CryoCryo-Cooler Thermal Control System- Cooler Thermal ... · AMS-02 Cryo-Cooler TCS. 15. 5. Thermal Analysis! HOT CASE with 150 W: 52581 52481 52311 52411 52511 52381 52281 52211

AMS-02 TIM, Dr. F. Bodendieck,CGS, Milan, March 2004

AMS-02 Cryo-Cooler TCS

1

Cryo-Cooler Thermal Control SystemCryoCryo--Cooler Thermal Control SystemCooler Thermal Control SystemDr. Frank Bodendieck,

Dr. Reinhard SchlittOHB-System AG, Bremen,

Germany

1. Introduction1. Introduction2. Description of 2. Description of CryoCryo--cooler Thermal Control Systemcooler Thermal Control System3. Main Features of LHP Thermal Mathematical Model3. Main Features of LHP Thermal Mathematical Model4. 4. CryoCryo--cooler Thermal Mathematical Modelcooler Thermal Mathematical Model5. Thermal Analysis5. Thermal Analysis6. Conclusions6. Conclusions



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1. Introduction1. Introduction!! AMS includes 4 AMS includes 4 StirlingStirling Cryogenic Cryogenic

Coolers (Coolers (CryoCryo--Coolers), which Coolers), which extract parasitic heat from the extract parasitic heat from the thermal protection shields of the thermal protection shields of the Helium cooled AMS magnet. Helium cooled AMS magnet.

!! Description of the performed Description of the performed thermal analysis for the AMSthermal analysis for the AMS--02 02 loop heat pipes (LHP), which are loop heat pipes (LHP), which are implemented into the AMS implemented into the AMS CryoCryo--cooler thermal control system.cooler thermal control system.



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2. Description of 2. Description of CryoCryo--cooler Thermal Control Systemcooler Thermal Control System

!! AMS AMS CryoCryo--cooler TCS cooler TCS consists of:consists of:-- LHP evaporator, LHP evaporator, -- pipelines andpipelines and-- condenser connectedcondenser connectedto the Zenith radiatorto the Zenith radiatorpanel. panel.



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2. Description of 2. Description of CryoCryo--cooler Thermal Control Systemcooler Thermal Control System!! The LHP systems can be characterized as follows:The LHP systems can be characterized as follows:

oo AMS contains four separate LHP systemsAMS contains four separate LHP systemsoo Each LHP system consists of:Each LHP system consists of:

-- two two LHPsLHPs (for redundancy reasons)(for redundancy reasons)-- one radiator subone radiator sub--panelpanel

oo The four radiator subThe four radiator sub--panels have identical configurations including identical panels have identical configurations including identical condenser lay outcondenser lay out

oo The four LHP systems can be divided into:The four LHP systems can be divided into:-- Two identical LHP systems serving the two Two identical LHP systems serving the two CryoCryo--Coolers at the lower Coolers at the lower

CryomagnetCryomagnet Assembly rim with longer fluid lines “Long LHP System”Assembly rim with longer fluid lines “Long LHP System”-- Two identical LHP systems serving the two Two identical LHP systems serving the two CryoCryo--Coolers at the upper Coolers at the upper

CryomagnetCryomagnet Assembly rim with shorter fluid lines “Short LHP System”Assembly rim with shorter fluid lines “Short LHP System”

oo Except from the different fluid line length the Long and Short LExcept from the different fluid line length the Long and Short LHP Systems HP Systems have different evaporator dimensions, especially different seizehave different evaporator dimensions, especially different seizes of the s of the compensation chamber. But all LHP Systems have identical mechanicompensation chamber. But all LHP Systems have identical mechanical cal interfaces to the interfaces to the CryoCryo--Cooler.Cooler.



