-15 to have 3-axis attitude control, with a nadir-facing communications antenna. Due to THF-15’s sun-synchronous orbit, the onboard solar panel will receive constant solar energy to meet the power requirements. The propulsion system, in the form of two pivoting thrusters, provides maneuverability and maintains attitude control. THF-15 also features a reaction wheel that will provide additional attitude control by rotating the satellite by small amounts. This appendage will assure proper alignment of THF-15 and may potentially reduce the amount of fuel needed to complete the mission. 3 II. Propulsion Subsystem A. Delta V Budget The first step to design the propulsion subsystem is developing a delta V budget, an accumulation of orbital maneuvers that THF-15 will be required to complete for mission success. The budget is divided into four phases: insertion, intercept, maintenance, and retirement. Insertion of THF-15 into its target orbit is achieved by a two-stage launch vehicle coupled with a plane change maneuver by the satellite. The intercept phase involves a delta V maneuver that will allow THF-15 to rendezvous with Landsat 8. Orbital maintenance includes atmospheric drag makeup, attitude control, station keeping, and evasive maneuvers. Finally, THF-15 will enter retirement by slowing down until it reaches an altitude of 350 kilometers. 1. Insertion In order to rendezvous with Landsat 8, THF-15 will need to enter the sun synchronous orbit described by Table 2. Table 2. Orbital Parameters Regime Semi-major axis Eccentricity Perigee Apogee Inclination Period Sun-synchronous 7,080.49 kilometers 7.63E-05 708 kilometers 710 kilometers 98.20 degrees 98.83 minutes The delta V requirement for orbital insertion was estimated using the Pythagorean Theorem to calculate the velocity vector at an orbit of 710 km. Figure 1. The orbital speed, which is directed tangent to the orbit, is given by Eq. 1. ππ 2 = π π π + β Eq. (1) Equation 2 is the drop speed due to gravitational acceleration and is directed towards the earth. Taking the sum of the squares gives Eq. 3, which is the estimated delta V requirement to achieve an orbit of 710 km. ππ 2 = 2πβ Eq. (2) βπ = √ππ 2 +ππ 2 Eq. (3) Equation 3 only accounts for reaching the altitude of the target orbit, not the inclination. To incorporate this requirement into the delta V budget, a simple plane change is added to the model. To model for the worst case scenario, the required plane change would be from 0 to 98.2 degrees. The delta V required is given by Eq. 4. π βπ = 2ππ sinβ‘( ) 2 Eq. (4) 4 Table 3 gives the results for the orbital insertion model. The final value is the required delta V to reach the target orbit. Table 3. Orbital Insertion Estimate Orbital Speed Drop Speed Altitude Delta V Plane Change Delta V Insertion Delta V 7.499 km/s 3.732 km/s 8.376 km/s 5.000 km/s 13.38 km/s The launch vehicle chosen is the Atlas V 401, shown in Fig. 2, which contains the Common Core Booster (CCB) and Centaur III (CIII) upper stage. The launch is scheduled for July 2016 from Vandenberg Air Force Base SLC-3E. The CCB is a Pratt & Whitney/NPO Energomash RD-180 engine able to generate 3,827 kN of thrust and a specific impulse (ISP) of 311.1 seconds at sea level. It has an inert mass of 20,743 kg and can hold up to 284,089 kg of propellant. The second stage CIII is also a Pratt & Whitney engine capable of 99.2 kN of thrust and an ISP of 450.5 seconds. It uses four 27 N hydrazine thrusters and eight 40.5 N lateral hydrazine thrusters. The CII is 1,914 kg and carries 20,672 kg of propellant. Figure 2. Atlas V 401 Configuration To calculate the delta V that can be achieved by the Atlas V 401, both stages were considered. Shown in Fig. 1 is the two-stage launch of the Atlas V 401. The CCB burns for 241 seconds and reaches an altitude of 113 km before detaching. The Centaur upper stage will then ignite and reach an altitude of 710 km and inclination of 98.2 degrees. 5 Figure 3. Atlas V 401 Launch Segment The delta V capability of the CCB and CIII were calculated using the Tsiolkovsky rocket equation given by Eq. 5. For the CCB, the initial mass is the total mass at launch including the launch vehicle and satellite. The initial mass for the CIII is the sum of the upper stage and satellite masses. The delta V calculated assumes that all propellant is consumed for that stage. βπ = πΌπ π π0 ln π0 π1 Eq. (5) Table 4 gives the results for exhaust velocity, delta V, and propellant required. As shown below, the total delta V achievable by the Atlas V 401 is 15.76 km/s. This value is greater than the delta V required of 13.38 km/s, so the launch vehicle chosen can achieve the target orbit. Table 4. Orbital Insertion Target Exhaust Velocity Delta V Common Core Booster 113 km 3.054 km/s 6.132 km/s Centaur III 710 km, 98.2 deg 4.419 km/s 9.628 km/s 6 2. Intercept Once THF-15 reaches the target orbit of 710 km and 98.2 degrees, it must rendezvous with Landsat 8 to initiate the repair of TIRS. The delta V requirement accounts for the worst case scenario, where THF-15 and Landsat 8 are separated by a phase of 180 degrees. The intercept is accomplished by THF-15 entering