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StatusOngoing
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Status date2024-12-21
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Activity Code4D.054
The payload of large telecom satellites is increasing. This leads to the high-power throughput from solar panels to the electronic payload. Except the power radiation through the antennas, all other loads lead to power losses within the satellite that have to be rejected to space via radiators. The state-of-the-art for thermal control within a high payload satellite is a mechanically pumped liquid loop transporting the heat losses to radiators - with the radiators operating at slightly lower temperatures than the heat sinks within the satellite. To increase the rejection capacity of the radiators without increasing the radiator surface, an increase of the radiator temperature is targeted, while keeping the heat sink temperature for the components within the satellite. For this temperature increase, a heat pump is required. As core part of the heat pump, a gas bearing centrifugal compressor (also called turbo compressor) is employed due to the space specific requirements for low weight and size, long lifetime, low vibration emission and oil-free operation. The aim of this project is the design, realization and ground testing of a gas bearing turbo compressor for such a heat pump system for spacecraft cooling.
The chosen refrigerant ammonia has been widely applied in spacecraft thermal systems and is therefore an optimal choice concerning space heritage. HoweverHowever, it is not the refrigerant of choice for gas bearing centrifugal compressors and therefore leads to technical risk in the gas bearing centrifugal compressor that shall be reduced with this project. The key challenges that are tackled with this project include:
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To achieve the required temperature and therefore pressure differences, a multi-stage centrifugal compressor system is required, with each stage running at the technical limit concerning rotational speed
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High rotational speed and high refrigerant density both contribute to high losses and therefore critical thermal design as well as lower efficiency
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Small manufacturing tolerances due to small relative clearances between the impeller and the volute
The key benefits that make the centrifugal gas bearing compressor the optimal compressor technology include:
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No impact on refrigerant and no need for service and maintenance due to oil-free operation
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Compactness and low weight
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No need for active control or additional sensors
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No pressure ripples
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Higher pointing accuracy for antennas due to low vibration emission
The key features that support the benefits of the centrifugal compressor include:
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Oil-free operation due to gas bearings
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Low weight and size due to high speed operation
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Low micro vibration emittance due to principle of centrifugal compressor: continuous flow machine results in no pressure ripple and forces only coming from residual imbalances
The main components of the heat pump system for telecom satellites are depicted below.
The main work packages and milestones of this project include:
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Definition of heat pump system and compressor system specification
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Design of one stage of the centrifugal compressor system
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Realization of one stage of the centrifugal compressor system
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Design and realization of a gas phase test bench for centrifugal compressor system testing
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Verification and testing of one stage of the centrifugal compressor system on the test bench
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Risk, reliability and business case assessment
The specification definition, preliminary detailed design of both centrifugal compressor and test bench has beenare completed. Currently, the detailed design of both centrifugal compressor and test bench is ongoingthe realization phase for theone stage of the centrifugal compressor and the one compressor stage test bench are ongoing.
FOTOSA current task is the definition of the sealing concept for the stator and the magnet of the electrical motor.