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Various candidates for nonpetroleum electric and hybrid vehicle (EHV) subsystems have been evaluated as part of the Advanced Vehicle (AV) Assessment at the Jet Propulsion Laboratory. The subsystems include battery and power-peaking energy storage, heat engine and fuel cell energy conversion devices, motor/controller subsystems, transmissions, and vehicle subsystem (structure and body) technologies. The primary objective of this effort, was to project the mature capabilities of the various components in the 1990’s for application in the systems evaluations in the next phase of this activity. This paper presents the basic characteristics of the subsystems and compares their capabilities with projected AV subsystem requirements.

This paper describes a study on the capillary limit of a loop heat pipe (LHP) with two evaporators and two condensers. Both theoretical analysis and experimental investigation are performed. Experimental tests conducted include heat load to one evaporator only, even heat loads to both evaporators, and uneven heat loads to both evaporators. Test results show that after the capillary limit is exceeded, vapor will penetrate through the wick of the weaker evaporator, and the compensation chamber (CC) of that evaporator will control the loop operating temperature regardless of which CC has been in control prior to the event. Because the evaporator can tolerate vapor bubbles, the loop can continue to work after vapor penetration. As the loop operating temperature increases, the system pressure drop actually decreases due to a decrease in liquid and vapor viscosities. Thus, the loop may reach a new steady state at a higher operating temperature after vapor penetration.

The Mars Exploration Rover (MER) flight system uses mechanical, paraffin-actuated heat switches as part of its secondary battery thermal control system. This paper describes the design, flight qualification, and performance of the heat switch. Although based on previous designs by Starsys Research Corporation1,2, the MER mission requirements have necessitated new design features and an extensive qualification program. The design utilizes the work created by the expansion of a paraffin wax by bringing into contact two aluminum surfaces, thereby forming a heat conduction path. As the paraffin freezes and contracts, compression springs separate the surfaces to remove the conduction path. The flight qualification program involved extensive thermal performance, structural, and life testing.

A paraffin-actuated heat switch has been developed for thermal control of the batteries used on the 2003 Mars Exploration Rovers. The heat switch is used to reject heat from the rover battery to a radiator. This paper describes the development test program designed, in part, to measure the thermal conductance of the heat switch in an 8 Torr CO2 environment over the expected operating temperature range of the battery. The switch has a closed conductance of about 0.6 W/°C and an open conductance of 0.019 W/°C. The test program also included measuring the battery temperature profile over a hot case and a cold case Mars diurnal cycle. The test results confirm that the battery will remain well within the upper and lower allowable flight temperatures in both cases.

The Third Generation ENose is an air quality monitor designed to operate in the environment of the US Lab on the International Space Station. It detects a selected group of analytes at target concentrations in the ppm regime at an environmental temperature range of 18 - 30 °C, relative humidity from 25 - 75% and pressure from 530 to 760 torr. The abilities of the device to detect ten analytes, to reject confounders as “unknown” and to deconvolute mixtures of two analytes under varying environmental conditions has been tested extensively in the laboratory. Results of ground testing showed an overall success rate for detection, identification and quantification of analytes of 87% under nominal temperature and humidity conditions and 83% over all conditions.

A technology demonstration propylene Loop Heat Pipe (LHP) has been tested extensively in support of the implementation of this two-phase thermal control technology on NASA’s Earth Observing System (EOS) Tropospheric Emission Spectrometer (TES) instrument. This cryogenic instrument is being developed at the Jet Propulsion Laboratory (JPL) for NASA. This paper reports on the transient characterization testing results showing low frequency temperature oscillations. Steady state performance and model correlation results can be found elsewhere. Results for transient startup and shutdown are also reported elsewhere. In space applications, when LHPs are used for thermal control, the power dissipation components are typically of large mass and may operate over a wide range of power dissipations; there is a concern that the LHP evaporator may see temperature oscillations at low powers and over some temperature range.

