Small Satellite Thermal Design, Test and Analysis

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ABSTRACT

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1. INTRODUCTION
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1.1. Small Satellites
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1.2. Space Simulation
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1.3. Computational Thermal Analysis
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2. FASTRAC SATELLITES
2.1. FASTRAC Satellite Description
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2.2. FASTRAC Mission
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3. METHODOLOGY
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3.1. Thermal Design
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3.2. Space Environment

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3.2.1. Orbit Sun/Shade Estimation

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3.2.2. Spacecraft Orientation

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3.2.3. Environmental Heat Flux Radiation

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3.3. Thermal Analysis

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Glass
Emissivity

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3.4.4. Test Description
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!

80

Temperature (C)

60
40
20
0

Time

-20
-40
-60
-80
-100

!
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4. RESULTS
!
4.1. Thermal Tests Results
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!

70

Temperature (C)

Temperature (C)

80

100
80
60
40
20
0
-20
-40
-60
-80
-100

50
40
30
20
10
0

-10

10
T-Drop In

20

Time (Hours)

30

40

Min./Max. Acceptable Temp.

10

20

Time (Hours)

Inside COM Box

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30

40

Max/Min Acceptable Temp.

!
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!
!

50
45
40
35
30
25
20
15
10
5
0

120
100

Temperature (C)

Temperature (C)

60

80
60
40
20
0
-20

10
Batteries

20

Time (Hours)

30

Max/Min Acceptable Temp.

40

10
Voltage Regulator

20
Time (Hours)

30

40

Max/Min Acceptable Temp.

'#-.56!HL`![0$?%-6!T6-.$%?05!:63F65%?.56!/.5#&-!:V:!
!

'#-.56!HO`!!S%??65A!:63F65%?.56!/.5#&-!:V:!
!
!

4.2. Test Thermal Analysis

:>6!?>653%$!30/6$!;%@!903F%56/!;#?>!?>6!/%?%!07@65C6/!D503!?>6!?>653%$!9A9$6!?6@?(!!Z&$A!0&6!?>#5/!0D!?>6!@%?6$$#?6!;%@!
30/6$6/1! #&9$./#&-! ?>6! C0$?%-6! 56-.$%?05! X[TY! 70E1! ?>6! 7%??65A! XS,:Y1! %&/! 0&6! ?>#5/! 0D! ?>6! ?%&Q(! ! :0! 6&@.56! ?>6!
?63F65%?.56!F50D#$6!0D!?>6!30/6$!;%@!%99.5%?61!?>6!903F.?%?#0&%$!/%?%!;%@!903F%56/!;#?>!?>6!?6@?#&-!/%?%(!!'#-.56!HM!
@>0;@!?>6!?#36!>#@?05A!0D!?>6!?>653%$!7$%&Q6?!X"=]Y!?6@?!?63F65%?.56!903F%56/!;#?>!?>6!@.5D%96!?63F65%?.56!0D!?>6!"=]!
D503!?>6!30/6$(!!:>6!30/6$!D0$$0;@!?>6!?56&/!0D!?>6!?>653%$!7$%&Q6?(!!'#-.56!Hf!@>0;@!?>6!?#36!>#@?05A!?63F65%?.56!0D!
?>6!S,:!70E!30/6$!%&/!?6@?!/%?%(!!:>6!30/6$!>%@!?>6!@%36!@>%F61!@$0F6@!%@!?>6!?6@?!/%?%!%&/!?>6!?63F65%?.56!F6%Q@!099.5!
%?!?>6!@%36!?#361!7.?!?>656!;656!?63F65%?.56!/#DD656&96@!76?;66&!?>63(!!:>#@!?63F65%?.56!/#DD656&96!;%@!9%.@6/!7A!?>6!
@#3F$#D#9%?#0&!0D!?>6!30/6$!903F%56/!?0!?>6!903F$6E#?A!0D!?>6!@%?6$$#?6(!!:>6!?63F65%?.56!0D!?>6!30/6$!#@!$0;65!?>%&!?>6!
?6@?#&-!?63F65%?.56!7A!%&!%C65%-6!0D!HIiV(!!!
4.3. Orbit Thermal Analysis
:>6! 7%??65#6@! ;656! %7$6! ?0! ;#?>@?%&/! ?>6! 90$/! 9%@6! ?63F65%?.56@1! 7.?! 0C65>6%?6/! /.5#&-! ?>6! >0?! 9%@6! ?63F65%?.56@(!!
'.5?>65!@#3.$%?#0&!@>0;6/!?>%?!%//#&-!%!@3%$$!50?%?#0&!?0!?>6!@%?6$$#?6!%&/!#&956%@#&-!?>6!?#36!#&!?>6!@>%/61!6&%7$6@!?>6!
7%??65#6@!?0!@?%A!;#?>#&!?>6#5!?63F65%?.56!$#3#?@(!
!
!