an elliptical phasing orbit to change the time-position along its orbit. Figure 4 shows the concept of an orbit phasing maneuver. Figure 4. Orbital Phasing Maneuver The first step to determining the delta V requirement is to calculate the mean motion, Eq. 6, of Landsat 8 in orbit. The mean motion is a measure of how fast a satellite progresses around its elliptical orbit. In an elliptical orbit the angular velocity is not constant, so mean motion is used as the time-average angular velocity over an orbit. π ππ‘ = √ 3 ππ‘ Eq. (6) Once the mean motion is found, the period of the phase maneuver is calculated by Eq. 7. It is dependent on the number of orbits that the target will complete before rendezvous. The period is for the entire phase orbit, not just one revolution around the Earth. ππ = ππ‘ 2π − βπ ππ‘ Eq. (7) Equation 8 calculates the semi-major axis of the phase orbit using Kepler’s third law of planetary motion. It is dependent on the number of orbits that the interceptor will complete before rendezvous. ππ 2 1 ππ = [π( ) ]3 2πππ Eq. (8) Finally, the delta V requirement is calculated as a two-impulse Hohman transfer where THF-15 will exit, then reenter, its original orbit. The velocity of THF-15 before and after the maneuver is given by Eq. 1, and the phase velocity can be calculated by Eq. 9. Therefore, the required engine impulses are given by 7 Eqs. 10 & 11.The magnitude of each delta V requirement is equal, but the directions are opposite to account for exiting and reentering the original orbit. π=√ 2π π − π ππ Eq. (9) 2π π π βπ1 = √ − −√ π ππ π Eq. (10) π 2π π βπ2 = √ − √ − π π π Eq. (11) Table 5 gives the results for the intercept maneuver. The number of orbits that Landsat 8 and THF-15 complete before rendezvous were iterated to find an acceptable value, with respect to reducing delta V while maintaining a reasonable elapsed time of the maneuver. The values used for calculation were Landsat 8 completing 490 revolutions and THF-15 completing 520. Table 5. Orbital Intercept Delta V Landsat 8 Mean Motion Phase Period Semi-major Axis Delta V 1 Delta V 2 1.060E-3 rad/s 3.073E6 s 7068 km -10.5 m/s 10.5 m/s As shown in the table above, THF-15 will slow down at perigee to enter an elliptical orbit that has a slightly shorter period than the original orbit. The difference between the periods of the original and phasing orbit is 15.24 seconds, and the maneuver will take a little more than 35 days to complete. 3. Maintenance THF-15 will need to be able to maintain its orbit to ensure complete mission success. The delta V budget for orbital maintenance is divided into drag makeup, attitude control, station keeping, and evasive maneuvers. These delta V requirements are typically very small and measured per year. In a low-Earth orbit, frequent collisions of gas molecules with the satellite cause drag. If left unchecked, the altitude of the satellite’s orbit will decay resulting in reentry. The delta V requirement for atmospheric drag makeup is given by Eq. 12. The requirement is given per revolution around the Earth. The drag coefficient is estimated to be 2.2, and the mass of the satellite is 575 kg. The cross-sectional area of THF15 is 5 m2. Atmospheric density at 710 km is 1.47E-13 kg/m3. πΆπ π΄ βπ = π( )ππ΄π π Eq. (12) 8 To meet the THF-15 satellite’s attitude control requirements, low-impulse thrust bits will be used to maintain the orientation. For a 3-axis stabilized spacecraft, such as THF-15, the delta V requirement per year is estimated to be 10 m/s. For Earth observation satellites in a sun-synchronous orbit, the gravitation of the Sun and Moon will affect the orbit. This gravitation will cause inclination changes that need to be compensated for. Solar gravitation is a significant factor for THF-15’s station keeping, and the delta V requirement per year is estimated to be 6 m/s for East/West and 55 m/s for North/South. In addition to orbital maintenance, the delta V budget needs to account for any evasive maneuvers that THF-15 could potentially have. 100 m/s of the budget will be allocated for this. Table 6 gives each delta V requirement for orbital maintenance. Table 6. Orbital Maintenance Delta V Drag Makeup Attitude Control East/West Station Keeping North/South Station Keeping Evasive Maneuvers Delta V Requirement 1.105 m/s per year 10 m/s per year 6 m/s per year 55 m/s per year 100 m/s 4. Retirement Once THF-15 has completed its mission, it will perform a maneuver to decrease its altitude to 350 km. At this altitude, controlled reentry will occur after approximately 217 days. Equation 13 is used to calculate the delta V requirement for this maneuver. π»π − π»π βπ = ππ [ ] 4(π π − π»π ) Eq. (13) The calculated delta V requirement for retirement is 100 m/s. B. Propulsion Subsystem Selection The selection of the propulsion type is based on key performance requirements that impact operation, weight, and cost. Those requirements are the delta V budget and thrust level constraints for orbital insertion and maintenance. With these requirements in mind, reasonable options can be identified for further analysis. 