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2. Description of 2. Description of CryoCryo--cooler Thermal Control Systemcooler Thermal Control System!! LHP systems (1/2):LHP systems (1/2):

LHP evaporators

Radiator panels



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2. Description of 2. Description of CryoCryo--cooler Thermal Control Systemcooler Thermal Control System!! LHP systems (2/2):LHP systems (2/2):

LHP evaporator

Cryo-cooler



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3. Main Features of LHP Thermal Mathematical Model (1/4)3. Main Features of LHP Thermal Mathematical Model (1/4)!! The developed LHP TMM is able to simulate transient operational The developed LHP TMM is able to simulate transient operational modes of modes of

entire loop under all spectrums of variations of environmental (entire loop under all spectrums of variations of environmental (i.e. under i.e. under gravity and zerogravity and zero--g conditions) and heat load conditions, including startg conditions) and heat load conditions, including start--up and up and switchswitch--down. It has the following features.down. It has the following features.!! The model nodes unite local conjugate energy, momentum and mass The model nodes unite local conjugate energy, momentum and mass

average balance over the node area.average balance over the node area.!! Transient pressure, mass flow and momentum balance are calculateTransient pressure, mass flow and momentum balance are calculated over d over

entire loopentire loop!! Conductive, flow enthalpy, Conductive, flow enthalpy, radiativeradiative and convective links are calculated and convective links are calculated

over the condenserover the condenser--radiatorradiator!! State of fluid is detected automatically by enthalpy balance at State of fluid is detected automatically by enthalpy balance at any location any location

of entire loop: twoof entire loop: two--phase, pure saturated, subphase, pure saturated, sub--cooled liquid or supercooled liquid or super--heated vapour. heated vapour.

!! The condensation model is based on annular flow with variable thThe condensation model is based on annular flow with variable thickness ickness of condensate film under vapourof condensate film under vapour--liquid interface stress balance.liquid interface stress balance.



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3. Main Features of LHP Thermal Mathematical Model (2/4)3. Main Features of LHP Thermal Mathematical Model (2/4)!! Gravity term is included.Gravity term is included.!! Two evaporator models can be chosen independent from the availabTwo evaporator models can be chosen independent from the availability of ility of

design parameters of evaporator and reservoir from LHP Developerdesign parameters of evaporator and reservoir from LHP Developer. If no . If no details are available, the appropriate uncertain parameters can details are available, the appropriate uncertain parameters can be adjusted by be adjusted by results of ground test.results of ground test.

!! The developed Interfacing Algorithm (IFA) allows LHP The developed Interfacing Algorithm (IFA) allows LHP modelingmodeling at two at two levels:levels:!! low level (LLM, i.e. detailed LHP model) and low level (LLM, i.e. detailed LHP model) and !! high level (HLM, few nodes representative of LLM at higher levelhigh level (HLM, few nodes representative of LLM at higher level). ).

!! AMS LHP model at LLM consists of 5 nodes for evaporator zone, 17AMS LHP model at LLM consists of 5 nodes for evaporator zone, 176 6 nodes for condenser zone , 10 nodes for liquid pipeline and 10 nnodes for condenser zone , 10 nodes for liquid pipeline and 10 nodes for odes for vapour pipeline. The corresponding HLM model consists of 1 node vapour pipeline. The corresponding HLM model consists of 1 node for for evaporator zone and 10 nodes for condenser zone.evaporator zone and 10 nodes for condenser zone.

!! IFA executes necessary exchange between LLM and HLM to guaranteeIFA executes necessary exchange between LLM and HLM to guaranteethe adequate representation of LLM model at high level.the adequate representation of LLM model at high level.



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3. Main Features of LHP Thermal Mathematical Model (3/4)3. Main Features of LHP Thermal Mathematical Model (3/4)!! Nodal layout of the evaporator at LNodal layout of the evaporator at L--levellevel ::

!! These 5 nodes are presented by temperature:These 5 nodes are presented by temperature:!! TqTq:: Temperature of dissipating element (i.e. here Temperature of dissipating element (i.e. here CryoCryo--cooler collar)cooler collar)!! TweTwe:: Temperature of evaporator wallTemperature of evaporator wall!! TifeTife:: Temperature of vapour / liquid I/F in evaporatorTemperature of vapour / liquid I/F in evaporator!! TwrTwr:: Temperature of reservoir wallTemperature of reservoir wall!! TifrTifr:: Temperature of vapour / liquid I/F in reservoirTemperature of vapour / liquid I/F in reservoir

!! The liquid inlet temperature The liquid inlet temperature TleTle is the last node temperature of liquid pipeline.is the last node temperature of liquid pipeline.



