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Acta Astronautica 56 (2005) 161 – 170

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Micro-satellites thermal control—concepts and components


Volodymyr Baturkin∗
National Technical University of Ukraine, Kyiv Polytechnic Institute, Peremogy Pr., 37, Kyiv 03056, Ukraine

Abstract
The main idea of this paper is to present the survey of current tendencies in micro-satellites thermal control concepts that
can be rational and useful for posterior missions due to intensive expansion of satellites of such type. For this purpose, the
available references and lessons learned by the National Technical University of Ukraine during the elaboration of thermal
control hardware for micro-satellites Magion 4, 5, BIRD and autonomous thermal control systems for interplanetary missions
VEGA, PHOBOS have been used. The main parameters taken into consideration for analysis are the satellite sizes, mass,
power consumption, orbit parameters, altitude control peculiarities and thermal control description. It was defined that passive
thermal control concepts are widely used, excepting autonomous temperature regulation for sensitive components such as
batteries, high-precision optics, and some types of sensors. The practical means for realization of passive thermal control
design as multi-layer insulation, optical coatings, heat conductive elements, gaskets are briefly described.
© 2004 Elsevier Ltd. All rights reserved.

1. Introduction mini-satellites (100–500 kg), interplanetary small


missions (< 500 kg). Table 1 presents some tech-
Last years conferences on small satellites activi- nical data for the above considered small-satellite
ties [1,2], the information about currently elaborated groups.
projects and future small-satellite missions planned Certain constraints originating in small-satellite de-
[3] emphasized the actuality of satellites and active signs due to limited mass and power definite available
interest in them. The intensive expansion of small volume for payload and housekeeping systems pro-
satellites could be explained by moderate enough duce the set of requirements for each of the satellite
cost, short time of elaboration and existing possi- systems and for the thermal control system as well.
bility to include the complicated devices like multi- The survey of thermal means used in practice in small-
functional equipment and optical systems as payload. satellite designs, visible perspectives and difficulties
According to small-satellite classification [3], there can be useful to be more oriented in this topic. Main
are the following conditional groups: nano- and pico- attention is devoted to small-satellite group with mass
satellites (< 10 kg), micro-satellites (10–100 kg), less and near 100 kg (micro-satellites), where compro-
mise in the power/mass/volume distribution between
∗ Tel./fax: +380 44 241 75 97. mandatory housekeeping needs and the payload re-
E-mail address: baturkin@carrier.kiev.ua (V. Baturkin). quirements is actual.

0094-5765/$ - see front matter © 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.actaastro.2004.09.003
162 V. Baturkin / Acta Astronautica 56 (2005) 161 – 170

Table 1
Attributes of small-satellite groups

Satellite class Mass (kg) Bus linear sizes (m) Power averaged (W)

Mini 100–500 More than 1 Up to 100


Micro 10–100 0.5–1 Tens
Nano Less than 10 Less than 0.2 Several

number of 2.1. External heat exchange


35 micro satellites per year
(by SSHP 2002)
30
Micro-satellites operate on low Earth circular orbits
25 (450–1200 km) with wide range of NASA  angles
20 and on high elliptical orbits. This means that satellite
15 sides can be exposed to external disturbances as IR
10 Earth radiation, Albedo, Sun. IR and Albedo can be
5 negligible for highly elliptical orbits. The typical max-
0 imal incident fluxes for 550 km orbit for flat surface
with normal to nadir are qIR ∼ 200 W/m2 , qALB,MAX
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003

∼ 450 W/m2 (averaged over orbit < 150 W/m2 ). The


Fig. 1. Launches of micro-satellites in years [3]. Dash line is a eclipse time can reach 0.5 h (circular) up to several
trend linear approximation of flying micro-satellites. hours for elliptic orbits. Most often used attitude con-
trol systems (ACS) are spin attitude control, gravity
and 3-axes stabilization. This means that the satellites
The paper does not cover the analysis of all thermal external light disturbances can be predicted due to ex-
control principles used and their technical embod- act knowledge of its attitude. Spin attitude presumes
iment, as according to [3] (Fig. 1) more than 250 the arrangement of rotation axes perpendicular or par-
micro-satellite launches have been realized during allel to Sun direction; ACS for 3-axes stabilized satel-
1980–2000, and each of them has something spe- lites has to be designed to change, often enough, the
cific. An additional difficulty is the insufficiency of satellite orientation along orbit movement to decide
available descriptions of thermal control details. the intended tasks.