1. Requirements From the delta V budget, the extreme conditions will be used as the initial criteria for selecting the subsystem. The maximum delta V requirement for the onboard propulsion system is 100 m/s. The minimum is 6 m/s per year for East/West station keeping. 2. Options The principal propulsion options for orbit maintenance and attitude control are cold gas, monopropellant, bipropellant, and dual mode. Cold gas systems are extremely simple, but have low performance and are 9 the heaviest system for a given performance level. Monopropellant systems are simple, reliable, and low cost, but also have low performance. Bipropellant and dual mode systems are high performance, but are significantly more complicated than other systems. The main drivers for the selection of the propulsion system are performance, complexity, and weight. Cold gas thrusters would not be able to generate the thrust required to perform the intercept or evasive maneuvers without large mass requirements. Bipropellant systems are complicated and generally used for large thrust maneuvers. THF-15’s mission will not require high thrust levels, so a bipropellant system would not be fully utilized. A monopropellant system would offer the most appropriate level of performance while remaining simple and low-weight. 3. Selection THF-15 will use a monopropellant system for onboard propulsion. One of the common monopropellants used in the space industry is hydrazine, N2H4. Hydrazine is generally used as a low-power propellant for spacecraft maneuvering thrusters. In hydrazine engines, the propellant is passed by a catalyst that causes it to decompose into ammonia, nitrogen gas, and hydrogen gas. Equations 14-16 show the reactions that occur in a hydrazine engine. 3π2 π»4 → 4ππ»3 + π2 Eq. (14) π2 π»4 → π2 + 2π»2 Eq. (15) 4ππ»3 + π2 π»4 → 3π2 + 8π»2 Eq. (15) The first two reactions are exothermic, producing large volumes of hot gas from a small volume of liquid. Thus, hydrazine is an efficient thruster propellant with a vacuum ISP of 225. C. Propulsion Subsystem Architecture 1. Hydrazine Thrusters For thrust operations, the flow of hydrazine is controlled by an electric-solenoid valve. Depending on the thrust requirement, this action may be pulsed or long duration. The pressure in the propellant tank forces hydrazine through the injection tube and into the injection head. The injection tube is bent in a coiled shape that provides flexibility for the tube to handle stresses caused by the temperature disparity between the inlet and injection head. The injection head has bores that uniformly distribute the hydrazine propellant across the front of the upper catalyst bed. A screen between the injection head and the upper catalyst bed prevents catalyst particles from entering the injection head and blocking the bores. The catalyst beds consist of alumina pellets impregnated with iridium that cause the liquid hydrazine to heat to its vaporization point upon contact. The upper and lower catalyst beds are separated by a screen and distinguished by different grain sizes, with the upper having slightly larger grains. The upper bed promotes the decomposition of the liquid or partially evaporated hydrazine, while the lower bed focuses on the partial dissociation of ammonia for efficiency. For most thruster applications requiring high specific impulse, the lowest percentage of ammonia dissociation that can be maintained reliably is between 3040%. Finally, the products of the hydrazine decomposition exit from the chamber through a high expansion nozzle to produce thrust. Figure 5 shows an example of a hydrazine thruster. 10 Figure 5. Hydrazine Thruster THF-15 will have a total of twelve hydrazine thrusters, two per axis for redundancy. 2. Propellant/Pressurant Tank THF-15 is 3-axis stabilized, and therefore requires a propellant orientation method that operates under zero gravity conditions. The simplest way to achieve this is to use high-pressure gas to displace the propellant from its storage tank. Pressure-fed systems are reliable, light-weight, and deliver low to moderate levels of thrust and total impulse. Alternative options are to use a pump or piston, but this requires the use of a turbine or electric motor to drive the system. Pump-fed systems allow for higher thrust and impulse levels, but are more complex and generally used for launch vehicles or upper stages. THF-15 will use the blowdown system model, Fig. 6, with a positive expulsion tank to provide the engines with fuel. Positive expulsion uses an active element, such as bladder or diaphragm, to serve as a barrier between the pressurant gas and liquid propellant. This forces the liquid propellant, without any gas or vapor, into the engine feed lines. Figure 6. Blowdown System There are several available options for positive expulsion tanks. The options that are typically used for spacecraft applications are metal diaphragms, rubber diaphragms, rubber bladders, and metal bellows. 