Temperature (C)

Temperature ( C)

100
80
60
40
20
0
-20
-40
-60
-80
-100
0

10

20
Time (hours)

MLI Temperature History

30

50
45
40
35
30
25
20
15
10
5
0
0

40

Model MLI Temperature History

!
'#-.56!HM`!!"=]!:63F65%?.56!V03F%5#@0&!

10

15

20

25

30

35

40

Time (hours)
Model Battery Box Temperature

Actual Battery Box Temperature

!
'#-.56!Hf`!!S%??65A!S0E!:63F65%?.56!V03F%5#@0&!

!
4.3.1. Hot Orbit Simulation
).5#&-! ?>6! >0?! 9%@61! #&! ;>#9>! ?>6! @%?6$$#?6! ;%@! %?! %&! #&9$#&%?#0&! 0D! OLi! %&/! %?! %&! %$?#?./6! 0D! NII! Q31! ?>6! @%?6$$#?6!
#336/#%?6$A!769%36!>0?1!%&/!F%@@6/!?>6!>0?!?63F65%?.56!$#3#?!0D!?>6!7%??65A!0D!JIiV1!%@!@66&!#&!'#-.56!GI(!!:>6!30/6$!
@?%5?6/!%?!%!?63F65%?.56!0D!GOiV1!%&/!HM!057#?@!;656!@#3.$%?6/(!!<C6&!;#?>!%&!%C65%-6!/#DD656&96!0D!HIiV!76?;66&!?>6!
30/6$! %&/! ?>6! ?6@?! /%?%1! %&/! %&! %C65%-6! ?63F65%?.56! /#DD656&96! 76?;66&! ?>6! #&@#/6! %&/! 0.?@#/6! 0D! ?>6! 7%??65A! 70E! 0D!
N(LOiV!/.5#&-!?>6!>0?!9A9$6@1!?>6!?63F65%?.56!0D!?>6!7%??65A!F%@@6@!?>6!3%E#3.3!7%??65A!$#3#?(!!
40
38

60

Temperature (C)

Temperature (C)

70

50
40

BAT Model Temperature History

30
20

36
34
32
30

BAT Model Temperature History

BAT Model with 10C Correction

28
26
24
22

10
0

500

1000

1500

20

2000

Time (min)

!
'#-.56!GI`!P0?!V%@6!Z57#?!K#3.$%?#0&!;#?>!ZC65>6%?#&-!
S%??65A!:63F65%?.56!P#@?05A!

500

1000

1500

2000

Time (min)

!
'#-.56!GH`!P0?!V%@6!Z57#?!K#3.$%?#0&!;#?>!S%??65A!:63F(!
P#@?05A!;#?>#&!:63F65%?.56!=#3#?@!