Mars Exploration Rover (MER) mission launched two spacecraft to Mars in June and July of 2003 and landed two rovers on Mars in January 2004. A Heat Rejection System (HRS) based on a mechanically pumped single-phase liquid cooling system was used to reject heat from electronics to space during the seven months cruise from Earth to Mars. Even though most of this HRS design was similar to the system used on Mars Pathfinder in 1996, several key modifications were made in the MER HRS design. These included the heat exchanger used in removing the heat from electronics, design of venting system used to vent the liquid prior to Mars entry, inclusion of pressure transducer in the HRS, and the spacecraft radiator design. Extensive thermal/fluids modeling and analysis were performed on the MER HRS design to verify the performance and reliability of the system. The HRS design and performance was verified during the spacecraft system thermal vacuum tests.

NASA launched two rovers in June and July of 2003 as a part of the Mars Exploration Rover (MER) project. MER-A (Spirit) landed on Mars in Gusev Crater at 15 degrees South latitude and 175 degrees East longitude on January 4, 2004 (Squyres, et al., Dec. 2004). MER-B (Opportunity) landed on Mars in Terra Meridiani at 2 degrees South latitude and 354 degrees East longitude on January 25, 2004 (Squyres, et al., Aug. 2004). Both rovers have well exceeded their design lifetime (90 Sols) by more than a factor of 5. Spirit and Opportunity are still healthy and continue to execute their roving science missions at the time of this writing. This paper discusses rover flight thermal performance during the surface missions of both vehicles, covering roughly the time from the MER-A landing in late Southern Summer (aereocentric longitude, Ls = 328, Sol 1A) through the Southern Winter solstice (Ls = 90, Sol 255A) to nearly Southern Vernal equinox (Ls = 160, Sol 398A).

In January 2004, two Mars Exploration Rovers (MER) landed on the surface of Mars to begin their mission as robotic geologists. A year prior to these historic landings, both rovers and the spacecraft that delivered them to Mars, were completing a series of environmental tests in facilities at the Jet Propulsion Laboratory. This paper describes the test program undertaken to validate the thermal design and verify the workmanship integrity of both rovers and the spacecraft. The spacecraft, which contained the rover within the aeroshell, were tested in a 7.5 m diameter thermal vacuum chamber. Thermal balance was performed for the near earth (hot case) condition and for the near Mars (cold case) condition. A solar simulator was used to provide the solar boundary condition on the solar array. IR lamps were used to simulate the solar heat load on the aeroshell for the off-sun attitudes experienced by the spacecraft during its cruise to Mars.

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.

The Jet Propulsion Laboratory Mars Exploration Program Office is currently planning a series of exciting missions to the Red Planet. During each launch opportunity, the missions to Mars will include a Rover mission. During the earlier Rover missions to Mars such as the Mars Pathfinder mission carrying the Sojourner Rover in 1997, the main rover power source was a solar array. The power subsystem of the Sojourner Rover included a solar panel for power during the day, a non-rechargeable lithium battery for power during the night, and a power electronics board for power conditioning and distribution. Starting with the year 2003 the rover missions to Mars will incorporate a rechargeable energy storage device rather than a non-rechargeable power source. Included in the power electronics board, will be a battery controller/charger. The battery controller/charger will be able to monitor and control three parallel 4-cell battery strings.

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.

The microbial burdens of 69 cabin air samples collected in-flight aboard commercial airliners were assessed via culture-dependent and molecular-based microbial enumeration assays. Cabin air samples from each of four separate flights aboard two different carriers were collected via air-impingement. Microbial enumeration techniques targeting DNA, ATP, and endotoxin were employed to estimate total microbial burden. The total viable microbial population ranged from 0 to 3.6 × 104 cells per 100 liters of air, as assessed by the ATP-assay. When these same samples were plated on minimal medium, anywhere from 2 to 80% of the viable population was cultivable. Five of the 29 samples examined exhibited higher cultivable plate counts than ATP-derived viable counts, perhaps a consequence of the dormant nature (lower concentration of intracellular ATP) of cells inhabiting these air cabin samples.

Launched on NASA's Aura spacecraft on July 15, 2004, JPL's Tropospheric Emission Spectrometer (TES) has been operating successfully for over three years in space. TES is an infrared high resolution, imaging fourier transform spectrometer with spectral coverage of 3.3 to 15.4 μm to measure and profile essentially all infrared-active molecules present in the Earth's lower atmosphere. It measures the three-dimensional distribution of ozone and its precursors in the lower atmosphere on a global scale. The Aura spacecraft was successfully placed in a sun-synchronous near-circular polar orbit with a mean altitude of 705 km and 98.9 minute orbit period. The observatory is designed for a nominal 5 year mission lifetime. The instrument thermal design features include four temperature zones needed for efficient cryogenic staging to provide cooling at 65 K, 180 K, 230 K and 300 K.