2.2. Thermal concepts


2. Typical micro-satellite thermal concepts
There are three conditional approaches in the
Main principles of space thermal control design, thermal scheme design—autonomous concept, cen-
software and hardware used are collected in [4–11] and tralized concept and combined concept (Fig. 2).
many other works. Nevertheless, namely, the details of Autonomous concept assumes the individual thermal
thermal control system (TCS) design are mostly im- control for each device or group of devices. The
portant in the case when they are embodied in practi- devices/equipment are thermally disconnected from
cally realized projects. each other. The centralized concept guesses the tight
The diverse information about thermal designs is thermal coupling of all units and the use of one
collected by Surrey Satellite Technology Ltd., [2, centralized radiator for external heat exchange. The
p. 417], Technical University of Berlin [2, p. 347], most exploited concept is combined concept, where
by Design Bureau “Pivdenne” [1, p. 437] and other some group of equipments (for example, housekeep-
leading small-satellite space hardware manufacturers ing equipment, satellite bus) has a common thermal
as well. Summarizing, it is possible to emphasize the control, several devices (some payload) are thermally
following regularities. disconnected from satellite bus and use autonomous
V. Baturkin / Acta Astronautica 56 (2005) 161 – 170 163

Fig. 2. Conditional thermal concepts of micro-satellites.

thermal control. The thermal concept defines the way lateral area should be covered with multi-layer insu-
length of heat roaming between the device and the lation MLI (1), area ∼ 0.5–1 m2 . Satellite radiator
aimed radiator and effective thermal mass of satellite temperature is sensitive to unsteadiness of the power
and units. Each of the concepts has its own peculiari- rejected, and roughly 1 W in energy variation causes
ties, depending on the satellite orientation and attitude 1–1.5 K temperature change. The coating of the front
control. For spinning satellite with perpendicular po- satellite area with optical selective coating (OSC)
sition of rotation and Sun light axes (Fig. 2) the exter- with s ∼ 0.2,  ∼ 0.85 allows to reach the radiator
nal sides can be used as a thermal sink, as with a ratio temperature level of 0–30 ◦ C.
s / < 1 the wall temperature will trend to the level Predominant design assumes non-hermetic shell of
of 10–20 ◦ C. The solar cells have the similar optical satellites that requires conductive and radiative means
characteristics, and they can also be used as a thermal for a heat transfer.
sink. For coinciding longitudinal and Sun light axes
(Fig. 2, spinning and 3-axes stabilized satellites) lat- 2.3. Inner thermal tasks
eral satellite surfaces can be used for heat rejecting.
The heat removing can be arranged through one cen- Typical requirements of satellite inner components
tralized radiator (all thermal lines go to it) or several are collected in Table 2 [8]. The most delicate devices
radiators distributed. The tight thermal connection of are batteries, optic instrumentation and individual pay-
all components enlarges the thermal mass of satellite, load. Requirements of average heat generation inside
reduces the temperature non-uniformity throughout the satellite are in the range of 15–40 W. This power
the satellite. Estimating that at power 40 W the area is produced mainly by housekeeping equipment, peak
of the radiator is only 0.15–0.2 m2 and the rest of the heat generation coincides with payload operation and
164 V. Baturkin / Acta Astronautica 56 (2005) 161 – 170

Table 2
Typical thermal requirements

Component name Temperature (◦ C) Peak power (W)