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3. Main Features of LHP Thermal Mathematical Model (4/4)3. Main Features of LHP Thermal Mathematical Model (4/4)!! LL--l and Hl and H--l nodal layout of the enlarged AMS l nodal layout of the enlarged AMS cryocoolercryocooler radiatorradiator

159

12

34

56

78

910

1112

1314

1516

1718

1920

21 22 2324 25 26 27 28

29 30 31 32 33 34 3536 37 38 39 40 41 42 43 4445 46 47 48 49 50 51 52 53 54

55 56 57 58 59 60 61 62 63 64 65 66

67 68 69 70 71 72 73 74 75 76 77 78

79 80 81 82 83 84 85 86 87 88 89 90

91 92 93 94 95 96 97 98 99 100 101 102 103

104 105 106 107 108 109 110 111 112 113 114 115 116

117 118 119 120 121 122 123 124 125 126 127

130 131 132 133 134 135 136 137 138 139 140141 142 143 144 145 146 147 148 149 150 151 152

153 154 155 156 157 158 160 161 162

165 166 167 168 169 170 171 172 173 174 175 176

128

16416352181

52281

52381

52481

52581

52111 52211 52311 52411 52511

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet



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4. 4. CryoCryo--cooler Thermal Mathematical Modelcooler Thermal Mathematical ModelMagnet B20116 bottom (reject)

D11000 B17000

T=-192 °C

LHP

Lower I/F of Cu collar D14000

Zenith

Cryo cooler top

D12000

Cryo cooler back

D12100

Passive balance mass

D16000

MLID31600

MERATB31601

MLI D31320

MERAT B31321

Torlon Cylinder D13200

Titanium ring

D13100

GL1 = 0.0008 W/K

GL6 = 0.0032 W/K GL4 = 44.0 W/K

GL10 = f(T)

GL** = 102.5 W/K

GL8 = 0.0536 W/K

GL1 = 0.027 W/K

GL10 = 5.14 W/K

GR = 0.05 . 0.017 m2

GR = 0.05 . 0.096 m2

GR = f(MERAT) GR = f(MERAT)

GL5

= 0

.006

8 W

/K

GL5 = 0.0068 W/K

GL3 = 20.8 W/K

GL5

= 0

.006

8 W

/K

LHP TMM

Temperature Requirements:!! Min. turnMin. turn--on and operational temperature on and operational temperature

of the of the CryoCryo--cooler:cooler: --1010°°CC!! Max. operational temperature of the Max. operational temperature of the

CryoCryo--cooler :cooler : +40 +40 °°CC!! Min. nonMin. non--operational and survival operational and survival

temperature of the temperature of the CryoCryo--cooler:cooler: --40 40 °°CC!! Max. nonMax. non--operational and survival operational and survival

temperature:temperature: +40 +40 °°CC

!! Dissipations:Dissipations:!! Minimum:Minimum: 60 Watts / 60 Watts / cryocoolercryocooler!! Maximum:Maximum: 150 Watts / 150 Watts / cryocoolercryocooler!! Nominal:Nominal: 100 Watts / 100 Watts / cryocoolercryocooler

!! Temperature Requirements:Cryocooler Cold tip

evaporator radiator



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5. Thermal Analysis5. Thermal Analysis!! Environment Cases for the CRYO coolers and the Zenith RadiatorEnvironment Cases for the CRYO coolers and the Zenith Radiator::

Meaning CGS input file: CASE: β Y P R

IF_DATA_B_75-15_15_15_COLD.xls COLD +75 -15 +15 +15IF_DATA_B_75-15-20-15_HOT.xls HOT +75 -15 -20 -15 IFdata_B_0MPA.xls NOMINAL 0 -2 -10 +1 !! LHP and Radiator Material Properties and Main Dimensions:LHP and Radiator Material Properties and Main Dimensions:

Name Dimensions Material ρ [kg/m³]

cp [J/kg K]

λ [W/m K]

Face sheet out t = 1.6 mm Al 2800 879 155 Face sheet in t = 0.3 mm Al 2800 879 155 Radiator core t = 10 mm ROHACELL 52 1500 0.028 LHP tubing lCond ≈ 4,6 m

llong ≈ 2.9 m lshort ≈ 1,3 m

Al SS SS

2800 7900 7900

879 510 510

155 14 14

LHP evaporator 12 mm OD SS 7900 510 14 LHP evaporator flange

100 x 30 x 15

Al 2800 879 155



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5. Thermal Analysis5. Thermal Analysis!! HOT CASE with 60 W:HOT CASE with 60 W:

