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.

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.

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