11 Metal diaphragm and bellows tanks are high-weight, high-cost configurations. The metal diaphragm requires a large pressure difference for expulsion, and the metal bellows has low volumetric efficiency. The rubber diaphragm has a smaller pressure difference requirement during expulsion and high expulsion efficiency. The only potential disadvantage of rubber diaphragm tanks is the compatibility with propellant. ATK PSI Operations, the world’s largest manufacturer of propellant and pressurant tanks, has developed a long-term hydrazine compatible diaphragm material, AF-E-332, that has over 30 years of demonstrated use. The diaphragm configuration is preferred over the bladder because of its lighter weight and less severe folding pattern during operation. On a side not, Landsat 8 currently uses a rubber diaphragm tank developed by ATK PSI. To size the propellant tank, the volume of the hydrazine propellant is needed. Using an alternate form of the Tsiolkovsky rocket equation, Eq, 16, the mass of hydrazine required for each delta V maneuver can be found. ππ = π0 ∗ π βπ − ππ Eq. (16) Table 7 lists the required propellant mass for each maneuver. The delta V requirements were calculated over a five year period, which is the maximum lifespan of THF-15. Table 7. Propellant Mass Required Intercept 1 Intercept 2 Drag Makeup Attitude Control East/West Station Keeping North/South Station Keeping Evasive Maneuver Deorbit Propellant Required 3.962 kg 3.943 kg 11.12 kg 15.36 kg 11.12 kg 95.21 kg 31.78 kg 29.79 kg The total mass of hydrazine required for the delta V budget is 194.4 kg. Using a 25% margin of error, the mass of onboard propellant is 250 kg. To find the volume required for the propellant tank, the mass is divided by the density of hydrazine at storage pressure and max operating temperature. The density of hydrazine at these properties is 1021 kg/m 3. Therefore, the required volume is .2449 m3 or 244.9 L. 12 Figure 7. ATK 80514-1 Blowdown Tank The ATK 80514-1, Fig. 7, is a blowdown tank designed to hold 245.8 L of propellant at an operating pressure of 28.41 bar. The pressurant volume for this tank configuration is 69.64 L of Helium. It is constructed of 6A1-4V titanium and has a diameter of 66.04 cm. It has a dry mass of 28.12 kg, which is approximately 8% of the total THF-15 bus mass. If estimating the fuel lines as 10% of the tank mass, THF-15 fuel lines will have a combined mass of 3 kg. 13 III. Power Subsystem The purpose of the electrical power subsystem is to provide, store, distribute, and control spacecraft electrical power. Electrical Power Subsystem Power Source Energy Storage Power Distribution Power Regulation and Control Figure 8. Functional Breakdown for the Satellite’s Power Subsystem When designing the power subsystem, the most important sizing requirements are the demands for average and peak electrical power and the inclination and altitude of the satellite. A. Power Requirements The electrical power loads for mission operations vary from beginning-of-life (BOL) to end-of-life (EOL). For this mission, the end-of-life power demands may need to be reduced to compensate for solar array performance degradation. Calculating the average electrical power needed at EOL will determine the necessary size of the power source. 1. Payload Our payload consists of both a replacement Thermal InfraRed Sensor and the robot that will replace the old sensor with the new one. As both of these have been developed by NASA and the USGS, our satellite does not need to provide power to either of the two payloads. 2. Propulsion The THF-15 will need to be 3-axis stabilized, which will be accomplished with hydrazine thrusters. Each one of these thrusters requires 5 W of power in order to operate. The satellite was designed with a total of twelve thrusters to allow for redundancy. The maximum power budget for the propulsion system was calculated to be 30 W as any maneuver would require at most six thrusters to be fired. 3. Attitude and Control To maintain a 3-axis stabilization, an altitude and control system will be used in conjunction with the onboard propulsion system. The system will use reaction and momentum wheels to allow for pitch axis torqueing and roll and yaw axis passive stability. Gyros and accelerometers will be implemented to maintain a desired level of precision for the orbital profile. Tables 8-9 compare the various sensors and actuators. From the tables, the power budget for the ADCD system is 310 W. 14 Table 8. ADCS Actuators Table 9. ADCS Sensors 4. Telemetry, Tracking, and Command The THF-15 will use a typical X-band communications system. This system allows for necessary redundancy and fulfills the mission requirements for a fixed ground station and a sun-synchronous orbit. From Table 10, the power requirement is found to be 45.4 W. 15 Table 10. Parameters for TT&C Subsystems 5. Command and Data Handling The mission does not include collecting and transferring data and as such, the THF-15 requires only a simple command and telemetry systems. A power budget of 12 W for this subsystem can be found using Table 11. 16 Table 11. C&DH Size, Weight, and Power 6. Thermal The thermal subsystem will have no power requirement and will instead be used to dissipate heat. 7. Power The power subsystem will require power in order to distribute and regulate power across the entire satellite. For a satellite of this size, 5-25% of operating power is required for the power subsystem to perform its functions. To allow for redundancy, the THF-15 has been designed with a power budget of 100 W for the power subsystem, which is 20% of the overall, power onboard the satellite. 