Electrical equipment −10 to +40 Max 10 per unit


Batteries −5 to +15 Up to 20
Consumable gas +9 to +50 —
Microprocessors −5 to +40 Up to 20
Microprocessors −5 to +40 Up to 20
Bearing mechanisms −5 to +40 —
Solar cells −60 to +55 —
Solid-state diodes −60 to +90 —
Orientation sensors −5 to +45 Max 5
Optics 21 Max 10
Payload Individually < 150
Satellite total 250, average 30–60

can reach 200 W; typical housekeeping heat generated


components are board computer, transmitter, ACS, and Fig. 3. Predicted rate of heat flux density for space electronic
batteries. If payload operates constantly, the power components [16].
generation does not change abruptly.
The most temperature sensitive units are battery micro-satellite thermal arrangement can be found on
sets, which should be used in the range of −5– +15 ◦ C. web sites of satellite developers [12–15].
More details about satellite component exploitation
temperatures are presented in [4–10]. Overwhelming
majority of the satellites are built as non-sealing ob- 3. Potential thermal control future tasks
jects, and heat transfer inside is realized by conduc-
tion of structure elements and radiation (black surface The following tasks have been distinguished for
coating  ∼ 0.85). Heat pipes (HP) and high conduc- satellite thermal control: to cool the high power gen-
tive carbon materials are effective means to improve erating components. The future problem is associated
the temperature uniformity. with growing heat dissipation of modern board com-
puter processors reaching 15–30 W with density up to
2.4. Satellite structure concept 100 kW/m2 [16], as seen in Fig. 3; to provide thermal
and geometrically stable mounting places for devices
Two tendencies are noticeable. The first: payload (illustration in Fig. 4 [17]); to ensure the conditions for
and housekeeping are developed and arranged by one operation of payloads with several temperature levels.
institution. In this case it will provide with the thermal The other important direction is miniaturization of
solution for the whole satellite. The second tendency: space equipment that leads to reduction of sizes of all
the multimission satellite bus with changeable payload the components and increase in the heat flux densities
is proposed to the consumer. That means that pay- of thermal control components.
load should be accommodated into the satellite thermal
surroundings. The solar arrays may cover the satel-
4. Software for thermal design
lite outer surface or could be deployable. After open-
ing they can not be re-oriented. The modern micro-
The wide set of the following products is available
satellite will carry the high-precision optics, which is
in the market:
sensitive to satellite structure and geometrical stability,
and this requirement can essentially influence on the 1. Lumped parameter methods: ESATAN (Ther-
structure design. Sometimes interesting details about mXL), SINDA/G/FLUINT, TRASSA,
V. Baturkin / Acta Astronautica 56 (2005) 161 – 170 165

5. the trace ability of mechanical and structural de-


sign changes in the course of project and adequate
modification of thermal model.

