All posts by Nadine LAURET

Visit us at Le Bourget Trade show (June 17-21, 2019), Hall 2B, Booth D40

May 24, 2019Aeronautic, SpaceNadine LAURET

The Latest Innovative Solutions for Temperature Measurement Sensors Heating Systems

Thermocoax Pedigree

For 25 years, THERMOCOAX has been a leading global figure in designing, developing and manufacturing heating systems for the Aerospace market.

We provide solutions for:

– Ground applications:

R&D programs in collaboration with institutes
Ground test equipment

-Flying models:

On board satellites, 50- & 100-volt communications satellites, low orbit constellations, long range space probes
On board planes, helicopters

– Defense

Armored Vehicles
On board fighters, long range missiles
Submarines

Our solutions include:

Heating systems for space propulsion, satellite heating management, shape-memory devices
Anti-icing system for pitot tubes, AoA tubing, Ta tubing, drain masts
Bleed Air Overheat and fire detection systems
Brake temperature monitoring system
Engine temperature measuring system
Oil and fuel temperature measuring system
Heating solutions for composite industries (curing, shaping, bonding…)

Heated Waste Water Drain Mast

To remove unnecessary weight, the greywater from the washbasins is ejected outside the plane.

Most airplanes are equipped with two drain masts, one at the front and one at the rear near the washbasins.

Heritage:
- Falcon Jet : F900, F2000, F7X
- A220, Ejet1&2

Technology with self-regulation or equipped with switches
Resin shell
Power: from 28 volts to 115 volts
Power dissipation: from 20 watts to 250 watts
RTCA/DO160

Brake Temperature Monitoring System

The brake thermocouple gives the brake temperature in real time and can be transformed into a “hot brake” alert for the pilot when the value goes over a predetermined temperature threshold.

It provides the cockpit with important information regarding the temperature of the right and left brakes. If the difference is too great, asymmetric brake friction can occur, leading to difficulties in maintaining constant heading and keeping speed under control.

Thanks to this system, the pilot receives a clear “Go/Don’t Go” message for the takeoff authorization. The brake thermocouple indicates that if an emergency brake needs to be carried out during the takeoff operation, the brake will have its full efficiency so that it can stop the aircraft on time for the safety of all passengers.

Heritage:
- Airbus 350
- Embraer E-jet
Soon to be available for:
- IRKUT MC21
- Mitsubishi MRJ
- COMAC C919
- Eurofighter
K type thermocouple
Class1
Dielectric 500V
Ø5 up to 4.75mm
RTCA/DO160

Heating System for Space Propulsion

Electrical and chemical thrusters are small rocket engines used for orbit raising as well as attitude, trajectory and orbit control for satellites and spacecraft

The main purpose of pre-heating thrusters is to improve their performance at startup and to increase the lifetime of their components.

Heritage:

E3000 100volts
Prisma
Smart 1
Planet constellation
Many more

100mN to 400 Newton thrust
3 to 100 watts under 28 to 55 volts
Redundancy made with 2 heating loops
Dielectric 500 volt
Up to 1600°C

SMA heater

In order to accomplish their mission, spacecrafts require a variety of mechanisms whose typical functions are designed for deployment, articulation, positioning and displacement operations.

However, pyrotechnic separation nuts, paraffin actuators and certain other devices are no longer compatible with satellite requirements due to shock wave generation and potential contamination risks.

Non-pyrotechnic devices make use of SMA technology and are equipped with internal heating elements, offering slow and smooth responses, cleanliness and good vibration & shock resistance.

-Application:

Single one-time use Valve
Hold Down & Release Mechanism

Data:
Cable Ø1 mm 28VDC
2 to 10 watts

Cable Ø5mm, 28volts:
- 30 watts with 1 loop activated
- 60 watts with 2 loops activated

Test List for Qualification Program

THERMOCOAX manages and conducts the qualification test programs in accordance with our customer’s specification.

Our engineers design the QTP for customer approval prior to running the test.

Most of the tests (thermal, humidity, electrical, etc.) are performed in HERMOCOAX’s labs.