8. Structure The satellite structure will not have a power requirement. The overall required power breakdown is shown in Table 12. Table 12. Power Consumption by Subsystem Satellite Subsystem Power Requirement [W] Payload 0 Propulsion 30 Attitude and Control 310 Telemetry, Tracking, and Command 45.4 Command and Data Handling 12 Thermal 0 Power 100 Structure 0 Overall Power 497.4 17 B. Power Sources The power source generates electrical power within the satellite. In general, there are four possible types of power sources that could be used. Photovoltaic solar cells convert incident solar radiation directly to electrical energy. Static power sources use a heat source for direct thermal-to-electrical conversion. Dynamic power systems also use a heat source to produce electrical power using the Brayton, Stirling, or Rankine cycles. Fuel cells convert the chemical energy of an oxidation reaction to electricity. Table 13 compares the various power source options. Table 13. Comparing Power Sources This mission requires an Earth-orbiting satellite, which does not allow for a nuclear reactor power source due to the threat of nuclear radiation. The satellite requires a relatively constant power consumption rather than large peaks throughout its orbit. Fuel fells could be used to fulfill the mission, but the required fuel tanks would add unnecessary weight. Fuel cells also have a finite amount of potential power production. Solar panels allow for continuous power production in a sun-synchronous orbit, and are known for being rather reliable. 18 C. Solar Array Design Mission life and the average power requirement are the two key design considerations in sizing the solar array for the satellite. The solar system must be sized to meet the power requirements at EOL, due to degradation over life. In order to calculate the solar-array needed for the satellite, the power provided by the solar array during daylight must first be determined. ππ π = ππ ππ ππ ππ + ππ ππ ππ Eq. (17) ππ π β‘: power provided by solar array ππ , ππ βΆβ‘ satellite’s power requirements during eclipse and daylight ππ , ππ βΆβ‘lengths of eclipse and daylight per orbit ππ = 0.65 , ππ = 0.85 βΆ efficiency values for eclipse and daylight for direct energy transfer As this satellite will be in a sun-synchronous orbit, there will not be an eclipse period. Using Eq. 17, the Psa is found to be 585.176 W. Table 14 shows the efficiencies of the three main types of solar cells: silicon, gallium arsenide, and indium phosphide. Table 14. Performance for Solar Cells Gallium arsenide has the highest efficiency and indium phosphide reduces the degrading effects of radiation, but both cost about three times more than silicon. Because cost is a driving factor for completing the mission, silicon will be used as the technology is more reliable and has a lower cost per π watt. Solar panels have a known solar-illumination intensity value of 1367β‘ 2 if the solar radiation is π normal to the surface, which can be used along with a material’s BOL efficiency to calculate the ideal solar cell output performance per unit area, P0. Silicon solar cells have an efficiency of 14% which gives π a P0 value of 202β‘ 2. As this is the ideal value, the realistic power production capability of the π manufactured solar array is needed. An assembled solar array is less efficient than single cells due to design inefficiencies, collectively referred to as inherent degradation, I d. Table 15 shows the inherent degradation values. 19 Table 15. Elements of Inherent Solar Array Degradation At beginning-of-life, a solar array’s power per unit area can be calculated using Eq. 18. ππ΅ππΏ = π0 πΌπ πππ π Eq. (18) ππ΅ππΏ βΆβ‘power at beginning-of-life π0 βΆ solar cell output performance per unit area πΌπ βΆ inherent degradation π βΆ Sun incidence angle between the vector normal to the surface and the Sun line Using an inherent degradation of 0.77 and a worst case Sun incidence angle of 23.5 °, the PBOL is π calculated to beβ‘142.64β‘ 2 . As the mission progresses, the solar array’s performance will degrade. The π life degradation, Ld, for a silicon solar array is as much as 3.75% per year. The actual lifetime degradation can be found using Eq. 19. πΏπ = (1 − ππππππππ‘πππ π ππ‘πππππ‘πβ‘ππππ ) π¦πππ Eq. (19) This gives a lifetime degradation value of 0.826 for the five year mission. Now that the lifetime degradation and power production capability at beginning-of-life are known, the power at end-of-life can be calculated using Eq. 20. ππΈππΏ = ππ΅ππΏ πΏπ Eq. (20) π The power production capability at end-of-life was found to beβ‘117.821β‘ 2. Finally, the required solar π array area to produce the necessary power can be sized. The solar-array area is calculated using Eq. 21. π΄π π = ππ π Eq. (21) ππΈππΏ The resulting Asa for the THF-15 is 4.967β‘π2 . Assuming the worst possible specific power value for solar π panels from Table 13,β‘25β‘ , the mass of the solar array was found to beβ‘23.407β‘ππ. The worst case cost ππ of these solar panels is found to be about $1,760,000 using the specific cost of 3000β‘ $ π from the table. D. Energy Storage As the solar panels aboard the THF-15 will be producing power continuously throughout the entire mission, a way to store the power is required. A secondary battery will be used as this class of battery sacrifices a lower specific energy density for the ability to be recharged. The battery will also work as a backup power source in the event the satellite changes to an undesired attitude. Secondary batteries are shown in Table 16. 