5. Thermal hardware

Main thermal control components did not vary


abruptly. For micro-satellites they are mainly passive:
multi-layer insulation, optical coating and finishing,
thermal conductive lines, thermal isolators, heat stor-
Fig. 4. Thermo- and geometry stable payload baseplate of mi-
age, heat pipes, and electrical heaters. Conditional
cro-satellite BIRD [17]: provides the geometrical stability of
mounting places and supports, parallel—precise of optical axes classification of hardware is presented in Table 3.
(± arcmin); provides the comfortable temperature regime for op- Typical multi-layer insulation consists of 20–30 in-
tics (+15–+20 ◦ C); provides heat removal. Courtesy of DLR. ner layers of less than 0.006 mm aluminized Mylar and
innermost and outermost layers 0.025 or 0.05 mm alu-
minized Kapton [7]. The effective emittance depends
2. finite element and finite difference methods: NAS- on discontinuity of MLI blankets, averaged tempera-
TRAN, COSMOS, ANSYS, FLOTHERM, TAS, ture, pressure, and pressing of blankets. The summary
TAK2000, on effective emittance is presented in Fig. 5 [7]. Rec-
3. radiation heat exchange (internal and external): ommended in [7] for draft estimation the value of ef-
ESARAD, TERMICA, TRASYS, RadCAD, fective emittance is 0.03 with tolerance ±0.02. This
SSPTA, OAZIS, value should be precised in the subsequent experi-
4. specific software is very useful for the thermal con- ments.
tact conductance definition, thermoelectric cooler Optical coating and finishing, optical selecting coat-
design, and heat pipe design. ing can provide the value of ration emittance/solar
absorptance 0.1 < /s < 10. Typical optical painting
The following peculiarities and problems can be for low-temperature radiator has s ∼ 0.2,  ∼ 0.85.
discovered during the thermal model preparation: Fig. 6 shows the optical properties for some finishing
and coatings [7].
1. Retrieval information and definition of exact ther- Heat transfer inside the satellite is realized by means
mal properties: thermal conductivity, heat capac- of conduction through structural elements and special
ity, density, uniformity of properties, and temper- conductive lines. Aluminum alloys are used as bus
ature dependence of properties, and conductive lines and heat capacity storage ( =
2. retrieval of information and definition of exact op- 2700 kg/m3 ,  = 150 W/mK, cp = 900 J/kg K), beryl-
tical properties and their variation during exploita- lium as heat transfer and heat storage (=1850 kg/m3 ,
tion  = 180 W/mK, cp = 1850 J/kg K). Conductive lines
• emittance, diffuse reflectivity, specular reflectiv- can be fabricated from flexible copper strings [18,19]
ity, and transmissivity in IR band, as geometrically adjustable thermal conductors (ther-
• absorptance, diffuse reflectivity, specular reflec- mal resistance less than 2 K/W). They allow to con-
tivity, and transmissivity in solar band, jugate the elements with unknown exact layout and
3. definition of realistic values of thermal contacts in permit to reduce the torque on clamping points.
joints, The other very effective heat conductance lines
4. reasonable simplification of thermal structure of are the heat pipes. For space application they are
simulated object, preparation of the thermal loads mostly presented by ammonium axially grooved heat
functions, and choice of heat transfer process func- pipes produced by extrusion, though other types of
tionalities, structures (as metal felts, screens) are used as well.
166 V. Baturkin / Acta Astronautica 56 (2005) 161 – 170

Table 3
Classification of thermal hardware for micro-satellites

Name of hardware Frequency of application

Passive means to regulate the satellite structure temperature level


Radiating surfaces and finishing Often
Multilayer insulation Often
Heat transport means to manipulate with satellite integral heat capacity Not often
Semi-passive and active means to regulate the satellite structure temperature level
Heaters; Louvers Not often
Heat storages; Variable conductance heat pipes Very random
Changes of satellite orientation; Change of on-off of device Possible
Hardware for individual devices installed on micro-satellite platform
Passive means to regulate the device/equipment temperature level
Radiating surfaces and finishing Very often
Multilayer insulation Often
Heat conductive lines (flexible lines, heat pipes) Often
Low conductive supports and standsoff Very often
Contact conductance means Very often
Semi-passive and active means to regulate the device temperature level
Heaters; Heat storages Often
Thermal switches, Thermoelectric coolers, Stirling coolers Random

Selecting the type of capillary structure and liquid


heat transfer medium one can match these heat transfer
instruments over wide temperature range from −190
to +100 ◦ C. Dimensional configurations of heat pipes
are presented in Fig. 7 [20].
The illustrations of heat pipe application in micro-
satellite thermal design are small-satellites Magion 4,
Magion 5 [21] and BIRD [22]. The aim of heat pipes
in both cases is to transport heat between remote satel-
lite zones (front and back compartments for Magion
satellites, distance 0.5 m; payload and main radiator
for BIRD satellite, distance 0.3 m). Scheme of heat
pipe configuration for BIRD satellite thermal control
system is presented in Fig. 8.
For future micro-satellite missions one of the heat
pipe modifications will be useful, namely, micro-heat
pipes by circumcircle diameters 1–6 mm. They are
constant conductance heat pipes, have wire wick or
grooves as liquid transfer medium; material of shell-
copper and silver; typical circumcircle diameter from
Fig. 5. Effective emittance of MLI blankets as function of area
and discontinuity by Stimpson & Jaworski [11]. AMLI -sizes of
1–6 mm; length up to 100 mm, heat carrier: alco-
MLI area for microsatellites, rec -recommended range of effective hol, water; maximum transfer heat flux 2–10 W/cm2 ;
emmitence. thermal resistance of HPs: less than 0.5–10 K/W.
Micro-heat pipe array dimensions are: 20–40 mm
Typical extruded profile has the diameter more than width, 110 mm length with thickness of 1–3 mm. The
8 mm, thermal resistance less than 0.1 K/W. other type of new heat pipe technology, so-called
V. Baturkin / Acta Astronautica 56 (2005) 161 – 170 167

