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CHALLENGES OF THE INSTRUMENTATIONFOR HIGH SPEED ENTRY VEHICLES
Ali Glhan, Thomas Thiele, Frank SiebeGerman Aerospace Center (DLR)
Linder Hoehe, 51147 Cologne
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CHALLENGES OF THE INSTRUMENTATIONFOR HIGH SPEED ENTRY VEHICLES
Outline
Introduction
Instrumentation of SHEFEX-I Flight Experiment
Instrumentation of SHEFEX-II Flight Experiment
Instrumentation of the Flaps of the ESA FlightExperiment EXPERT
Proposed Instrumentation for the Exomars DemonstatorBack Cover
Concluding Remarks
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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 themaximum possible instrumentation.
Coupled simulations with Fluid-Structure-Interaction showed that in
most cases the temperature peaks computed with radiativeequilibrium assumption, are less pronounced. Validation
experiments provided the same results.
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SHEFEX-I Payload
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Vehicle based on existing components Instable re-entry behaviour
Vehicle based on new / modified Components
Stable re-entry behaviour
Imp. OrionS30
SHEFEX Basic Vehicle Configuration / Actual Vehicle Configuration
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Max. Downrange ~ 250km
3
Impact Radius ~ 60km
Andya Rocket Range
Impact andMarit ime Recovery
SHEFEX Launch Site Andya Rocket Range, Norway
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Flying windtunnel for
getting real flight data
Test bed for different TPS
concepts and materials
Aerodynamic and structural
verification of advanced
outer shapes
SHEFEX Sharp Edge Flight Experiment
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time [s]
altitude[km]
velocit
y[km/s]
0 100 200 300 400 500
0
50
100
150
200
250
0.5
1
1.5
2
SHEFEX Flight Trajectory
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flight time [s]
pressure[mbar]
428 430 432 434 436 438 440 442 444 446 448
0
200
400
600
800
1000
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)
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flight time [s]
heatflux
rate[kW/m
2]
420 425 430 435 440 445
0
100
200
300
400
500
600
700
800
900
1000
HFS-1 (P5-h)
HFS-2 (P13-h)
HFS-3 (P22-v)
HFS-4 (P22-m)
HFS-5 (P22-h)
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flight time [s]
temp
erature[K]
410 420 430 440
300
400
500
600
700
800
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)
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Post fl ight analysis
Experiments on steps and gaps effects in L3K
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SHEFEX-II Instrumentation
Increase of re-entry velocity from Ma 6.5 up to Ma 11
Increase of experiment duration from 20 s to 45 s
Temperatures, pressure, heat flux measurements also
during ascentIncrease number of sensors (from 60 to 140)
Flush Air Data System (FADS)
SHEFEX I => SHEFEX II
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Instrumentation of the SHEFEX II flight experiment
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.
Camera interfaceCeramic nose with attachedpressure tubing
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TPS Sensor Interfaces for SHEFEX II
TPS C/C-SiC ti le
Combined heat-flux / pressure port
Interface for heat flux sensor also contains a pressureport 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.
SHEFEX II
forebody
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Thermal analysis for the SHEFEX II TPS interfaces
The verification of the TPS interfaces concerning temperature resistance was done bystructural analysis.
Input heat flux from CFD
Pressure port / Heat flux sensor maximum temperatures
0
200
400
600
800
1000
1200
650,00 660,00 670,00 680,00 690,00 700,00
Flight time [s ]
Tempera
ture
[C]
C/C-SiC tile Bushing Spring HFM Sensor
Temperature
distribution at
end of experiment
time
Temperature vs
flight time for
different
interface parts
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EXPERT High Temperature Pressure Ports
A pressure measurement at the control surfaces (flaps) of the EXPERT vehicle is verychallenging due to very high temperatures at the flaps (2000 K) during re-entry.
A spring loaded ceramic pressure port was designed and qualified at DLR Cologne which is
able to withstand the thermal environment at the EXPERT flaps.
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EXPERT High Temperature Pressure Ports
Tconst=
300K
Heat
flux 2
Heat flux 1
Qualification of the pressure port design was done by structural analysis and windtunnel testing.
The numerical simulation was performed with heat flux values from worst-case CFD
computations (peak heat flux 1.3 MW/m2) using the windtunnel setup for the structural model.
All computations show that the limit temperatures for the
different materials were not exceeded.
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EXPERT High Temperature Pressure Ports
Windtunnel tests for the pressure port qualification were performed in the arc-heated facility L3Kat DLR Cologne. The temperature distribution was monitored with thermocouples, pyrometers
and an infrared camera.
Despite oxidation of the metallic parts the
pressure port parts showed no damageafter the tests. The pressure measurement
during the tests worked well without
malfunctions.