20 Table 16. Characteristics of Secondary Batteries The nickel-cadmium secondary battery was chosen as it will fulfill the mission requirements as a backup power source and has a favorable specific energy density. This is also a well-tested and space-qualified battery which is essential for a backup power source. 21 IV. Thermal Subsystem THF-15 will require a thermal subsystem to ensure all onboard components will remain functional throughout the mission and guaranteed mission success. Due to limits on time full thermal analysis will be unavailable, but in discussion with the contractor it has been agreed upon that steady state conditions will be satisfactory for this mission segment. In order to achieve this steady state condition the following formula must be satisfied. πππ + ππππππππ‘ππ − πππ’π‘ = 0 Eq. (22) πππ + ππππππππ‘ππ = πππ’π‘ Eq. (23) Which can easily be simplified to. By using the energy absorbed by the space craft as well as the energy created by the internal parts in the space craft, the overall minimum and maximum temperature of the body of THF-15 can be calculated at a steady state condition. A. Target Temperature Differing components on board the THF-15 will require different temperature ranges to remain operational. Below in Table 17 are the reasonable estimates for both the operational as well as survival temperatures for many of the crucial components. Table 17. Typical Temperature Ranges Component placement within the satellite is crucial, as the elements that can operate in colder conditions can be placed along the colder deep space facing walls, and the components that require more heat can be centralized around others that are generating that heat. As stated a full thermal analyses will be unavailable and we will only be looking at the overall body temperature of the satellite. As seen from the Table 17 above the batteries will be the restricting factor for our satellite with an operational temperature 22 range of 273 – 288 Kelvin. In discussion with the contractor a differing temperature range of 5 degrees higher was settled upon, 278-293 Kelvin, due to the steady state calculations vs. a full thermal analysis. B. Satellite Configuration THF-15 has been designed to carry the replacement TIRS as well as the robot designed for installation, both provided by NASA and the USGS. The dimensions for the THF-15 are 2.2 x 1 x 2.1 m tall, this will provide room for the TIRS (2 x .76 x .19 m) as well as an additional 1.74 m 3 for the replacement robot. The THF-15 will be in sun-synchronous orbit and will always have one nadir facing side as well as one side always facing the sun. Both of these faces will be the larger sides (2.2 x 2.1 m) of the satellite with the goal of absorbing as much heat as possible. The other four sides, with a combined total surface area of 8.6 m2, will always be facing out into deep space radiating off the excess heat. A simple drawing is shown below in Figure 9. Figure 9. Satellite Configuration Diagram 23 C. Thermal Control Options In general there are two different types of ways to control the onboard temperature of a space craft. This first is having an active thermal control system, or ATCS, and the second is a passive control thermal system, PCTS. For this project we will utilized a PCTS to save weight, time, as well as money. Passive control thermal systems are comprised of different insulations as well as coatings that are applied to the outside of the space craft. Different coatings and materials have differing absorptivity, α, and emissivity, ε, properties that can be combined to find the optimal temperature range. Below in Table 18 are the different coatings and their properties we tested for the THF-15. Table 18. Thermal Material Properties α min α max ε S13G-LO .2 .25 .85 Z93 .17 .2 .92 ZOT .18 .2 .91 Chemglaze A276 .22 .28 .88 Chemglaze Z306 .92 .98 .89 3M Black Velvet .97 .97 .84 8 mil Quartz Mirror .05 .08 .8 2 mil Silvered Teflon .05 .09 .66 5 mil Silvered Teflon .05 .09 .78 2 mil Aluminized Teflon .1 .16 .66 5 mil Aluminized Teflon .1 .16 .78 ½ mil .34 .34 .55 1 mil .38 .38 .67 2 mil .41 .41 .75 5 mil .46 .46 .86 .08 .17 .04 Material White Paints Black Paints Optical Solar Reflectors Aluminized Kapton Metallic Vapor Deposited Aluminum 24 Bare Aluminum .09 .17 .07 Vaporized Deposited Gold .19 .3 .03 Anodized Aluminum .25 .86 .45 ¼ mil Mylar Deteriorates Deteriorates .34 Beta Cloth .32 .32 .86 Astro Quartz .22 .22 .8 MAXORB .9 .9 .1 Miscellaneous D. Thermal Calculations