Tests requiring heavy equipment (vibration, acceleration, shocks etc.) are subcontracted to external laboratories or supported by our customers with the complete propulsion system.

List of possible Qualification Test:
Vibration
Acceleration
Mechanical shock
Pyrotechnic shock
Helium leak
Burn-in
Humidity
Hot Firing
Electrical cycling
Thermal cycling
Lead attachment
Dielectric
Destructive physical analysis
X-ray examination

THERMOCOAX is a major competitor for onboard heating solutions for electrical heating systems and is proud to be a part of challenging international space programs.

THERMOCOAX focuses on high quality heating products for maximum stability and repeatability during operation. For 20 years we have understood our customers’ challenges to manufacture spacecrafts to create a better life for human beings.

Extensive new constellation programs are currently in construction.

THERMOCOAX is now ready to support the market with highly reliable and efficient heating elements.

THERMOCOAX Nuclear department : 2018 highlights

April 30, 2019NuclearNadine LAURET

DISCOMS project: a happy ending with promising results.

Following the FUKUSHIMA disaster, the French government decided to allocate some of its budget to stimulate R&D in the field of nuclear safety and radiation protection.

The DISCOMS (DIstributed Sensing for COrium Monitoring & Safety) project aims at developing an innovative under-vessel remote monitoring instrumentation to improve NPPs safety in operation.

A team of reputable Research Institutes, universities and Industrial companies was formed to address the development of a remote monitoring solution able to improve the safety of Nuclear Power Plants and strengthen the third containment barrier in case of a severe accident with a reactor breakthrough and corium release.

Long-length Self Powered Nuclear Detectors have been developed to identify the reactor core debris progression, the erosion of the concrete floor, as well as to monitor the corium cooling.

After multiple simulations and theoretical validations, a complete system (sensors + electronics) has been tested with corium and has demonstrated its technological readiness.

Safety Culture

THERMOCOAX was distinguished with a Safety Culture award from Rolls Royce. In 2019, THX will continue its effort to improve working practices and place safety as a main priority.

Skills & Knowledge Management

At the WNE, THERMOCOAX was nominated for an award in the “Skills & Knowledge Management” category.

In its Quality Assurance Manual, THERMOCOAX takes into account the requirement presented in the ISO 19443.

One goal: anticipate chain standards for future nuclear supply today to maintain the highest standard of safety culture, quality and competitiveness.

“During Rolls Royce Nuclear supplier days” sounds unnatural in English but difficult to amend without knowing meaning of source text.

High-End Thermal Solutions for Semicon Front-End Processes

February 28, 2019SemiconductorALD, Ampoule heater, Canister heater, Chucks, CVD, Gas delivery, Gas line, Gas line heaters, Gas line heating jackets, Heating jackets, HF thermocouple, PeALD, PeCVD, RF thermocouple, Semicon, Thin-film deposition, Transfer linesNadine LAURET

In the semiconductor sector, machine-manufacturers at different stages of the wafer manufacturing process are looking for high-performing heating solutions that meet cutting-edge specifications in terms of design, uniformity, repeatability and lifetime but that are also able to withstand very corrosive environments under ultra-high vacuum and with ambient temperatures above 100°C.

THERMOCOAX’s expertise is in responding to strict specifications and in designing tailor-made high-performing thermal solutions from mineral insulated cables.

Our engineering know-how, our prototyping capacity and our knowledge of mineral insulated cables allow us to offer unique solutions to our customers.

We are also able to develop complex mechanical parts that incorporate our heating elements.

Our strength is that we master all these processes internally with a factory certified “Copy exact” dedicated to SEMICON applications for wafer manufacturing processes: high precision machining, welding, soldering, tests and qualifications, control, ….

Over the last few months, THERMOCOAX has developed an innovative, reliable and efficient solution to heat a system inside a vacuum chamber.

The challenge of this project was combining two thermal systems that had to be integrated into the customer’s final system, in an ultra-high vacuum and corrosive environment at high temperature.

