GIFTS Blackbody Subsystem Critical Design Review Blackbody Controller

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GIFTSBlackbody SubsystemCritical Design Review
Blackbody Controller

• 9 March 2004
• Scott Ellington
• sellington_at_ssec.wisc.edu
• 608 263-6771

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Blackbody Controller

• Performance Requirements and Design Overview
• Changes since PDR
• Controller Operation
• Electronics Error Budget
• Power Budget
• Supporting Analysis
• Part Selection
• Engineering Model Test Results
• Controller Verification Plan
• Calibration Overview

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Subsystem Block Diagram
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Key Electronics Requirements

• Blackbody Temperature Measurement
• Hot Blackbody Range 0 to 40C
• Ambient Blackbody Range -40 to 0C
• Long-term accuracy 0.03C (Electronics only)
• Measurement Update Rate 2.7 Hz
• Blackbody Temperature Control
• Constant Temperature and Constant Power Modes
• HBB Control Temperature Range 0 to 40C
• ABB Control Temperature Range -40 to 0C
• Set Point Resolution 0.2C
• Set Point Drift 0.005C, for a Controller board
  temperature change of 1C
• Electronics Power 1.2 W, maximum

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Changes Since PDR

• Control of both blackbodies
• Maximum total power increases from 3.0 to 5.2 W
• Redundant heater drivers deleted, dual heaters
  retained
• Add low power Reset mode
• Default operation for both blackbodies is
  constant temperature
• Add autoranging of temperature measurement ranges
• Change 15V supplies to 12V
• Add primary overtemperature protection
• Increase measurement update rate from 2.0 to 2.7
  Hz
• Command and data interface modified as necessary
• Blackbody thermal environment is colder
• Increase electronics power from 1.0 to 1.2 W
• Change controller operating temperature range to
  -55 to 50C. (Accuracy guaranteed -40 to 30C
  only)

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Blackbody Controller Operation
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Operational Commands

• Blackbody Modes
• Constant Temperature
• Constant Power
• Set Points
• Control Thermistor Select
• Temperature Measurement Range
• Range Select
• Autorange On/Off
• Reset Mode

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Electronics Error Budget Summary
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Power Budget Summary
Worst-case for cold side of orbit
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Model Transient Response
0.14 W Blackbody Power Step
Temperature Error
Time (sec)
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Model Orbital Response
Blackbody Power
Time (Hours)
Temperature Error
Time (Hours)
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Measurement Ranges and Self-Calibration
Self-Calibration Point
ADC Output
Thermistor Voltage (V)
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Self-Calibration Example
Self-Calibration Point
NB
CAL B
ADC Output
NA
CAL A
VA
VB
Thermistor Voltage (V)
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Self-Calibration
Self-calibration corrects for drift of gain and
offset in electronics Residual error depends
mainly on stability of precision resistors
NA Value at self-calibration point A NB Value
at self-calibration point B VA Voltage at
self-calibration point A (known) VB Voltage at
self-calibration point B (known) K1 Gain
constant K2 Offset constant N Value at
measurement of unknown temperature V Thermistor
voltage at unknown temperature T Blackbody
Temperature
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Controller Parts Selection Summary
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Non-Standard Parts
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Radiation and Shielding
Total mission radiation dose assumed to be 100K
Rad, including X2 safety factor RH108A (Op Amp)
requires additional shielding to 20K Rad
7872RPFS (ADC) and HS9-1840 (Mpx) performance
improves with additional shielding 110 mils
(2.8mm) of additional aluminum shielding is
provided for these parts
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PWB Thermal Analysis

• Neglected radiation, assumed conduction only to
  edges at 50C
• Modeled board as single layer with equivalent
  lateral conductivity based on copper and
  polyimide layer thicknesses
• Heat flux into board assumed uniform over each
  components area
• Total power dissipation is 1.2W
• Components shown total 0.81W, remaining 0.39W
  evenly distributed over remaining board surface
• Heat to left edge is 0.43W, heat to right edge
  0.77W
• Maximum temperature is 54C

Wedgelock
Wedgelock
Board layout
Temperature results
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Parts Derating Summary
Note Maximum PWB temperature 55C
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Engineering Model Test Set-up
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Engineering Model Test Results

• Tested at 25 C only
• Data Interface
• Resistance Measurement
• Temperature Control
• Preliminary results meet specifications

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Engineering Model 1 Photograph
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Flight Unit Acceptance Test Plan
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Electrical Test Outline
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Flight Test Set-up
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Testing Issues

• SDL Bus Simulator built with commercial
  components may not allow testing of Blackbody
  Controller over entire temperature range.
• SDL Bus Simulator required for all electrical
  tests
• SDL Bus Simulator and Blackbody Controller must
  be installed on the common motherboard in close
  proximity
• Temperature Tests of Blackbody Controller require
  SDL Bus Simulator to operate over the same
  temperature range
• Motherboard does not allow direct measurement of
  Blackbody Controller power supply currents.

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Calibration Overview

• Direct Temperature Calibration Only
• No Temperature to Resistance or Data to
  Resistance Calibration
• Would require extremely precise resistance
  references
• Intermediate calibration allows accumulation of
  errors
• Interchangeability is not an issue
• Acceptance Test Resistance Measurements
• Verify measurement ranges
• Linearity