!
).5#&-!?>6!>0?!9%@61!%!50?%?#0&!;%@!#&?50/.96/!;>656!?>6!@%?6$$#?6!50?%?6/!%70.?!?>6!):!&053%$!X@66&!#&!'#-.56!OY!%?!%!5%?6!
%?! HI! 56C0$.?#0&@! F65! 057#?! XI(HIb! 56C0$.?#0&@! F65! 3#&.?6Y1! ?>50.->! GG! 057#?@(! ! :>#@! 50?%?#0&! 3#->?! 099.5! /.5#&-! ?>6!
/6F$0A36&?!0D!?>6!@%?6$$#?6!D503!?>6!$%.&9>!C6>#9$6(!!',K:T,V!3.@?!&0?!>%C6!%!50?%?#0&!5%?6!-56%?65!?>%&!N!56CR3#&1!%@!#?!
;0.$/!&0?!76!%7$6!?0!%9g.#56!4WK1!;>#9>!#@!95.9#%$!D05!3#@@#0&!@.996@@(!!,&!#&956%@6!0D!?>6!@>%/6/!56-#0&!0D!?>6!057#?!
;%@!%$@0!&696@@%5A!?0!/6956%@6!?>6!7%??65A!?63F65%?.56(!!'05!?>6!7%??65A!?0!76!;#?>#&!?>6!?63F65%?.56!$#3#?1!Nfm!0D!?>6!
057#?!>%/!?0!76!#&!?>6!@>%/6(!!:>6!7%??65A!?63F65%?.56!>#@?05A!9%&!76!@66&!#&!'#-.56!GH(!!
4.3.2. Cold Orbit Simulation
).5#&-!?>6!90$/!9%@61!?>6!7%??65#6@!;656!%7$6!?0!@?%A!;#?>#&!?>6!70.&/%5A!?63F65%?.56@(!!'#-.56!GG!@>0;@!?>6!?63F65%?.56!
0D!?>6!7%??65A!70E!9A9$#&-!?>50.->!GN!057#?@!@?%5?#&-!%?!%!?63F65%?.56!0D!LiV(!!:>6!%C65%-6!?63F65%?.56!D#5@?!$0;65@!%&/!
?>6&!#&956%@6@!-6&?$A(!!:>#@!#&956%@6!#&!?63F65%?.56!76D056!07?%#&#&-!?>6!?>653%$!7%$%&96!0D!?>6!@F%9695%D?!#@!9%.@6/!7A!
?>6!?>653%$!7$%&Q6?!?5%FF#&-!#&!?>6!>6%?(!!:>6!?>653%$!7%$%&96!#@!%9>#6C6/!;>6&!?>6!>6%?!5%/#%?6/!?0!?>6!@%?6$$#?6!#@!6g.%$!
?0!?>6!>6%?!5%/#%?6/!7A!?>6!@%?6$$#?6(!

:>6!3#&#3.3!7%??65A!?63F65%?.56!#@!OiV!;>#$6!9>%5-#&-(!!,@!@>0;&!#&!K69?#0&!J(G!X'#-(!HfY1!?>6!3#&#3.3!?63F65%?.56!
0D!?>6!30/6$!#@!$0;65!?>%&!?>6!?6@?#&-!?63F65%?.56!7A!%&!%C65%-6!0D!HIiV(!!]&!%//#?#0&1!/.5#&-!?>6!?6@?!?>6!0.?@#/6!0D!?>6!
7%??65A!70E!;%@!%?!%!$0;65!?63F65%?.56!?>%&!?>6!#&@#/6!0D!?>6!7%??65A!70E!/.5#&-!?>6!90$/!9A9$61!7A!%&!%C65%-6!0D!N(OiV!
/.5#&-!?>6!90$/!@0%Q(!!SA!%//#&-!%&!%C65%-6!0D!HN(OiV!?0!?>6!?0?%$!30/6$!?63F65%?.561!;6!07?%#&!%!?63F65%?.56!;#?>#&!?>6!
7%??65A!$#3#?@(!!!
!
40.5

Percentage of Orbit in the

Shade

18

Temperature (C)

16
14
12

BAT Model Temperature History

BAT Model with 10C Correction

10
8
6
4
2
0
0

500

1000

1500

2000

2500

40
39.5
39
38.5
38
300 Km Altitude
330 Km Altitude
360 Km Altitude

37.5
37
36.5
36
35.5
0

Time (min)

10

20

30

40

50

60

Inclination (deg)

!
'#-.56!GG`!V0$/!V%@6!Z57#?!K#3.$%?#0&!;#?>!S%??65A!:63F(!
P#@?05A!;#?>#&!:63F65%?.56!=#3#?@!

