Blog #3

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Over the work period of Oct. 29 - Nov. 12, progress has been made for the heat transfer and vibration calculations. The 1D transient heat conduction is being used to model the cooling system as a sphere, and the team is still working on incorporating a cold substance into the calculations to get a more accurate result. Figure 1 shows the model we used for the heat transfer calculations. Originally, the team planned to conduct vibration calculations on the screws that will secure the cooling system to the payload housing. After discussing with the team’s advisor, Alex Blick, the team decided that the cooling system will require threaded rods to constrain the case instead of screws. Instead of doing hand calculations for the rods, the team will now perform finite element analysis on the design to find the forces transferred from the rods to the cooling system. Team 7 visited the Iron Ring Technologies facility to discuss the project with Alex Blick, and view the equipment available to the team for validation testing. At Iron Ring Technologies, Team 7 was able to test the thermal oven with a thermocouple and prepare for next semester’s validation testing. Additional supplies are being provided to the team such as the GORE sealant and aerogel tape for the manufacturing process of the design. These materials are shown in Figure 2. The material selection process is complete. Aluminum will be used for its material properties, and aerogel will be used for its insulation properties. 


Figure 1 - Cooling System Structural Overview


Figure 2 - Exterior Housing with Threaded Rod Mounting Plates



Figure 3 - GORE Sealant and Aerogel Tape

One of the biggest challenges the team has had during this work period is figuring out how to properly model the design for analysis calculations. The initial heat transfer calculations done using the 1D transient heat conduction equation were correct and confirmed by Dr. Ghasemi. However, the model used to calculate the final internal temperature does not account for a cooling substance being within the insulating case. In order to make the most educated decision, the team will conduct the necessary research in addition to receiving advice from Dr. Ghasemi. The team also had a challenge of validating that the design can withstand the forces of flight. This challenge is due to the complexity of the various forces that are applied to the case. Another challenge the team has encountered is finalizing methods of manufacturing for the design. Additionally, Team 7 has faced challenges in redesigning the cooling system case using threaded rods to secure the case to the payload bay housing. With the constraint of the four metal rods used to secure the payload bay, Team 7 was required to redesign the Camera Cooling System by including a baseplate below the case itself that will be bolted to the metal rods. 

Team 7’s plan for Nov. 12 to Nov. 26 will be to finalize the design for the cooling system that can be manufactured in the Spring semester. The team will continue work on the bill of materials and finalize decisions for methods of manufacturing. Determining the methods of manufacturing will be an important task for the team since an airtight seal is necessary for an effective resealable cooling system. The team plans to use a GORE sealant (Figure 2) to achieve a seal, but will continue to brainstorm other possible methods.

After finalizing design changes, the team will update and finalize the CAD which will then be presented to SCR’s Payload team. The team expects to complete milestone 2 with complete design by November 16.

 

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