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Acta Astronautica 91 (2013) 187–193

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Acta Astronautica
journal homepage: www.elsevier.com/locate/actaastro

Endurance testing of a pulsed plasma thruster


for nanosatellites
David Krejci a,n, Bernhard Seifert a, Carsten Scharlemann b
a
Fotec GmbH, 2700 Wiener Neustadt, Austria
b
University of Applied Science, 2700 Wiener Neustadt, Austria

a r t i c l e i n f o abstract

Article history: The mission complexity of Nanosatellites has increased tremendously in recent years, but
Received 10 July 2012 their mission range is limited due to the lack of an active orbit control or Δv capability.
Received in revised form Pulsed Plasma Thrusters (PPT), featuring structural simplicity and very low power
14 June 2013
consumption are a prime candidate for such applications. However, the required
Accepted 15 June 2013
miniaturization of standard PPTs and the adaption to the low power consumption is not
Available online 22 June 2013
straightforward. Most investigated systems have failed to show the required lifetime. The
Keywords: present coaxial design has shown a lifetime of up to 1 million discharges at discharge
μPPT energies of 1.8 J in previous studies. The present paper focuses on performance char-
PPT
acterizations of this design. For this purpose direct thrust measurements with a mN thrust
Pulsed plasma thruster
balance were conducted. Thrust measurements in conjunction with mass bit determina-
Thrust measurement
CubeSat tion allowed a comprehensive assessment. Based on those measurements the present
Propulsion mPPT has a total impulses capability of approximately I≈1.7 Ns, an average mass bit of
0.37 mg s−1 and an average specific impulse of Isp≈904 s. All tests have shown very good
EM compatibility of the PPT with the electronics of the flight-like printed circuit board.
Consequently, a complete mPPT unit can provide a Δv change of 5.1 m/s or 2.6 m/s to a
standard 1-unit or 2-unit CubeSat respectively.
& 2013 IAA. Published by Elsevier Ltd. All rights reserved.

1. Introduction Currently there are various efforts in miniaturizing propul-


sion technologies appropriate for the size of CubeSats,
The recent success of CubeSats allows the definition of including cold gas thrusters based on both gaseous (CanX-
advanced mission concepts, having CubeSats employed in 2) [6,7] and solidified propellant (Delfi-n3Xt) [8] and
advanced scientific applications, including formation flying electrical propulsion systems, such as vacuum arc thrusters
[1,2]. However, the enabling technology for such missions, (ION) [9] and Field Emission based ion thruster (FEEP) [10].
namely autonomous propulsion and active attitude control Another electrical type of thruster which lends itself
with high pointing accuracy remains elusive [3,4]. This well to miniaturization is the structurally simple pulsed
originates from the difficulties of miniaturizing existing plasma thruster (PPT), which is operated in pulsed mode,
propulsion concepts either regarding structural–mechanical adapting well to low power available. Thanks to their ability
limits in the case of chemical propulsion, or too stringent to deliver small impulse bits and their high reliability,
power limitations for many types of electric propulsion [5]. miniaturized PPTs (mPPTs) are well suited to enable precise
formation flying. Furthermore, pointing accuracies currently
n
only obtainable by reaction wheels are expected, which
Corresponding author.
E-mail addresses: david.krejci.fl@fotec.at (D. Krejci),
could therefore considerably reduce mass and power
seifert@fotec.at, bseifert@gmx.at (B. Seifert), requirements for high performance stabilization [11]. An
carsten.scharlemann@fhwn.ac.at (C. Scharlemann). additional system benefit of PPTs is the quasi-neutrality

0094-5765/$ - see front matter & 2013 IAA. Published by Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.actaastro.2013.06.012
188 D. Krejci et al. / Acta Astronautica 91 (2013) 187–193