!
'#-.56!GN`!!]&9$#&%?#0&!C@(!W6596&?%-6!0D!?>6!Z57#?!#&!?>6!
K>%/6!D05!)#DD656&?!Z57#?!,$?#?./6@!
!

4.3.3. Acceptable Orbits

:>6! @%?6$$#?6! 3.@?! >%C6! %?! $6%@?! Nfm! 0D! ?>6! 057#?! #&! ?>6! @>%/6(! ! '#-.56! GN! @>0;@! @6C65%$! 057#?! %$?#?./6@! %?! /#DD656&?!
#&9$#&%?#0&@! ;>#9>! >%C6! %&! %C65%-6! F6596&?%-6! 0D! ?>6! 057#?! %70C6! Nfm(! ! :>6! 3%E#3.3! %996F?%7$6! 057#?! %$?#?./6! #@! 0D!
NbIQ3(!!S6?%!%&-$6@!;656!9%$9.$%?6/!?0!D#&/!?>6!0F?#3%$!$%.&9>!;#&/0;@1!7.?!?>6A!/#/!&0?!%DD69?!?>6!%C65%-6!F6596&?%-6!
0D!?>6!057#?!?>6!@%?6$$#?6!;0.$/!563%#&!#&!?>6!@>%/6(!!S69%.@6!0D!$0;!#&9$#&%?#0&@!0D!?>6!%996F?%7$6!057#?@1!76?%!%&-$6@!/0!
&0?!$%5-6$A!%DD69?!?>6!@%?6$$#?6!@>%/6/!?#36(!!!
!

5. CONCLUSIONS
!
:>6! @%?6$$#?6! F65D0536/! ;6$$! /.5#&-! ?6@?#&-! %&/! %&%$A@#@(! ! "0@?! 0D! ?>6! @.7@A@?63@! @>0;6/! -00/! ;05Q3%&@>#F! %&/!
56%/#&6@@!D05!@F%96D$#->?(!!'05!',K:T,V_@!3#@@#0&!?0!76!@.996@@D.$1!?>6!@%?6$$#?6!3.@?!>%C6!%?!$6%@?!Nfm!0D!?>6!057#?!#&!
?>6!@>%/6(!!:>#@!$#3#?@!?>6!5%&-6!0D!%$?#?./6!%&/!#&9$#&%?#0&@!0D!?>6!@%?6$$#?6_@!057#?(!!!
5.1. Thermal Vacuum Test
:>6!?>653%$!?6@?!#&/#9%?6/!?>%?!3%&A!@.7@A@?63@!;656!;#?>#&!?>6#5!?63F65%?.56!$#3#?@`!VZ"1!4WK1!Vk)P1!%&/!F0;65(!!
:>6!F50F.$@#0&!@.7@A@?63!;6&?!0C65!?>6!3%E#3.3!?63F65%?.56!$#3#?1!70.&/6/!7A!?>6!C%$C6!3%E#3.3!?63F65%?.56!$#3#?!
/.5#&-!?>6!D#5@?!9A9$6(!!).5#&-!?>6!?6@?!?>6!?>653090.F$6@!;656!F$%96/!0&!?>6!?%&Q!%&/!&0?!0&!?>6!C%$C6@(!!'.?.56!?6@?#&-!
3.@?!#&C0$C6!F$%9#&-!%!?>653090.F$6!0&!?>6!C%$C6@(!!).5#&-!?>6!?>653%$!9A9$6!?6@?!',K:T,V!F50C6/!#?@!3%?65#%$@!%&/!
;05Q3%&@>#F!%56!%7$6!?0!;#?>@?%&/!$%5-6!?63F65%?.56!9>%&-6@!.&/65!90&/#?#0&@!@#3#$%5!?0!@F%96D$#->?(!!',K:T,V!;%@!
0F65%?#0&%$!/.5#&-!?>6!6&?#56!?6@?(!
5.2. Thermal Model
:>6!30/6$!-%C6!?63F65%?.56!F6%Q@!%?!@#3#$%5!?#36@!?>%&!?>6!?6@?!/%?%(!!]?!%$@0!-%C6!@$0F6@!?>50.->!?>6!>0?!%&/!90$/!9A9$6@!
@#3#$%5! ?0! ?>6! ?6@?! /%?%(! ! :>6!30/6$! ?63F65%?.56@!/#/! &0?! 90#&9#/6! 6E%9?$A! ;#?>! ?>6! ?63F65%?.56!/%?%1!%&/! %@@.3F?#0&@!
;656!3%/6!?0!?>6!30/6$!;>6&!5.&&#&-!057#?!@#3.$%?#0&@1!7A!%//#&-!%?!$6%@?!LiV!?0!?>6!30/6$!#&!?>6!90$/!9%@6!@96&%5#0!
%&/!%//#&-!HOiV!?0!?>6!>0?!9%@6!@96&%5#0(!!!
5.3. Orbit Thermal Analysis
:>656!;656!?;0!;05@?!9%@6!@96&%5#0@!?>%?!;656!30/6$6/!?0!#&C6@?#-%?6!?>6!?>653%$!56@F0&@6!0D!?>6!@%?6$$#?6`!>0?!%&/!90$/(!!
:>6!S,:!70E!?63F65%?.56!#@!@6&@#?#C6!?0!?>6!6E?65&%$!>6%?!D$.E!D503!?>6!<%5?>1!K.&!%&/!%$76/0(!!:>#@!@6&@#?#C#?A!#@!9%.@6/!
7A!?>6!F$%9636&?!0D!?>6!70E!&6%5!?>6!6E?65&%$!F%5?!0D!?>6!@?5.9?.56(!!SA!.@#&-!&0&!90&/.9?#C6!6F0EA!0&!?>6!7%??65#6@!;>6&!

