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The Mars Science Laboratory (MSL) mission to land a large rover on Mars is being prepared for Launch in 2011. A Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) on the rover provides an electrical power of 110 W for use in the rover and the science payload. Unlike the solar arrays, MMRTG provides a constant electrical power during both day and night for all seasons (year around) and latitudes. The MMRTG dissipates about 2000 W of waste heat to produce the desired electrical power. One of the challenges for MSL Rover is the thermal management of the large amount of MMRTG waste heat. During operations on the surface of Mars this heat can be harnessed to maintain the rover and the science payload within their allowable limits during nights and winters without the use of electrical survival heaters. A mechanically pumped fluid loop heat rejection and recovery system (HRS) is used to pick up some of this waste heat and supply it to the rover and payload.

One of the new technologies successfully demonstrated on the recent Mars Pathfinder mission was the active Heat Rejection System (HRS). This system consisted of a mechanically pumped cooling loop, which actively controlled the temperatures of the various parts of the spacecraft. A single phase Refrigerant 11 liquid was mechanically circulated through the lander and cruise electronics box heat exchangers. This liquid transferred the excess heat to an external radiator on the cruise stage. This is the first time in unmanned spacecraft history that an active heat rejection system of this type has been used on a long duration spacecraft mission. Pathfinder was launched in December 1996 and landed on the Martian surface on July 4, 1997. The system functioned flawlessly during the entire seven months of flight from Earth to Mars. A life test set up of the cooling loop was used to verify the life of the system.

Future planetary science missions planned for Mars are expected to be more complex and thermally challenging than any of the previous missions. For future rovers, the operational parameters such as landing site latitudes, mission life, distance traversed, and rover thermal energy to be managed will be significantly higher (two to five times) than the previous missions. It is a very challenging problem to provide an effective thermal control for the future rovers using traditional passive thermal control technologies. Recent investigations at the Jet Propulsion Laboratory (JPL) have shown that mechanical pump based fluid loops provide a robust and effective thermal control system needed for these future rovers. Mechanical pump based fluid loop (MPFL) technologies are currently being developed at JPL for use on such rovers. These fluid loops are planned for use during spacecraft cruise from earth to Mars and also on the Martian surface operations.

The Mars Pathfinder spacecraft which will be launched in December 1996 features an active cooling system for controlling the temperature of the spacecraft. This will be the first time that such a mechanical pump cooling system is used on an interplanetary or long duration flight (over two weeks) in space. The major element of the cooling system is the Integrated Pump Assembly (IPA). It uses centrifugal pumps to circulate liquid freon to transfer heat from spacecraft electronics to an external radiator. The IPA consists of redundant pumps, motor control electronics, thermal control valves, check valves, and an accumulator. The design and flight implementation of this pump assembly were accomplished in less than two years. This paper describes the design, fabrication, assembly, and testing of the IPA.

Mechanically pumped single-phase fluid loops are well suited for transporting and rejecting large amounts of waste heat from spacecraft electronics and power supplies. While past implementations of such loops on spacecraft have used moderate operating temperatures (less than 60ºC), higher operating temperatures would allow equivalent heat loads to be rejected by smaller and less massive radiators. A high temperature (100 to 150ºC) mechanically pumped fluid loop is currently being investigated at the Jet Propulsion Laboratory (JPL) for use on future Mars missions. This paper details the trade study used to select the high temperature working fluid for the system and the initial development testing of loop components.

Multi Layer Insulation (MLI) is very commonly used in all spacecraft for heat conservation. In most instances one has to deal with MLI facing space or other cold surfaces while protecting the thermally controlled surface at more moderate temperatures than the heat sink. But in some instances, either in steady state or transient modes, one has to deal with the MLI facing the sun. Examples of such situations are during spacecraft turns, deliberate or inadvertent, when the MLI is exposed to solar insolation for short or extended periods. The effective emittance of MLI is commonly used to describe its heat loss behavior in the absence of solar incidence and is well documented in widespread literature based on measurements and rules of thumb from practice. However, when MLI faces the sun, its effective solar absorptance comes into play to determine its effectiveness in controlling the temperature of the object that it was designed to protect thermally.

Passively activated thermal control valves were developed for use in a mechanically pumped single-phase fluid liquid loop (MPFL) of the Mars Science Laboratory (MSL) rover. A key approach to the thermal control of the rover with the fluid loop is to control the flow through the rover's heat generating or heat rejecting components. This is achieved by either splitting or mixing the fluid stream coming from different branches of the system at different temperatures; actively or passively controlled flow valves are typically used for such purposes. To meet the thermal control requirements of the Mars Science Laboratory (MSL) rover, a splitting and a mixing thermal control valves with gradual control capabilities using a linear thermal actuator and a spool was developed at Jet Propulsion Laboratory (JPL). The key feature of these control valves is the balancing of the flow through the various branches of the fluid loop in order to balance the heat loads of the whole thermal system.