In this section the formulas for all calculations will be discussed along with associated values found for the different materials. As stated earlier the driving equation for these calculations is shown below. πππ + ππππππππ‘ππ = πππ’π‘ Eq. (24) 1. Energy In From Sun The first step in designing the thermal system was to determine the amount of heat that was being taken in by THF-15. There are multiple different sources that contribute heat to the satellite while in orbit. The first, being the most obvious, is the direct heat taken in from the sun. One side of THF-15 will always be facing the sun and must be able to absorb the energy without over heating the entire satellite. The equation for energy absorbed from the sun is shown below. ππ π’π = 1367β‘ π€ π2 ∗ π΄π π’π ∗ β‘ πΌπππ‘πππππ Eq. (25) Where π΄π π’π = π΄πππβ‘ππβ‘πππ‘πππππ‘πβ‘πΉπππππβ‘ππ’π Eq. (26) πΌπππ‘πππππ = πΆπππππ πππππππβ‘πππ‘πππππβ‘π΄ππ πππ‘ππ£ππ‘π¦ Eq. (27) This equation was run with all materials using both the minimum and maximum absorptivity, α, to calculate the worst case scenarios. These values can be seen below in Table 19. Table 19. Material Absorptivity Material Minimum (W) Maximum (W) S13G-LO 1271.42 1589.28 Z93 1080.71 1271.42 White Paints 25 ZOT 1144.28 1271.42 Chemglaze A276 1398.57 1778.00 Chemglaze Z306 5848.55 6229.98 3M Black Velvet 6166.41 6166.41 8 mil Quartz Mirror 317.86 508.57 2 mil Silvered Teflon 317.86 572.14 5 mil Silvered Teflon 317.86 572.14 2 mil Aluminized Teflon 635.71 1017.14 5 mil Aluminized Teflon 635.71 1017.14 ½ mil 2161.42 2161.42 1 mil 2415.71 2415.71 2 mil 2606.42 2606.42 5 mil 2924.28 2924.28 Vapor Deposited Aluminum 508.57 1080.71 Bare Aluminum 572.14 1080.71 Vaporized Deposited Gold 1207.85 1907.14 Anodized Aluminum 1589.28 5467.12 ¼ mil Mylar N/A N/A Beta Cloth 2034.28 2034.28 Astro Quartz 1398.57 1398.57 MAXORB 5721.41 5721.41 Black Paints Optical Solar Reflectors Aluminized Kapton Metallic Miscellaneous 26 2. Energy In From Earth The energy taken in from the Earth is divided into two separate categories. There is the heat that is reflected from the earth, albedo, as well as the heat that is naturally given off by the earth. The amount of heat naturally given off as well as the amount of heat reflected by the earth is dependent on the orbit of the satellite. Emitted radiation values as well as the albedo percentage are represented in the figure below. Table 20. Radiation for Orbit Inclination The THF-15 will be at in inclination of around 90 degrees so only the bottom row applies to our calculations. Throughout its period the satellite we receive between 218 and 244 W/m 2 directly radiated from the earth, qradiation. It can also be seen from the above figure that it will receive an albedo of 23-57% of the total reflected heat. The formulas for calculating the energy taken in by the satellite are given below. πππππππ‘ππ = β‘ πππππππ‘πππ ∗ π΄ππππ‘β ∗ πΌπππ‘πππππ Eq. (28) πππππππ = πππππππ ∗ ππππππ ∗ π΄ππππ‘β ∗ β‘ πΌπππ‘πππππ Eq. (29) Where ππππππ‘πππ = πΈπππ‘π‘ππβ‘π πππππ‘πππ πππππππ = 1000β‘ π π2 Eq. (30) Eq. (31) π΄ππππ‘β = π΄πππβ‘ππβ‘πππ‘πππππ‘πβ‘πΉπππππβ‘πΈπππ‘β Eq. (32) πΌπππ‘πππππ = πΆπππππ πππππππβ‘πππ‘πππππβ‘π΄ππ πππ‘ππ£ππ‘π¦ Eq. (33) Because Aearth and αmaterial are the same in both cases, a simplified formula for total Q earth is given below. πππππ‘β = (ππππππ‘πππ + (πππππππ ∗ ππππππ)) ∗ π΄ππππ‘β ∗ πΌπππ‘πππππ Eq. (34) 27 This was calculated for all materials using the minimum and maximum values for emitted radiation, albedo, and absorptivity to find the worst case scenarios. The values are given in Table 21 below. Table 21. Material Radiation Material Minimum (W) Maximum (W) S13G-LO 413.95 940.17 Z93 351.56 752.14 ZOT 372.56 752.14 Chemglaze A276 455.35 1052.99 Chemglaze Z306 1904.18 3685.47 3M Black Velvet 2007.67 3647.86 8 mil Quartz Mirror 103.49 300.85 2 mil Silvered Teflon 103.49 338.46 5 mil Silvered Teflon 103.49 338.46 2 mil Aluminized Teflon 206.98 601.71 5 mil Aluminized Teflon 206.98 601.71 ½ mil 703.72 1278.63 1 mil 786.51 1429.06 2 mil 848.60 1541.88 5 mil 952.09 1729.91 165.58 639.32 White Paints Black Paints Optical Solar Reflectors Aluminized Kapton Metallic Vapor Deposited Aluminum 28 Bare Aluminum 186.28 639.32 Vaporized Deposited Gold 393.25 1128.20 Anodized Aluminum 517.44 3234.48 ¼ mil Mylar N/A N/A Beta Cloth 662.32 1203.42 Astro Quartz 455.35 827.35 MAXORB 1862.78 3384.61 Miscellaneous 3. Energy Generated The last component that makes up the total energy taken in by THF-15 is the actual energy generated on board by the components. The power subsystem lead, Matt Chapin, was consulted with to estimate the energy needed for THF-15 to have a successful mission. For our calculations it was estimated about 497.4 watts of power would be generated, and of that 75% would be given off as heat. This gives us a value of 373.05 watts that needs to be accounted for in the thermal system. 