-30

-25

-20

-15

-10

-5

0

5

10

15

20

25

30

35

40

0 5400 10800 16200 21600 27000 32400 37800 43200 48600 54000

Orbit time [s]

Tem

pera

ture

[°C

]

Cryo bottomCryo topCryo backTitanium ringTorlon CylinderPassive massCu CollarD52111D52181D52211D52281D52311D52381D52411D52481D52511D52581

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet



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52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-20

-15

-10

-5

0

5

10

15

20

25

30

35

40

0 5400 10800 16200 21600 27000 32400 37800 43200 48600 54000

Orbit time [s]

Tem

pera

ture

[°C

]




15


52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-20-15-10-505

10152025303540455055

0 2700 5400 8100 10800 13500 16200 18900 21600 24300 27000

Orbit time [s]

Tem

pera

ture

[°C

]




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5. Thermal Analysis5. Thermal Analysis!! COLD CASE with 100 W:COLD CASE with 100 W:

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-80-75-70-65-60-55-50-45-40-35-30-25-20-15-10-505

10

0 1350 2700 4050 5400 6750 8100 9450 10800

Orbit time [s]

Tem

pera

ture

[°C

]




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-80

-70

-60

-50

-40

-30

-20

-10

Twx (

164)

Twx (

162)

Twx (

160)

Twx (

158)

Twx (

156)

Twx (

154)

Twx (

130)

Twx (

105)

Twx (

80)

Twx (

56)

Twx (

37)

Twx (

25)

Twx (

12)

Twx (

14)

Twx (

33)

Twx (

49)

Twx (

71)

Twx (

95)

Twx (

121)

Twx (

123)

Twx (

98)

Twx (

74)

Twx (

52)

Twx (

17)

Twx (

19)

Twx (

65)

Twx (

89)

Twx (

115)

Twx (

128)

Fluid Nodes

Tem

pera

ture

[°C

]

After 4500 secAfter 22500 sec

Ammonia freezing



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52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-50

-40

-30

-20

-10

0

10

20

0 5400 10800 16200 21600 27000 32400 37800 43200 48600 54000

Orbit time [s]

Tem

pera

ture

[°C

]




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5. Thermal Analysis5. Thermal Analysis!! COLD CASE starting with 100 W and switching to 150 W, if RadiatoCOLD CASE starting with 100 W and switching to 150 W, if Radiator r

Node D52581 is below Node D52581 is below ––6060°°CC

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-70

-60

-50

-40

-30

-20

-10

0

10

0 2700 5400 8100 10800 13500 16200 18900 21600 24300 27000

Orbit time [s]

Tem

pera

ture

[°C

]




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5. Thermal Analysis5. Thermal Analysis!! COLD CASE starting with 100 W and switching to 150 W, if Cu CollCOLD CASE starting with 100 W and switching to 150 W, if Cu Collar ar

is below is below ––1010°°CC

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-80

-70

-60

-50

-40

-30

-20

-10

0

10

0 2700 5400 8100 10800 13500 16200 18900 21600 24300 27000

Orbit time [s]

Tem

pera

ture

[°C

]




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5. Thermal Analysis5. Thermal Analysis!! COLD CASE without Power:COLD CASE without Power:

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-130

-120

-110

-100

-90

-80

-70

-60

-50

-40

-30

-20

-10

0

0 5400 10800 16200 21600 27000 32400 37800 43200 48600 54000

Orbit time [s]

Tem

pera

ture

[°C

]




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5. Thermal Analysis5. Thermal Analysis!! NOMINAL CASE for CRYO Cooler No. 4 with 100 WNOMINAL CASE for CRYO Cooler No. 4 with 100 W ::

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-60-55-50-45-40-35-30-25-20-15-10-505

10152025

0 2700 5400 8100 10800 13500 16200 18900 21600 24300 27000

Orbit time [s]

Tem

pera

ture

[°C

]




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5. Thermal Analysis5. Thermal Analysis!! Substitution Heaters on the Zenith RadiatorSubstitution Heaters on the Zenith Radiator

