Miniature passive thermal control valve for mixing or splitting single-phase fluid

NASAs Jet Propulsion Laboratory (JPL) developed mechanically pumped single-phase fluid loop (MPFL) thermal system for the Mars Science Laboratory (MSL) rover fluid loop that used mixing or splitting passive thermal control valve (TCV) to control the fluid flow path during different environmental scenarios. NASA has also used passively actuated TCVs in the MPFL for the past robotic space missions like Mars Pathfinder (MPF) and Mars Exploration Rovers (MER). The challenging requirements and higher cooling demands of these space missions result in increase in vehicle power and mass of the system. Therefore, the NASA is seeking an innovation that reduces the mass/volume and increases the flow capacity of TCVs. During Phase I, Kalsi Engineering designed a miniature passive TCV which was supported by computational fluid dynamics (CFD) analyses, separate effects testing of valve spool, design calculations, finite element analyses (FEA) for pressure retaining components, and wear calculations. The KEI designed TCV will passively actuate in response to a change in temperature of the working fluid and will control the fluid flow path. Both mixing and splitting TCV will have a similar valve design. The KEI TCV design will provide an improved controllability, increased flow rate, and operating capability over a tighter temperature control range while significantly reducing the weight and size as compared to the current state-of-the-art TCVs. The TCV will be used in MPFL systems of various NASAs space applications. The key components of the KEI TCV assembly include thermal actuator, valve body, lever mechanism, and valve spool. At the conclusion of Phase II, KEI will deliver a functioning prototype of the thermal control valve that demonstrate the potential to meet the performance goals of the technology. The prototype functioning will be validated through rigorous qualification and endurance testing. During Phase I, Kalsi Engineering (KEI) designed a miniature passive TCV and the design efforts were supported by analyses and testing. The KEI TCV will passively actuate in response to a change in temperature of the working fluid and will control the fluid flow path. Both mixing and splitting TCV will have similar valve designs. A tighter temperature control range of 5°C to 10°C is possible with KEI TCV design. The current TCVs are designed for a temperature control range of 20°C. If the current TCV is designed for the same temperature control range as the KEI TCV, then it will be at least five times heavier and two to three times bigger than the KEI TCV. The KEI thermal control valve design will provide an improved controllability on flow transition, increased flow rate, and operating capability over a tighter temperature control range while significantly reducing the weight and size compared to the current state-of-the-art TCVs. The technical objectives of Phase I were: Design and develop a novel three-way valve that can operate as either a mixing valve or splitting valve in a mechanically pumped single-phase fluid liquid loop system and that can be used to passively control loop temperatures by degree fraction of radiator bypass The design must focus on reducing the mass and volume and increase the flow capacity of the passive thermal control valve compared to the current state-of-the-art TCVs Demonstrate analytical and/or empirical proof-of-concept of the passive TCV at the end of Phase I and show a path forward to meet Phase II goals   The Phase II technical objectives are: Verify the thermal actuator design via separate effects and qualification testing. Verify the thermal control valve design via functional and life cycle (endurance) testing. If required, modify the TCV design to address any design issues identified during functional testing.   At the conclusion of Phase II, KEI will deliver a functioning prototype of the thermal control valve that demonstrate the potential to meet the performance goals of the technology. The prototype functioning will be validated through rigorous qualification and endurance testing.

The developed thermal control valve (TCV) will be commercially used in mechanically pumped single-phase fluid loop (MPFL) thermal systems of various NASA’s space missions/programs like, Europa Clipper, Mars Perseverance Rover, Orion, and any future Mars, Lunar, and deep space manned/robotic exploration missions. The developed thermal control valve (TCV) will be commercially used in mechanically pumped fluid loop (MPFL) thermal management systems of various non-NASA space exploration missions conducted by other space agencies like European Space Agency, Canadian Space Agency, and Indian Space Research Organization. Another application of TCV is in processor cooling and in small modular nuclear reactor. 

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