4. Total Energy In The formula for totally energy in is given below, followed by the resulting values for all materials in Table 22. πππ + ππππππππ‘ππ = πππππ‘β + ππ π’π + β‘ ππππππππ‘ππ Eq. (35) πππ + ππππππππ‘ππ = ((ππππππ‘πππ + (πππππππ ∗ ππππππ)) ∗ π΄ππππ‘β ∗ πΌππππ‘ββ‘πππ‘πππππ ) + (1367β‘ β‘πΌπ π’πβ‘πππ‘πππππ ) + (375) π€ π2 ∗ π΄π π’π ∗ Eq. (36) Table 22. Material Total Energy Material Minimum (W) Maximum (W) S13G-LO 2060.38 2904.45 Z93 1807.57 2398.56 ZOT 1891.84 2398.56 White Paints 29 Chemglaze A276 2228.91 3207.98 Chemglaze Z306 8127.73 10290.44 3M Black Velvet 8549.07 10189.27 8 mil Quartz Mirror 796.34 1184.42 2 mil Silvered Teflon 796.34 1285.60 5 mil Silvered Teflon 796.34 1285.60 2 mil Aluminized Teflon 1217.69 1993.85 5 mil Aluminized Teflon 1217.69 1993.85 ½ mil 3240.14 3815.05 1 mil 3577.21 4219.76 2 mil 3830.02 4523.30 5 mil 4251.36 5029.19 Vapor Deposited Aluminum 1049.15 2095.03 Bare Aluminum 1133.42 2095.03 Vaporized Deposited Gold 1976.11 3410.34 Anodized Aluminum 2481.72 9076.31 ¼ mil Mylar N/A N/A Beta Cloth 3071.60 3612.70 Astro Quartz 2228.91 2600.92 MAXORB 7959.19 9481.02 Black Paints Optical Solar Reflectors Aluminized Kapton Metallic Miscellaneous 5. Energy Out With four out of the six sides of THF-15 always facing deep space there is a worry that all heat radiating out of the satellite will leave components on board frozen or below survival temperatures when the satellite reaches its equilibrium. The equation below will yield a Tsatellite based on the radiation formula for a black body. πππ’π‘ = π΄π ππππ ∗ β‘π ∗ β‘ ππππ‘πππππ ∗ (ππ ππ‘πππππ‘π 4 − ππ ππππ 4 ) Eq. (37) 30 Where π΄π ππππ = ππππβ‘π΄πππβ‘πΉπππππβ‘πππππ π = 5.76 ∗ 10−8 β‘( π π2 πΎ 4 Eq. (38) ) Eq. (39) π = ππππ π ππ£ππ‘π¦β‘ππβ‘πππ‘πππππβ‘ππππππβ‘π ππππ Eq. (40) ππ ππππ = 3β‘(πΎ) Eq. (41) Because not all sides facing deep space have to be the same material the equation above was expanded to allow for more customization to narrow down the temperature in which THF-15 would be subject to. πππ’π‘ = (π΄π 1 ∗ π ∗ β‘ ππ 1 ∗ (ππ ππ‘πππππ‘π 4 − ππ ππππ 4 )) + (π΄π 2 ∗ π ∗ β‘ ππ 2 ∗ (ππ ππ‘πππππ‘π 4 − ππ ππππ 4 )) + (π΄π 3 ∗ π ∗ β‘ ππ 3 ∗ (ππ ππ‘πππππ‘π 4 − ππ ππππ 4 )) + (π΄π 4 ∗ π ∗ β‘ ππ 4 ∗ (ππ ππ‘πππππ‘π 4 − ππ ππππ 4 )) Eq. (42) Solving the equation for the temperate of the satellite yields the following. ππ ππ‘πππππ‘π = 4 πππ’π‘ +(π΄π 1 ∗π∗ππ 1 ∗ππ ππππ 4 )+(π΄π 2 ∗π∗ππ 2 ∗ππ ππππ4 )+(π΄π 3 ∗π∗ππ 3 ∗ππ ππππ 4 )+(π΄π 4 ∗π∗ππ 4 ∗ππ ππππ 4 ) √ (π΄π 1 ∗π∗ππ 1 )+(π΄π 2 ∗π∗ππ 2 )+(π΄π 3 ∗π∗ππ 3 )+π΄π 4 ∗π∗ππ 4 ) Eq. (43) And from our stead state condition we know πππ + ππππππππ‘ππ = πππ’π‘ Eq. (44) So πππ’π‘ = ((ππππππ‘πππ + (πππππππ ∗ ππππππ)) ∗ π΄ππππ‘β ∗ πΌππππ‘ββ‘πππ‘πππππ ) + (1367β‘ π€ π2 ∗ π΄π π’π ∗ β‘ πΌπ π’πβ‘πππ‘πππππ ) + (375) Eq. (45) Which can then be substituted into the equation for the temperature of the satellite to solve for the minimum and maximum temperatures of THF-15 based on the differing materials and coatings used on all the sides E. Final Design 1. Properties By following the above equations the thermal design team was able to put together a system that will keep the THF-15 between 279.3 and 290.4 Kelvin. This not only fits perfectly within the goal temperature range of 278 to 293 Kelvin, but also was accomplished using only materials for outer coatings and will not require any extra power and add minimal weight. The design will feature Astro Quartz on both the side facing the earth as well as the side facing the sun, and 2 mil aluminized kapton on all four sides facing deep space. 31 2. Absorbing Sides Astro Quartz was decided on for the two walls that will be absorbing energy because of its constant absorptivity. The difference between worse case hot and worse case cold can only vary by 15 degrees so the amount of energy absorbed by the material, no matter the condition, being constant was a positive quality of all the miscellaneous materials tested. Initial testing was done with the Beta Cloth material but even with all other sides painted white, for maximum emissivity, that spacecraft was reaching about 300 kelvin. With 300 kelvin being directly out of our target range we looked into the next lowest constant absorptivity, which was Astro Quartz. Table 23 below shows all properties and calculated values for the Astro Quartz material. Table 23. Astro Quartz Properties Material α MIN α MAX ε Qearth MIN Qearth MAX Qsun MIN Qsun MAX Qgen Qin MIN Qin MAX Astro Quartz .22 .22 .8 455.35 827.35 1398.57 1398.57 373.05 2226.96 2598.97 32 V. Concept Drawing Figure 10. THF-15 Satellite 33 VI. References A. Atlas V Launch Services User’s Guide http://www.ulalaunch.com/uploads/docs/AtlasVUsersGuide2010.pdf B. Falcon 9 Launch Vehicle Payload User’s Guide http://decadal.gsfc.nasa.gov/pace-201206mdl/Launch%20Vehicle%20Information/Falcon9UsersGuide_2009.pdf C. NASA – Landsat 8 http://www.nasa.gov/mission_pages/landsat/main/#.VDznD_ldXyA D. USGS – Landsat 8 http://landsat.usgs.gov/landsat8.php E. Space Mission Analysis and Design, Third Edition F. Orbital Decay Calculator http://www.lizard-tail.com/isana/lab/orbital_decay/ G. Orbital Mechanics Handout http://ccar.colorado.edu/asen5050/projects/projects_2012/bartkowicz/website/orbital_mechanics_4.html H. ATK PSI Blowdown Tank Data Sheet http://www.psi-pci.com/Data_Sheets_Library/DS514.pdf I. Physical and Chemical Properties of Hydrazine http://webbook.nist.gov/cgi/cbook.cgi?ID=C302012&Units 34