Design and Analysis of a Modular Thermal Vacuum Test Setup for Space Mechatronic Systems

Abstract

Robotic and mechatronic systems are particularly sensitive regarding their thermal environment. The operational range is narrow, and performance and functionality are strongly temperature-dependent. The highly complex moving systems are for example prone to increased friction or blocking due to material deformation, and sensors have a limited temperature range, in which they provide valid data for successful operation. At the Institute of Robotics and Mechatronics of the German Aerospace Center (DLR), functional testing as an important element of system development is performed. To support design decisions at important milestones, single components and breadboards are tested using a thermal vacuum test facility. The objective of this work was to add thermal balance testing capability to accompany system modelling. This improves system understanding and enables predictions to minimize the risk of problems. A modular passive thermal shroud with a focus on ease of handling was developed, that can be flexibly adapted to the diverse requirements of development tests of space mechatronic systems. Thermal analysis proved high homogeneity and feasible test preparation times. The design is also scalable, so that theoretically any size within the boundaries of the thermal vacuum chamber’s thermal control system can be implemented. The new test setup will first be used this year in the development of the locomotion system of the Martian Moons Exploration Rover (MMX) and the robotic arm CAESAR and provides the prerequisites for meeting the demands of future projects.