Windtunnel test
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Data Acquisition System for SHEFEX II / EXPERT
A similar electronic box is used for the SHEFEX II and EXPERT re-entry experiments. The dataacquisition system consists of the following PCBs:
Analogue Amplification Card (AAC): Signal conditioning (filtering, amplification) of 28 sensor
channels. This card was designed, manufactured and tested at DLR Cologne.
Multifunction Card (MFC): Digitization of the sensor signals and serial communication to the
onboard computer. This card is provided by DLR MORABA.
Power Distribution Card (PDC): Power conversion for the power supply of active sensors.
This card was designed, manufactured and tested at DLR Cologne.
SHEFEX II EBX
interior view
EXPERT EBX
exterior view
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Data Acquisition System for SHEFEX II / EXPERT
A major issue for the electronics of the data acquisition system are the high vibration and shockloads during launch and stage separation.
For the EXPERT project the data acquisition system was qualified according to ESA standards
for a very severe random vibration environment up to 35 gRMS and shock loads up to 1000g.
EBX OOP Random vibration environment(qualification)
0
0.2
0.4
0.6
0.8
1
1.2
0 500 1000 1500 2000
Frequency [Hz]
ASD
[g^2/Hz]
EBX Shock Specification (qualification)
0
200
400
600
800
1000
1200
10 100 1000 10000
Frequency [Hz]
SRS[g]
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.
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Aerothermal heating on the capsule front surface and back cover
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COMARS+ and Radiometer on EDM Back Cover
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Overview Sensors
COMARS+ 1
Pressure sensorPressure signal 1
Reference temperature 2
Heat flux sensorHeat flux signal 3
Reference temperature 4
Optical fiber (CNES) Sensor 1 5Sensor 2 6
COMARS+ 2
Pressure sensorPressure signal 7
Reference temperature 8
Heat flux sensorHeat flux signal 9
Reference temperature 10
Optical fiber (CNES)Sensor 1 11
Sensor 2 12
COMARS+ 3
Pressure sensorPressure signal 13
Reference temperature 14
Heat flux sensorHeat flux signal 15
Reference temperature 16
Optical fiber (CNES)Sensor 1 17
Sensor 2 18
RadiometerSignal 19
Reference Temperature 20
!!! Reference temperature means the temperature of the sensing element of each sensor and not i ts case !!!
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COMARS+ Sensor
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Details of COMARS+ Sensor
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DLR radiometer for Exomars EDM flight
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Thermal analysis at flight conditions
Temperature of radiometer mounting surface
-45
-25
-5
15
35
55
75
95
115
135
0 100 200 300 400 500 600Time [s]
Temperature[C]
Temperature of radiometermounting surface
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Tests in the arc jet facil ity L2K
M-I M-II M-III
mass flow rate of CO222
/NCO
mm [g/s] 39/1.2 39/1.2 39/1.2
reservoir pressure0
p [hPa] 730 910 950
specific enthalpy0h [MJ/kg] 4.7 9.3 10.4
total temperature0T [K] 2663 3300 3432
nozzle throat/exit diameter et D/D [mm] 29/100 29/100 29/100
distance from nozzle exit ex [mm] 160 160 160
distance from nozzle throat tx [mm] 329 329 329
free stream static pressure p1 [hPa] 2.02 1.97 1.84
free stream static temperature T1 [K] 998 881 833
free stream density 1 [kg/m3] 9.410
-4 8.210-4 7.710-4
free stream velocity v1 [m/s] 2083 2498 2592
mole fraction of CO22
COn [] 0.647 0.211 0.153
mole fraction of CO COn [] 0.203 0.461 0.486
mole fraction of O22
On [] 0.093 0.159 0.149
mole fraction of O On [] 0.013 0.132 0.175
mole fraction of N22N
n [] 0.038 0.026 0.024
mole fraction of NONOn [] 0.005 0.011 0.012
mole fraction of NNn [] < 10
-6 < 10-6 < 10-6
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Calibration tests on the DLR radiometers are in progress
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Calibration tests on the DLR radiometers (sensor 2) in L2K
0.86
1.1
4
0.7
6
M - III
950 mbar
M - I
730 mbar
M - II
910 mbar
time [s]
radiativeheat
fluxrate[kW/m2]
0 100 200 300-0.5
0
0.5
1
1.5
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Conclusions
Although the recovery action failed, SHEFEX-I flight experiment was a bigsuccess with respect to complete flight trajectory until the parachute failureat an altitude of about 13.5 km.
Almost the complete instrumentation provided very clear and reliable flightdata, which showed a very good consistency with the rocket platform data.
SHEFEX-II with more sophisticated instrumentation (140 sensors) will belaunched 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 andelectronic components are designed in such a way that they can surviveshock 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 preliminarydesign for the EDM Mission in 2016 has been completed