F$%96/! 0&! ?>6! 7%??65A! >0$/65! 3#->?! /6956%@6! ?>6! ?63F65%?.56! @;#&-@! ?>6! 7%??65A! 3#->?! 07@65C6! /.5#&-! ?>6! 057#?(! ! ,!
?>653%$! 7$%&Q6?! ;#?>! $6@@! #&@.$%?#&-! $%A65@! 05! ;#?>! -56%?65!0F6&! %56%@! 3#->?! %$@0! >6$F! 0&! /6956%@#&-! ?>6! ?63F65%?.56!
#&@#/6!?>6!@%?6$$#?6(!
!
5.3.1. Hot Case Orbit Simulation
).5#&-!?>6!>0?!9%@61!;#?>!?>6!@.5D%96!0D!?>6!7%??65A!70E!@.7@A@?63!/#569?6/!?0;%5/@!?>6!K.&!%?!%$$!?#36@1!?>6!7%??65A!70E!
0C65>6%?6/(! ! '.?.56! %&%$A@#@! 3.@?! 76! 903F$6?6/! ?0! @>0;! ?>%?! 7A! 56/.9#&-! ?>6! &.3765! 0D! "A$%5! $%A65@! ?>6! %C65%-6!
?63F65%?.56!0D!?>6!@%?6$$#?6!/6956%@6@(!!:>6!S,:!?63F65%?.56!/6956%@6/!D503!?>6!>0?!9%@6!@#3.$%?#0&!%?!I(HIb!5F31!%&/!
?>6! ?#36! #&! ?>6! @>%/6! ;%@! #&956%@6/! ?0! Nfm! 0D! ?>6! 057#?(! ! ',K:T,V! $0;! 7%??65A! ?63F65%?.56! 5%&-61! /6956%@6@! ?>6!
#&9$#&%?#0&!0&!;>#9>!?>6!@%?6$$#?6!9%&!76!#&@65?6/(!!!
!
5.3.2. Cold Case Orbit Simulation
',K:T,V!?>653%$!30/6$!;%@!%7$6!?0!;#?>@?%&/!;05@?!90$/!9%@6!@#?.%?#0&@1!;>#$6!?>6!@.5D%96!0D!?>6!@%?6$$#?6!;%@!/#569?6/!
?0;%5/@!<%5?>!/.5#&-!?>6!K.&!@69?#0&!0D!?>6!057#?1!%&/!%;%A!D503!?>6!<%5?>!/.5#&-!?>6!@>%/6/!@69?#0&!0D!?>6!057#?(!!:>6!
?>653%$!7$%&Q6?!?5%FF6/!>6%?!;>#9>!#&956%@6/!?>6!?63F65%?.56!0D!?>6!@%?6$$#?6!?>653%$!7%$%&96(!
!