Nomenclature U Voltage at electrostatic calibration comb, V

b Electrostatic comb plate width, m Greek symbols:


d Plate distance of electrostatic comb, m
I Impulse, kg m s−1 Δv Velocity increment, m s-1
I Bit Impulse bit, mN s ε0 Permittivity of free space, As V−1 m−1
l Electrostatic comb overlapping length, m κ Coefficient of thrust balance torsion spring,
lE Distance of electrostatic comb from balance N m rad−1
spring bearings, m θ Thrust balance beam angular deviation, rad
n Number of plates in electrostatic comb μ0 Permeability of free space, H m−1
r Distance of thruster to balance bearings, m
T Thrust, N

of the expelled plasma, making the need for charge acceleration chamber consists of two concentric, tubular
neutralization obsolete. shaped electrodes made of copper with the propellant
PPTs were first flown in space on the Soviet Zond-2 TEFLONs in between. The external diameter of the PPT is
mission [12]. Ever since then, PPTs have been employed in roughly 9 mm and its length is 35 mm. The diameters of
various space missions [13], with utilization reaching from the concentric electrodes are 6.0 mm and 4.8 mm respec-
orbit insertion and drag make-up (TIP/NOVA with a total of tively. With the total propellant area of 10.2 mm² and the
28 thruster) to east-west station keeping (LES-6) [14] to total weight of only 15 g, even 2-unit CubeSats can easily
active attitude control (SMS and LES-8/9) [15,16]. Typical be equipped with multiple PPTs in order to allow sophis-
discharge energy levels of flight experienced PPTs range ticated attitude control and formation flight maneuvers.
from a few joules (LES-6, SMS) to one hundred joules (EO-1, The PPT head was designed and manufactured at FOTEC
MightySat-II) [17–19]. and is optimized for low mass and volume, low discharge
Presently, several research teams focus on the investiga- energy and good electro-magnetic compatibility. A high
tion of mPPTs [20,21], but none has shown the reliability and voltage capacitor, used to store the discharge energy for
lifetime necessary for such application. The investigation one pulse, is connected to the electrodes. While the
presented in the following has focused on mPPT performance plasma acceleration process is a highly complex physical
evaluation during long term employment, similar to future matter [23–27], simple models are available to guide the
employments on CubeSats. Fig. 1 shows the plasma plume of preliminary thruster design [28–35]. The size of the
the coaxial mPPT design investigated in this work. With the complete thruster module including four PPT heads, high
available resources no further characterization of the plume, voltage capacitors shared between the individual mPPTs
especially the divergence angle, could be performed. heads, igniters and conditioning electronics is 90  90 
30 mm3. Total weight of the unit is about 300 g with the
capacitors being the major driver of the weight. The usage
2. Operation principle of custom-made peak current optimized capacitors, sig-
nificant weight reduction is expected for future revisions.
The PPT is an electro-dynamic thruster, accelerating The igniter is introduced annularly into the acceleration
ionized propellant by interaction of the electric current in chamber through the TEFLONs propellant. The igniter
the plasma and the self-induced electromagnetic fields triggers the main discharge, featuring peak current values
[22]. In an annular coaxial design, shown in Fig. 2, the

Current I

Lorentz force
Capacitor F=jxB
C

Current I

Propellant Plasma Magnetic


PTFE Sheet Field B
CurrentI

Fig. 1. Plasma plume of coaxial mPPT. Fig. 2. Simplified schematic of PPTs.


D. Krejci et al. / Acta Astronautica 91 (2013) 187–193 189

3
AR = 1
2 AR = 1.67
AR = 2.5
AR = 3.33
1

Current [kA]
0

-1

-2

-3
0 5 10 15 20
Time [µs]
Fig. 3. Typical current pulse during discharge.

up to 3 kA, which then ablates, dissociates, ionizes and


accelerates the propellant.
In Fig. 3 the typical current pulse during discharge is
shown for standard-shape mPPT with different width-to-
gap aspect ratios. Due to the encapsulated mPPT design and
its fixed assembly on the PCB, the discharge characteristics
could not be determined in the scope of this work, but
because of similar geometric dimensions and the same
electrical setup, similar results can be expected.