Fig. 8. Scheme of heat pipe arrangement in BIRD satellite. Heat


moves from evaporator (payload)—condensator (radiator) in mea-
surement.

loop-heat pipes (LHPs), allows to operate indepen-


dently of gravity forces. Distance between heat input
Fig. 6. Values of emittance  and solar absorptance [7]. Zone and output zones can reach several meters at transfer
1—selective blacks (solar absorbers); 2—sandblasted metals and power up to 100 W. Also, the connecting lines in LHP
conversion coatings; 3—white paints and second surface mirrors; are flexible (thin wall tubes with diameter of 2–3 mm)
4—bulk metals (unpolished); 5—dielectric films on polished met- that allows to apply this device for thermal coupling of
als. Ideal reflector  = 0; s = 0—in left bottom corner; ideal
moveable parts. Alternative solution for heat transport
painting  = 1; s = 0—in right bottom corner; ideal solar ab-
sorber  = 0; s = 1—in left upper corner; ideal black painting at a distance less than 0.3 m and for heat spreading
 = 1; s = 1—is in right upper corner. is based on the use of variety of graphite materials,
with effective conductivity more than copper [23].
Thermal contacts between satellite structural ele-
ments, thermal contact of high power generating com-
ponents with cooling means or substrates could be im-
proved by application of different types of interface
pads, greases, gap fillers and encapsulates. Typically,
these means are placed between contacting surfaces
that is presented in Fig. 9 [24].
Typical conductivity of pads is 1–6 W/mK, they can-
not be applied with high pressure (typically 10–30 psi
or 0.7–2 bar), and allow to reduce the contact resis-
tance in coupling joint [25]. Other variant to cool the
power-generated micro-elements is to use the con-
formable gap fillers, which allow to connect the heat
generated component with thermal shield and rear-
range the heat flux. Scheme of conformable pad ap-
plication is shown in Fig. 10.
Potential problems in space application of inter-
face pads, gap fillers, greases, encapsulates and ad-
Fig. 7. Examples of heat pipe configurations with metal belt wick. hesives are associated with risk of mass losses and
subsequent spacecraft and payload contamination. The
168 V. Baturkin / Acta Astronautica 56 (2005) 161 – 170

Fig. 11. Scheme of low-conductance standoff [19]. Insulating


material—glass fibers with epoxy, attachment elements made of
stainless steel.