The Third Generation ENose is an air quality monitor designed to operate in the environment of the US Lab on the International Space Station (ISS). It detects a selected group of analytes at target concentrations in the ppm regime at an environmental temperature range of 18 – 30 °C, relative humidity from 25 – 75% and pressure from 530 to 760 torr. This device was installed and activated on ISS on Dec. 9, 2008 and has been operating continuously since activation. Data are downlinked and analyzed weekly. Results of analysis of ENose monitoring data show the short term presence of low concentration of alcohols, octafluoropropane and formaldehyde as well as frequent short term unknown events.

Work is underway to deliver an instrument for analysis of the atmosphere aboard the International Space Station. The Vehicle Cabin Atmosphere Monitor (VCAM) is based on a low-mass, low-power miniature preconcentrator gas chromatograph/mass spectrometer (PCGC/MS) capable of providing sub-ppm measurements of volatile constituents in a space vehicle or outpost. VCAM is designed to operate autonomously, maintenance-free, once per day, with its own carrier and calibration gas supplies sufficient for a one-year lifetime. VCAM performance is sufficient to detect and identify 90% of the target compounds specified at their 180-day Spacecraft Maximum Allowable Concentration (SMAC) levels. The flight units will be delivered in mid-2008 and be operated in the ISS EXPRESS rack.

In contrast to the primary batteries (lithium thionyl chloride) on the Sojourner Mars Rover and the upcoming 2001 Mars Rover, the Mars Sample Return (MSR) Athena Rover will utilize rechargeable lithium ion batteries, following the footsteps of MSP 2001 Lander. The MSR Athena Rover will contain a rechargeable lithium ion battery of 16 V and a total energy of 150 Wh. The mass and volume of the projected power system will be a maximum of 3 kg and 2 liters, respectively. Each battery consists of twelve cells (6-7 Ah), combined in three parallel strings of four cells (16 V) each, such that the capability of the Rover shall be maintained even in the event of one string failure. In addition to usual requirements of high specific energy and energy density and long cycle life (100 cycles), the battery is required to operate at wide range of temperatures, especially at sub-zero temperatures down to -20°C.

NASA requires lightweight rechargeable batteries for future missions to Mars and the outer planets that are capable of operating over a wide range of temperatures, with high specific energy and energy densities. Due to the attractive performance characteristics, lithium-ion batteries have been identified as the battery chemistry of choice for a number of future applications, including Mars rovers and landers. The Mars 2001 Lander (Mars Surveyor Program MSP 01) will be among one of the first missions which will utilize lithium-ion technology. This application will require two lithium-ion batteries, each being 28 V (eight cells), 25 Ah and 8 kg. In addition to the requirement of being able to supply at least 200 cycles and 90 days of operation upon the surface of Mars, the battery must be capable of operation (both charge and discharge) at temperatures as low as -20°C.

This paper presents the results of a developmental program designed to determine physical and environmental effects on the response of balsa wood as an energy dissipator. Specifically, the effects of moisture content, density, temperature, and pressure on the energy dissipating characteristics of balsa wood are presented. It is shown that the response of balsa wood is critically dependent on physical and environmental conditions, and that the energy dissipating capacity of the material increases significantly under certain combinations of these conditions.

Progress on the delivery of the Vehicle Cabin Atmosphere Monitor (VCAM) is reported. VCAM is an autonomous trace-species detector to be used aboard the International Space Station (ISS) for atmospheric analysis. The instrument is based on a low-mass, low-power miniature preconcentrator, gas chromatograph, and Paul ion trap mass spectrometer (PCGC/MS) capable of measuring volatile constituents in a space vehicle or planetary outpost at sub-ppm levels. VCAM detects and quantifies 40 target compounds at their 180-day Spacecraft Maximum Allowable Concentration (SMAC) levels. It is designed to operate autonomously, maintenance-free, with a self-contained carrier and calibration gas supplies sufficient for a one-year lifetime. Two flight units will be delivered for operation in the ISS EXPRESS rack.