ACKNOWLEDGEMENTS
!
:>#@!F%F65!;%@!3%/6!F0@@#7$6!7A!%$$!?>6!@?./6&?@!%&/!F50D6@@05@!%?!?>6!B&#C65@#?A!0D!:6E%@!%?!,.@?#&!;>0!>6$F6/!/6@#-&!
%&/!7.#$/!',K:T,V(!!,$@01!3%&A!?>%&Q@!?0!U,K,_@!20>&@0&!KF%96!V6&?65!D05!$6??#&-!.@!.@6!?>6#5!D%9#$#?#6@!?>50.->0.?!
?>6!?>653%$!9A9$6!?6@?(!!'#&%$$A1!?>6!-.#/%&96!D503!?>6!,#5!'0596!T6@6%59>!]&@?#?.?6!;%@!#&C%$.%7$6!?0!?>6!903F$6?#0&!0D!
',K:T,V(!
!

REFERENCES
H(
P0$?!4(1!K?6;%5?!K(1!"%.$/#&!2(1!V%3F76$$!:(1!<9Q>0DD!W(1!<$3%@5#!P(1!<C%&@!S(1!4%5-!"(1!4566&7%.3!2(1!
=#&D05/!"(1!W00$6!"(1!=#->?@6A!<(!4(1!T%\%!=(!=(1!nT6$%?#C6!U%C#-%?#0&1!"#950/#@9>%5-6!W$%@3%!:>5.@?651!%&/!
)#@?5#7.?6/!V033.&#9%?#0&@!<EF65#36&?@!0&!?>6!',K:T,V!"#@@#0&o!HL?>!,&&.%$!,],,RBKB!V0&D656&96!0&!K3%$$!
K%?6$$#?6@1!!GIIN!
G(
86$9>1!2(8(1!n:>653%$!:6@?#&-!0D!K3%$$!V$%@@!V!KF%96![6>#9$6@`!,!K?./A1o!,],,!Gb?>!:>6530F>A@#9@!
V0&D656&961!P0&0$.$.!P%;%##1!2.&6!HffH!
N(
P0DD3%&1!<5#9!2(1!'0.&?%#&1!4$6&!P(1!n:>6!KA@?63!,FF50%9>!?0!K.996@@D.$!KF%96!"#@@#0&!)6C6$0F36&?o1!20>&!
P0FQ#&@!,W=!:69>&#9%$!)#-6@?1![0$.36!GI1!U.3765!J!XHfffY!
J(
)#%*+,-.%/01!"(!'(1!n'053%?#0&!,.?0&03A!KF%9695%D?!;#?>!:>5.@?!T6$%?#C6!U%C#-%?#0&1!,??#?./6!%&/!V50@@$#&Q!
W50-5%3!:>653%$!:6@?!%&/!,&%$A@#@o1!:>6!B&#C65@#?A!0D!:6E%@!%?!,.@?#&1!:6E%@1!)6963765!GIIO!
O(
4#$30561!)%C#/!4(!1nKF%9695%D?!:>653%$!V0&?50$!P%&/700Qo1!:>6!,650@F%96!W56@@1!<$!K6-.&/01!V,(1!GIIG!
b(
[%$$%/01!)(,(1!n'.&/%36&?%$!0D!,@?50/A&%3#9@!%&/!,FF$#9%?#0&@o1!G&/(!</#?#0&1!:>6!KF%96!:69>&0$0-A!
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