3. Thrust balance

3.1. A. Balance description

In order to determine the generated thrust of the mPPT, a


mN torsion balance has been set up. The operational balance
set up in the vacuum chamber is shown in Fig. 4. The system
is comprised of a horizontal Aluminum beam with a total
length of 70 cm which is suspended by two stainless steel
spring bearings manufactured by C-Flex with a spring rate of
Fig. 4. Torsion balance put on rails in the vacuum chamber.
0.2 Nm/rad per bearing (not visible). In the front of the
picture one of the two 12  12 cm2 tables can be recognized
which are directly mounted on the beam—one for the Ref. [36] gives a comprehensive derivation of this
thruster module and the other one for the corresponding relation from the general second-order differential equa-
counterweight. The displacement of the beam is measured tion for the torsion balances and damping systems and
using a high-precision optical distance transducer mini DMS discusses the justification of averaging the measured
manufactured by Philtec. The oscillation frequency of the parameters for the given configuration.
system is measured and knowing the torques of inertia of the Since Eq. (1) is dependent on the spring rate κ, which
arm and the tables, the exact spring rate can be computed might be subjected to thermal drift, the balance was
which is required to determine the generated thrust of the additionally equipped with an electrostatic comb struc-
mPPT. To account for the low damping of the beam which in ture, allowing alternative thrust measurements indepen-
vacuum is only caused by friction of the bearings, a passive dent of material parameters. Therefore, the generated
magnetic eddy current brake has been implemented to lower thrust by the mPPT is compensated by applying an anti-
the measurement noise and oscillations (in the foreground parallel force of the same strength using the comb struc-
just below the table the disc-shaped magnet can be ture. According to Ref. [36], the thrust from the mPPT can
recognized). be expressed as function of the applied comb structure
The time-averaged thrust transferred to the torsion voltage difference U
balance by the mPPT, with thrust axis oriented perpendi-
cular to the balance beam at distant r ¼29 cm from the 1 b lE 2
T¼ ε0 n U ð2Þ
pivot, can be expressed as a function of angular deviation θ 2 d l
The reflective displacement transducer and the static
θκ comb structure have been identified as critical parts of the
T¼ : ð1Þ
r balance with respect to high sensitive thrust measurement.
190 D. Krejci et al. / Acta Astronautica 91 (2013) 187–193

Therefore, proper performance of these crucial components (or alternatively 1 Hz, 1/2 Hz and 1/4 Hz), resembling the
has been validated. The accurate operation of the reflective operation conditions for limited power budgets when
displacement transducer was verified with the aid of a Key- employed in CubeSats. An operation time of 60 s was
ence LC-2400W laser displacement meter. No malfunction or found to be long enough to compute a reliable value of
unexpected deviations have been detected. In addition, mag- the average thrust. To account for the thermal drift of the
netic deflection has been used to validate the electrostatic thrust balance which results in a drift rate as given in
comb structure since only small direct currents are used and Table 1, that distorts the measurement results when used
no high voltage is needed which may be a potential source of over a long-term interval, the deflection is measured
measurement errors due to unmeant static charging. before and after the mPPT operation for 60 s when kept
idle. Fig. 5 shows a section of a thrust measurement at the
3.2. B. Balance accuracy discharge energy of 1.82 J where the mPPT is kept idle for
60 s and then pulsed at 1/3 Hz for 120 s. The generated
The optical displacement sensor uncertainty was deter- mean thrust is indicated based on an averaging interval of
mined using a mirror at mechanically fixed distance to the 3 s. The recorded thrust signal shows constant thrust
sensor face. The resulting measurement noise and drift of the levels throughout the entire firing period, without any
reflective displacement sensor and the measurement electro- noticeable influences caused by initial thermal disequili-
nics are listed in Table 1. The noise and drift of the overall, brium and thus justifies the choice of measurement inter-
fully equipped, thrust balance was determined at vacuum vals of 60 s. Due to the inertia of the thrust balance and the
operation conditions for a chamber pressure below 5  aforementioned natural frequency of 0.6 Hz, the arm does
10−7 mbar after 48 h in vacuum conditions in order to achieve not return to its initial position between the pulses.
thermal equilibrium and to rule out outgassing effects. The corrected thrust is then given by
The balance response time was determined by applying T before þ T after
a step force of 100 mN to the fully equipped thrust balance T corr ¼ T− : ð3Þ
2
using the electrostatic comb. The response time, defined as
with the subscripts “before” and “after” referring to the
the time elapsed from 10% to 90% of the final deflection
measurements periods in which the thruster is kept idle.
was found to be 1.6 s. The natural frequency of the balance
is therefore 0.6 Hz but it strongly depends on the weights
put on the tables. 5. Thrust measurement of a miniaturized coaxial thruster