The first thermal system that we had to develop was a kind of heating element coiled on a mandrel

The solution was complex because we had to meet critical specifications such as:
• The limitations and dimensional tolerances of the heater
• Critical operating temperature of 800°C
• Achieving a 10% power distribution uniformity – Several heating areas have been designed with different power densities
• Operational guarantee > 5 years, in ultra-high vacuum with a corrosive environment

We designed 6 different concepts and compared these solutions in order to select one.

THERMOCOAX chose a design with EC wound / brazed on a metal support which was mass-produced in line with a specific process.

Progress achieved – results achieved – originality of the chosen solution

This design, which at first glance looks like a heating cartridge, is innovative in its design because it has a fully wound heating element integrated in a mandrel by a process developed by THERMOCOAX.

The expected performances and lifetime results were validated during the qualification phase of the prototypes.

This all-encompassing design by THERMOCOAX targets many areas, with its performance advantages, its low cost design and its long lifetime performance.

The second thermal system is a complex assembly of a 3D design metal part with high temperature heating elements

Problems to solve

Being able to assemble complex metallics with a demanding dimensional specification and an operating temperature that can reach up to 800-900°C.

This temperature is near critical, especially when specifying a lifetime greater than 5 years.

We had to resolve the problem of complex machining.

It was also necessary to take the deformations caused by the machining into account, as well as the deformation from the welding and brazing processes.

The design and manufacturing method was developed entirely by THERMOCOAX to achieve a feasible design suitable for high volume manufacturing and minimizing the risk of non-compliance with dimensional or functional specifications.

We worked on raw material (304L) and evaluated and selected the material that was the most cost / quality / time effective.
For the metallic parts we evaluated: Full mass / forged / foundry material.

The other challenge with these pieces was treating them on the surface so that the highly corrosive liquid in the vacuum chamber would not stick to them.

After much research and testing we identified a substance that has very good anti-wetting properties and could be used for this type of application.

Work has also been done to validate the most suitable deposition process (PVD or CVD).
We finally selected the best deposit solution that operates in up to 600°C.

THERMOCOAX Turbines Solutions Long-life Thermocouples

January 25, 2019AeronauticNadine LAURET

Thermocoax announces a new thermocouple generation :

24 000 operation hours in heavy duty gas turbine
Exceptional resistance to vibration, thermal stress, corrosion…
Already demonstrated in air-cooled 446MWatt machine
37 gas turbine already equipped
18 currently under operation
1.2 Million hours cumulated
699 starts

Technical application of long-life thermocouples

The gas turbine frames market is a challenging business. On the one hand, the frames are more and more high-tech and expensive and on the other hand, the energy producer is driven by low electricity production prices. To make them both compatible, gas turbine frames have to be reliable to minimize operation disruption and to offer longer periods without maintenance. Therefore, providing thermocouples with an increased lifespan decreases the downtime of the turbine, thereby significantly reducing the maintenance costs.

Required Benefits

One of the key aims of the OEM GT is to find high-accuracy thermocouples on the market that are able to perform in harsh environments and work for 24,000 operating hours without failing.

Thermocouples installed in exhaust gas lines are exposed to corrosion, vibration, thermal expansion and much more.

Thermocoax’s Solution: Design a thermocouple that is out of the excitation bandwidth

Based on the capitalized cumulative return of experience in several fields, such as aeronautical, nuclear and oil & gas, THERMOCOAX has developed a vibration absorber that is secured to the thermocouple to avoid premature breaking when the thermocouple is subject to vibrations and thermal expansion. This solution is protected by a patent.

The invention with the patent number 63638FR/CZ/BB – 17 58061 is a vibration absorber that is secured to the thermocouple cable and is made to fit inside the screen/thermowell.

The number and size of the absorbers depend on the gas turbine specification in terms of vibration, acceleration and thermal cycles.

