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Ali Glhan, Thomas Thiele, Frank Siebe German Aerospace Center (DLR) Linder Hoehe, 51147 Cologne
1 > Challenges of the Instrumentation for High Speed Entry Vehicles > A. Glhan
IPPW-8 > 6.-10. June 2011, Portsmouth
Introduction Instrumentation of SHEFEX-I Flight Experiment Instrumentation of SHEFEX-II Flight Experiment Instrumentation of the Flaps of the ESA Flight Experiment EXPERT Proposed Instrumentation for the Exomars Demonstator Back Cover Concluding Remarks
2 > Challenges of the Instrumentation for High Speed Entry Vehicles > A. Glhan
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Introduction
Ground testing facilities and CFD codes have shortcomings to
simulate the flight parameters fully. Therefore flight experiments are essential for the development of future spacecrafts.
Hypersonic flight testing is costly and risky. It does not allow to
perform parameter study, i.e. difficult to use for the validation of physical modelling and CFD codes.
Therefore hypersonic experiments have to be performed with the
most cases the temperature peaks computed with radiative equilibrium assumption, are less pronounced. Validation experiments provided the same results.
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SHEFEX-I Payload
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S30
Imp. Orion
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200 1.5
150 1 100
0.5 50
100
200
300
400
500
time [s]
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velocity [km/s]
altitude [km]
1000
800
pressure [mbar]
600
400
Pres-1 (P5-h) Pres-2 (P8-h) Pres-3 (P13-v) Pres-4 (P13-m) Pres-5 (P13-h) Pres-6 (P22-v) Pres-7 (P22-m) Pres-8 (P22-h)
200
0 428 430 432 434 436 438 440 442 444 446 448
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700 600 500 400 300 200 100 0 420 425 430 435 440 445
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HFS-1 (P5-h) HFS-2 (P13-h) HFS-3 (P22-v) HFS-4 (P22-m) HFS-5 (P22-h)
800
700
temperature [K]
600 Ts-2 (P1-v) TK-01 (P5-m) TK-02 (P5-h) Tk-14 (P13-v) Tk-15 (P13-m) Tk-16 (P13-h) Tk-28 (P22-v) Tk-29 (P22-m) Tk-30 (P22-h)
500
400
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SHEFEX-II Instrumentation
14 > Challenges of the Instrumentation for High Speed Entry Vehicles > A. Glhan
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Camera interface
Two cameras are installed between the stabiliser fins (one on each side) looking forward. They are integrated in separate small fins with surrounding high temperature insulation. Quartz windows with 5mm thickness are used for the optical access. The cameras use a CCD chip with 752x582 pixel resolution. The video signal is stored in the on-board system or transmitted real-time to the ground station.
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Combined heat-flux / pressure port Interface for heat flux sensor also contains a pressure port leading to a reduction of the number of necessary TPS interfaces. Interface manufactured from high-temperature steel. TPS interface is spring-loaded to compensate for thermal expansion in axial direction. Pressure transducer located internally is connected via metallic tubing.
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Temperature [C]
660,00
670,00
680,00
690,00
700,00
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Heat flux 2
Tconst=
300K
All computations show that the limit temperatures for the different materials were not exceeded.
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Despite oxidation of the metallic parts the pressure port parts showed no damage after the tests. The pressure measurement during the tests worked well without malfunctions.
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1.2 1 0.8 0.6 0.4 0.2 0 0 500 1000 Frequency [Hz] 1500 2000
1000 SRS [g] 800 600 400 200 0 10 100 1000 10000 Frequency [Hz]
Due to the severe random vibration a special mounting frame was designed for the electronic cards using structural PSD analysis to minimize the card vibrations.
ASD [g^2/Hz]
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Overview Sensors
Pressure sensor COMARS+ 1 Heat flux sensor Optical fiber (CNES) Pressure sensor COMARS+ 2 Heat flux sensor Optical fiber (CNES) Pressure sensor COMARS+ 3 Heat flux sensor Optical fiber (CNES) Radiometer Pressure signal Reference temperature Heat flux signal Reference temperature Sensor 1 Sensor 2 Pressure signal Reference temperature Heat flux signal Reference temperature Sensor 1 Sensor 2 Pressure signal Reference temperature Heat flux signal Reference temperature Sensor 1 Sensor 2 Signal Reference Temperature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
!!! Reference temperature means the temperature of the sensing element of each sensor and not its case !!!
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COMARS+ Sensor
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400
500
600
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M-I 39/1.2 730 4.7 2663 29/100 160 329 2.02 998 9.410-4 2083 0.647 0.203 0.093 0.013 0.038 0.005 < 10-6
M-II 39/1.2 910 9.3 3300 29/100 160 329 1.97 881 8.210-4 2498 0.211 0.461 0.159 0.132 0.026 0.011 < 10-6
M-III 39/1.2 950 10.4 3432 29/100 160 329 1.84 833 7.710-4 2592 0.153 0.486 0.149 0.175 0.024 0.012 < 10-6
reservoir pressure p0 [hPa] specific enthalpy h0 [MJ/kg] total temperature T0 [K] nozzle throat/exit diameter Dt / De [mm] distance from nozzle exit x e [mm] distance from nozzle throat x t [mm] free stream static pressure p1 [hPa] free stream static temperature T1 [K] free stream density 1 [kg/m3] free stream velocity v1 [m/s] mole fraction of CO2 nCO2 [] mole fraction of CO nCO [] mole fraction of O2 mole fraction of O mole fraction of N2
nO2 []
nO []
nN 2
[]
[]
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1 0.86
-0.5
100
300
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0.76
0.5
1.14
Conclusions
Although the recovery action failed, SHEFEX-I flight experiment was a big success with respect to complete flight trajectory until the parachute failure at an altitude of about 13.5 km. Almost the complete instrumentation provided very clear and reliable flight data, which showed a very good consistency with the rocket platform data. SHEFEX-II with more sophisticated instrumentation (140 sensors) will be launched in September11. The flight Mach number will be above 10. ESA flight experimental vehicle EXPERT has to withstand very high thermo-mechanical and dynamic loads. Therefore the instrumentation and electronic components are designed in such a way that they can survive shock loads up to 1000 g and random loads up to 35 gMRS. Based on SHEFEX and EXPERT experience DLR developed a new combined sensor COMARS+, which allows measuring the temperature, heat flux rate, pressure and radiative heating simultanously. Its preliminary design for the EDM Mission in 2016 has been completed
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