159

12

34

56

78

910

1112

1314

1516

1718

1920

21 22 2324 25 26 27 28

29 30 31 32 33 34 3536 37 38 39 40 41 42 43 4445 46 47 48 49 50 51 52 53 54

55 56 57 58 59 60 61 62 63 64 65 66

67 68 69 70 71 72 73 74 75 76 77 78

79 80 81 82 83 84 85 86 87 88 89 90

91 92 93 94 95 96 97 98 99 100 101 102 103

104 105 106 107 108 109 110 111 112 113 114 115 116

117 118 119 120 121 122 123 124 125 126 127

130 131 132 133 134 135 136 137 138 139 140141 142 143 144 145 146 147 148 149 150 151 152

153 154 155 156 157 158 160 161 162

165 166 167 168 169 170 171 172 173 174 175 176

128

16416352181

52281

52381

52481

52581

52111 52211 52311 52411 52511

Heater location (TBC)

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet



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5. Thermal Analysis5. Thermal Analysis!! Operating of the Operating of the CryoCryo--Cooler with 100 W during COLD CASE plus Cooler with 100 W during COLD CASE plus

Thermostat Regulated Substitution Heaters of 50 W located near tThermostat Regulated Substitution Heaters of 50 W located near the he Fluid LinesFluid Lines::

52581

52481

52311

52411

52511 52381

52281

52211 52181

52111

Outlet

Inlet

-60

-55

-50

-45

-40

-35

-30

-25

-20

-15

-10

-5

0

5

10

0 2700 5400 8100 10800 13500 16200 18900 21600 24300 27000

Orbit time [s]

Tem

pera

ture

[°C

]




25

6. Conclusions (1/2)6. Conclusions (1/2)!! The following analysis cases were performed for the AMS The following analysis cases were performed for the AMS CryoCryo--cooler cooler

TCS:TCS:!! Worst hot environment case with different power levels of the Worst hot environment case with different power levels of the CryoCryo--

coolerscoolers

!! Worst cold environment case with different power levels of the Worst cold environment case with different power levels of the CryoCryo--coolerscoolers

!! ““TypicalTypical”” environment case with 100 W dissipation of the environment case with 100 W dissipation of the CryoCryo--coolerscoolers

!! Heater / power regulation during worst cold environment case to Heater / power regulation during worst cold environment case to reach reach a radiator temperature above the freezing point of ammoniaa radiator temperature above the freezing point of ammonia



26

6. Conclusions (2/2)6. Conclusions (2/2)!! The temperature requirements for the The temperature requirements for the CryoCryo--cooler collar can be cooler collar can be

fulfilled for the defined worst hot and the fulfilled for the defined worst hot and the ““typicaltypical”” environment cases environment cases with nominal (100 W) or minimum power (60 W) and with maximum with nominal (100 W) or minimum power (60 W) and with maximum power of 150 W during the worst cold case.power of 150 W during the worst cold case.

!! The collar I/F temperature requirement for the worst cold case cThe collar I/F temperature requirement for the worst cold case can not an not be reached with the nominal power of 100W due to the freezing ofbe reached with the nominal power of 100W due to the freezing ofammonia inside the fluid lines of the LHP system. ammonia inside the fluid lines of the LHP system.

!! To avoid the freezing of the ammonia additional power of about 5To avoid the freezing of the ammonia additional power of about 50 W 0 W is necessary, which can be supplied due to additional dissipatiois necessary, which can be supplied due to additional dissipation of n of the the CryoCryo--coolers (switch from 100 W to 150 W), or due to the coolers (switch from 100 W to 150 W), or due to the substitution (startsubstitution (start--up) heaters on the LHP evaporator flanges, or due up) heaters on the LHP evaporator flanges, or due to additional substitution heaters on the Zenith radiator (locatto additional substitution heaters on the Zenith radiator (located ed between the fluid lines). between the fluid lines).

!! The substitution heaters (P = TBD) on the radiator are also needThe substitution heaters (P = TBD) on the radiator are also needed to ed to warmwarm--up the radiator after AMSup the radiator after AMS--02 power off conditions.02 power off conditions.

Documents

CryoCryo-Cooler Thermal Control System- Cooler Thermal ... · AMS-02 Cryo-Cooler TCS. 15. 5. Thermal Analysis! HOT CASE with 150 W: 52581 52481 52311 52411 52511 52381 52281 52211