To demonstrate the advantage of this new design and its ability to reach 24,000 operating hours, THERMOCOAX has undertaken simulation and experimental testing:

1.1 Simulation: Comparison between a thermocouple with and without a vibration absorber

Input data:

Ø ≈ 3mm Type K thermocouple with 316L SS sheath
Length ≈ 500mm insertion length in SS316L thermowell
Temperature 870°C
Frequency range: 0 to 250Hz, mean value 100Hz

	Long-Life TC	Standard TC
Resonant Frequency of the TC	174Hz	68 Hz
Stress produced by the Resonant Frequency of the TC	11.1MPa	450MPa
Number of cycles made before Breaking of TC at its Resonant Frequency	9×10⁹	40
Life-span at the Resonant Frequency of the TC	2.1×10⁹ days	10 days

1.2) Field test results: Comparison between a thermocouple with and without a vibration absorber

Ø ≈ 3mm Type K thermocouple with 316L SS sheath
Length ≈ 300mm insertion length in SS316L thermowell
Temperature 900°C
Frequency range: 0 to 1000Hz,

Long-Life TC

Standard TC

Resonant Frequency of the TC

68Hz

174Hz

Life-span during the Endurance Test

Still works after

20,000h

Stops working before 3000h

The test is still ongoing. We can already say that the field results demonstrate the extraordinary positive impact on the reliability of the gas turbine. This new long-life thermocouple lasts 7 times as long as a standard thermocouple.

For the powerplant operator, the cost saving is at least 150,000 euros in thermocouples for every 20,000 hours of operation because there are no costs incurred from the frame shutting for unexpected maintenance.

THERMOCOAX Pedigree

For 60 years THERMOCOAX has been a worldwide key player in designing, developing and manufacturing thermocouple temperature sensors for industrial and aircraft gas engines.

With our custom-made Mineral Insulated Cable, we are providing our customers with solutions for:

Development applications:
- R&D programs with institutes
- Ground, aero & industrial test equipment
Production models:
- Thermocouples in harsh environments with an installed base of over 300,000 thermocouples:
  - Heavy duty gas turbine
  - Stroke engine
  - Steam turbine
- Thermocouples for helicopter engines with 15,000 units installed
Thermocouple characteristics:

Thermocouples are produced with Class 1 custom-made cables with a diameter from 0.25mm up to 6mm.

Single (2 wires) or duplex design (4 wires)
Types K and N are the most used in the industry.

Thermocoax recommends type N thermocouples for a working temperature of between 600°C and 1100°C, which offer a smaller drift compared to type K.

We have several sheath alloys available:

Stainless Steel
Inconel
Haynes
Platinum
Tantalum

THERMOCOAX Calibration Lab

100% of the mineral insulated cable and finished thermocouples are controlled in the calibration lab.

Capabilities

Fixed points

TEMPERATURE -Thermocouple
Calibration purpose	Mesurand	Measurement range	Best calibration uncertainty	Measurement principle/Method reference (*)	Calibration tools (reference, Equipement)	Activities in Lab and/or on site
Thermoelectric couple	Temperature Electromotive Force Signal Voltage	Melting ice point 0,00°C	±0,3°C	Method by comparaison at a fixed point / PP200D010 Rev06	Water triple, Sn, Pb, Zn cells Platinum resistance thermometer multimeter Melting ice point	Lab
		Water Triple point 0,01°C	±0,3°C
		Sn Melting point 231,928°C	±0,5°C
		Pb melting point 327,46°C	±0,5°C
		Zn melting point 419,46°C	±0,5°C
		Sb freezing point 630,62°C	±0,9°C		Sb Cells Thermoelectric couple S Type Multimeter Melting ice point

By comparison

TEMPERATURE -Thermocouple
Calibration purpose	Mesurand	Measurement range	Best calibration uncertainty	Measurement principle/Method reference (*)	Calibration tools (reference, Equipement)	Activities in Lab and/or on site
Thermoelectric couple	Temperature Electromotive Force Signal Voltage	-40°C to 0°C	±0,4°C	Method by comparison / PP200D022 rev 08	Ethylene/Glycol constant temperature bath Platinum resistance thermometer Multimeter Melting ice point	Lab
		0°C to 80°C	±0,3°C
		50°C to 200°C	±0,4°C		Oil Constant temperature bath Platinum resistance thermometer Multimeter Melting ice point
		150°C to 400°C	±0,5°C		Bath of melted salts Platinum resistance thermometer multimeter
		400°C to 500°C	±0,6°C
		500°C to 700°C	±1,3°C		Tubular furnace S type thermoelectric couple Multimeter Melting ice point
		700°C to 1100°C	±1,4°C
		1100°C to 1200°C	±1,6°C
		1200°C to 1300°C	±2,1°C
		1300°C to 1500°C	±2,4°C

Heated cable inlet for climatic chambers

December 21, 2018ISOPADNadine LAURET

Target market :

Manufacturers and operators of climatic chambers.