The coaxial type ablative mPPT design offers favorable


4. Test facility and balance operation mechanical properties, since the outer electrode fully
confines the propellant and the plasma and thus acts as
For thrust measurements, the mPPTs were pulsed at a shielding barrier protecting the surrounding structure,
three different frequencies of 1/3 Hz, 1/6 Hz and 1/9 Hz making additional shielding, which can cause leakage
current when covered with carbon, obsolete. For energy
Table 1
Balance accuracy. storage, two capacitors of 1 mF each were charged to
1350 V. A mockup of the module containing the PPU and
Noise [mNrms] Drift [nN s−1] four thrusters is shown in Fig. 6, with potential application
shown on the right hand side. Each of the mPPTs on
Displacement sensor 0.07 1.3
Balance total 0.37 2.0 the module is equipped with a dedicated igniter circuit,
allowing for individual control of each thruster.

3
Thrust [µN]

-1
0 50 100 150
Time [s]
Fig. 5. Typical thrust measurement sequence of a mPPT.
D. Krejci et al. / Acta Astronautica 91 (2013) 187–193 191

Fig. 6. mPPT EBB module for CubeSats with four independently controllable thrusters and application example (CubeSat structure by Pumpkin, Inc.).

25 20
Force, 0.5Hz
Force, 0.25Hz
20 Force, 1.0Hz 15

Impulse Bit [µNs]


Average Impulse Bit
Force [µN]

15
10
10

5
5

0 0
0.5 0.7 0.9 1.1 1.3 1.5
Energy [J]
Fig. 7. Averaged impulse bit for coaxial annular electrode configuration.

Fig. 7 shows the direct thrust measurements for three 4.2  105 discharges. The resulting impulse bit measured
different firing frequencies, each repeated three times, and as function of the number of ignitions is shown in Fig. 8.
the resulting mean impulse bit measured as a function of To avoid the increasing complexity of a moving pro-
the discharge energy. Three different discharge energies pellant in the highly miniaturized design employed, the
were tested by varying the capacitor charging voltage. As propellant was not repositioned as in the case of standard
can be seen, in this energy and discharge frequency range, PPT designs, in which the propellant front face position is
the impulse bit determination is independent from dis- kept constant. Therefore, ablation of the propellant leads
charge frequency, only showing minor effects of increased to recession of the propellant face relative to the thruster
thermal load for increased firing frequencies. The bars electrodes, prolonging the acceleration chamber. The
indicate the deviation between the single measurements degradation of thrust as already been observed in previous
and do not correspond to the total thrust measurement designs [42] is traced back to this recession of propellant.
error. Further measurements will be necessary in order to The accumulated impulse delivered by the thruster was
determine the temperature increase of the PPT head for determined to I ¼ 1:7 N s for 4.2  105 discharges. Assum-
various ignition frequencies. ing a standard 1-unit CubeSat with a maximum mass of
1.33 kg, a propulsion unit containing four thruster heads
would be able to deliver a Δv change of Δv≈5:1 m=s,
5.1. A. Lifetime thrust measurement enabling drag make-up maneuvers, formation flight and
constellation maintenance [37–41]. In a realistic scenario
Lifetime tests have been performed using a coaxial type concerning volume and power budgets available, the
mPPT incorporated into the PPU module. The entire thrus- thruster module will most likely be employed in a 2- or
ter module was mounted on the balance and fired at 3-unit CubeSat architecture, with accordingly reduced
1/3 Hz continuously to simulate CubeSat operational con- velocity changes delivered to the satellite of Δv≈2:6 m=s
ditions with an average power consumption of less than or Δv≈1:7 m=s respectively, again assuming a mass of
1 W. 1.33 kg per CubeSat unit. However, long duration tests
Thrust measurements using the test procedure performed without thrust measurements showed success-
described before were conducted at intervals of 2 h, or ful thruster operation up to 106 discharges, therefore
approximately 2400 ignitions. A long duration test includ- significantly increasing the total impulse per thruster and
ing thrust measurement was conducted for a total of the corresponding Δv change.
192 D. Krejci et al. / Acta Astronautica 91 (2013) 187–193

15 The specific impulse measured is found in the lower


region of range of specific impulse expected for this type of
thruster which is anticipated considering the given min-
iaturization and low energy operation [44]. This translates
Impulse bit [µNs]

10 directly, using a time-averaged mass bit given in Fig. 9 and


basic energy relations, into an initial efficiency of  3.9%
which decays to 1.1% after 1,00,000 ignitions and reaches
lower values of 0.7% after succeeding 3,00,000 ignitions.
5 These values are located near the lower end of expected
efficiency range for this type of thruster.