tated by the conductivity, temperature range, thermal


expansion and mechanical properties. Typical variant
of support design, used many times in space for the
temperature range of 170–350 K for thermal isolation
of 2 kg device is shown in Fig. 11. Four such supports
Fig. 9. Scheme of interface pad application to improve the contact
conductance [25]. provide the thermal resistance higher than 400 K/W
and thermally disconnect the device from satellite bus
[19].
Such effective thermal control means as the louvers,
radiators with changeable optical properties, unfolded
radiators, radiators-variable conductance heat pipes,
heat storage, thermal switches, controlled electrical
heaters have not been considered in this paper.
The louvers and radiators with variable emitting
ability are more typical for larger satellite with mass
more than 100 kg. Heat storage, thermal switches, ther-
Fig. 10. Cooling of electronic components of different
moelectric cooling and controlled electrical heaters are
sizes: 1—printed card; 2—electromagnetic and thermal shield; the attributes of autonomous thermal control techno-
3—electronic components; 4—conformble pad; 5—ways of heat logy. More details concerning the above-mentioned
movement to heat sink. instruments can be found in special literature [7].
Among advanced thermal technologies one can note
the following means, which are very soon going to be
other important task is to verify the stability of the used in practice [7]:
component characteristics under space environment
factors and preliminary estimation of technical effi- 1. Variable emittance coating technology (variation of
ciency of selected application. emittance 0.2–0.8),
Important passive thermal control means are the low 2. micro-louvers (change of effective emittance in 2
conductive supports and standoffs. They are exploited times),
for thermal isolation of the device (part of the device) 3. mini two-phase heat transfer devices
from the satellite. Mainly such a measure is necessary • mini heat pipes: diameters 1–2 mm, length
for devices with autonomous thermal control either for 60–100 mm, heat power transferred 1–10 W,
devices or their parts, which have other temperature • mini capillary pump loops: diameter 1–2 mm,
levels, different from interior of the satellite. Typical length 300–1000 mm, heat power transferred
materials for these supports are a wide variety of low- 3–100 W,
conductivity materials, including fiberglass, stainless 4. mechanical thermal mini-switches (thermal resis-
steel, titanium or plastics. The choice of material is dic- tance change 100:1),
V. Baturkin / Acta Astronautica 56 (2005) 161 – 170 169

5. high performance C–C composites with conductiv-


ity 400–1100 W/mK, which can be used either for
the structure elements or heat transport elements.

6. Ground testing and verification of thermal


control design

Verification of the thermal design should be con-


ducted prior to the launch. For micro-satellites the vac-
Fig. 12. Space simulation chamber of DLR’s Space Center in
uum chamber with inner sizes of about 2 m length and Berlin with volume of 3.2 m3 [26].
1.5 m in diameter is often enough for arbitrary satellite
layout inside the chamber. The vacuum chamber with
pressure of 0.0013 Pa (10−5 Torr) or less, cooled by
liquid nitrogen screen simulates the thermal condition
of the outer space (Figs. 12 and 13).
The Earth, Sun heat fluxes are simulated by aiding
heaters, installed on the back side of radiating sur-
faces, on the base of the absorbed fluxes knowledge.
Sometimes the Earth radiation is simulated by radia-
tive heat sinks with regulated temperature. The ther-
mal balance test of the satellite system, for cold and
hot cases of exploitation, should confirm or precise
the accepted parameters of most of the thermal control
components and approve used thermal concept.
Exploitation temperature boundary for satellite
components should be enlarged by ±11 ◦ C [7] to
compensate the uncertainty connecting with calcula-
tions, design and environmental conditions. Among
Fig. 13. Installation of micro-satellite BIRD into vacuum chamber
possible recommendations, based on satellite design for thermo-vacuum testing. Courtesy of DLR [27,28].
and flight performance experience, the following ones
could be useful:
7. Conclusion
• Keep in mind the possibility of unpredictable sit-
uation with satellite orientation with respect to Summary of the information concerning present-
sun light and with variation of power generation day thermal control concepts conformably to micro-
value inside the satellite. They can shift satellite satellite group (mass less than 100 kg) is surveyed and
temperature level essentially. analyzed. The description of the conventional thermal
• Maintain the battery in comfortable temperature hardware used in micro-satellite design is briefly pre-
range during charge–recharge mode during the sented. The base for the survey was the lessons learned
satellite’s shadow period. by the National Technical University of Ukraine “Kyiv
• Degradation of optical surfaces is the real pro- Polytechnic Institute” during the elaboration of ther-
cess, which is important especially for the front mal control hardware for micro-satellites Magion 4,
direction toward the Sun surfaces. 5 (launched in 1995 and 1996), BIRD (launched in
• Not all the factors can be simulated and estimated 2001), autonomous thermal control systems for inter-
in the ground tests and by calculations. Design planetary missions VEGA (launched in 1984), PHO-
your equipment for wider temperature range. BOS (launched in 1986) and other public data.
170 V. Baturkin / Acta Astronautica 56 (2005) 161 – 170

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