0
0 100 200 300 400 ·103 6. Conclusion

Number of ignitions [-]


The pulsed plasma thruster is a candidate propulsion
Fig. 8. Long duration thrust measurement of mPPT. technology for miniaturization to meet the stringent
requirements posed by nanosatellites. These miniaturiza-
1 tion requirements especially pose difficulties regarding the
0.9 reliability and lifetime of such miniaturized thrusters. The
mass bit [µg/discharge]

0.8 current paper presents a highly miniaturized pulsed


plasma thruster in recessive ablative coaxial configuration
0.7
for low power operation. The thruster was characterized
0.6
and its performance in long duration tests was manufac-
0.5 tured in-house and investigated. The thruster was incor-
0.4 porated in a fully operational propulsion unit containing
0.3 the PPU and up to four thrusters, and thrust was measured
0.2 throughout a period of 4:2  105 ignitions. Direct thrust
measurement of the thruster was performed using a
0.1
dedicated thrust balance, able to resolve mN forces. Total
0
impulses delivered throughout the lifetime test were
0 100 200 300 400 500 600 700 ·103
determined to be foI≈1:7 N sr one thruster. For the minia-
Number of ignitions [-]
turized thruster module presented, which comprises four
Fig. 9. Long-term mass bit measurement of mPPT. thrusters, this amounts to a Δv change, based on a 1-unit
CubeSat, of Δv≈5:1 m=s, and correspondingly decreased
Disassembly of the TEFLONs propellant bar for weight values of Δv≈2:6 m=s and Δv≈1:7 m=s for 2-unit and 3-unit
measurements and mass bit determination respectively CubeSats respectively, based on a satellite mass of 1.33 kg
was not possible due to the fashion the mPPT is assembled per CubeSat unit. Minimum discrete impulse bits, neces-
within the propulsion module. Therefore, mass bit deter- sary for fine attitude control, were measured to
mination was performed in a separate long duration test I bit ≈10 mN s, decreasing to I bit ≈3:5 mN s for increased
for an identical mPPT without direct attachment of the operational lifetime.
mPPT to the PPU module, allowing easy disassembling and Long duration mass bit measurement was performed
weight determination of the propellant. This method over the test duration of 6:9  105 ignitions. This test
improved the accuracy of the measurement compared to showed degradation in mass bit with increasing total
past results [43]. In this configuration, mass bit determina- number of discharges corresponding to impulse bit degra-
tion was performed by gravimetric weight determination dation. The combined data allowed for an estimate of the
of the propellant before and after the test interval. All achieved specific impulse over the entire test period of
weight measurements have been conducted after storage Isp ¼904 7212 s for the low power, miniaturized thruster
of the propellant under ambient conditions for 24 h to configuration.
account for atmospheric humidity intake. The resulting The thruster module described and used for testing in
mass bit values (shown in Fig. 9) are therefore mean values this paper allows the individual control of each of the four
averaged over the number of discharges of the determina- thrusters, using four separate ignition circuits, allowing for
tion interval. As in the case of the impulse bit, the recess of individual change on discharge frequency and thus thrust
the propellant surface leads to a degradation of the mass produced. The ability to individually address each thruster
bit. Although the different ways of connecting the mPPT to allows for flexible control in case of thrust deviation of a
the PPU in the case of thrust and mass bit measurements single thruster head by modifying the discharge frequency
introduce an unknown error in the electrical circuit para- of such a thruster, maintaining a uniform thrust, if neces-
meters of the system, the combination of the data pre- sary. The discharge frequencies achieved by the four
sented in Figs. 8 and 9 allows an estimation of the average thrusters within the module will be limited by the power
specific impulse achieved for the mPPT configuration budget delivered by the CubeSat only.
employed. The mean specific impulse averaged over The mPPT presented and investigated in this work is
4.2  105 discharges becomes Isp ¼904 7212 s. therefore found capable of providing reliable autonomous
D. Krejci et al. / Acta Astronautica 91 (2013) 187–193 193

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