Challenge :

Prevention of condensation at the cable inlet inside and outside of climatic chambers.

Description of the problem without a heated cable inlet :

Condensation at the cable inlet due to climatic differences between the inside and the outside of the chamber.

Condensation on the measuring cables inside and outside of the temperature test chamber when using a standard inlet.

Risk :

High financial risk if long-term climatic tests have to be cancelled because of condensation in the climatic chamber. Condensation damages the test materials and affects the climate regulation in the chamber.

Solution :

Heated cable inlet from THERMOCOAX Isopad® GmbH. A standard inlet with geometric properties, the best possible sealing and a heated area inside of the cable inlet.

Test results with a heated cable inlet :

Decrease in the amount of condensation formed inside the climatic chamber by approx. 95% and by 100% outside of the climatic chamber!

The risk of failure is extremely reduced because there are hardly any condensation drops in the chamber (airflow can spread the drops onto the test material).

No water on the floor outside the chamber. The risk of slipping is eliminated, thereby extremely reducing the risk of accidents !

Successful test campaign on neutron sensors

November 30, 2018NuclearNadine LAURET

THERMOCOAX has finalized a test campaign on neutron sensors.

Reactor Pool : experimental fixture

Despite stringent time constraint, a highly professional IJS team was prompt to react and welcome a team conducted by THERMOCOAX and relying on the best internationally recognized experts from different European nuclear organizations.

Multiple irradiation tests have been carried out.

IJS reactor being very well characterized, results are confirmed to match with our stringent expectations: perfect matching between theory and practical results!

An additional demonstration of the THERMOCOAX mature technology readiness.

About THERMOCOAX

THERMOCOAX has over 60 years of expertise in instrumentation and heating solutions. It provides solutions in the world of nuclear, aerospace and semicon industries. It design, qualify and manufactures sensors for harsh environment with a focus on nuclear on temperature and radiation measurement.

About IJS Jozef Stefan Institute

IJS Jozef Stefan Institute in Slovenia has over 50 years of expertise. Reactor Infrastructure Centre (RIC) department is operating a TRIGA Mark II reactor. Reactor physics department is directed mostly towards development of new calculation methods for research and power reactors. Several program packages for reactor calculations both for TRIGA research reactor and Krško nuclear power plant. Jozef Stefan Institute also study advanced fourth generation reactors, advanced neutron sources and data and materials for fusion technology are also studied.

THERMOCOAX ISOPAD Gas line heating Jackets

October 17, 2018ISOPADALD, Ampoule heater, Canister heater, Chucks, CVD, Gas delivery, Gas line, Gas line heaters, Gas line heating jackets, Heating jackets, HF thermocouple, PeALD, PeCVD, RF thermocouple, Semicon, Thinfilm deposition, Transfer linesNadine LAURET

Gas line heating jackets for high purity gas delivery systems

Gas line heater

THERMOCOAX is involved in many levels of the wafer manufacturing processes working with OEM all around the world.

We provide thermal solutions for applications such as lithography, deposition, etching, ion implantation, or annealing.

While developing our business in the ALD deposition processes, we understood the need of our customers to heat the high purity gas delivery systems from the ampoule to the deposition chambers.

Temperature control is extremely important in the deposition process.

This is why industrials need to have a high performance gas delivery system in terms of management of the gas flow rate and temperatures.

Transfer line heating jackets are used for both solid and liquid precursor management in semiconductor deposition processes.

The heating temperature requested is in the range of 80°C to120°C. Typically, the range of thermal solutions is provided by our German subsidiary ISOPAD, specifalist in the development and manufacture of customized silicon heating solutions.

The main concern of our customers was the need to keep the temperature uniform all the way from the gas generation ampoule to the deposition chamber. This complex way includes straight tubes, Tees, elbows (2P,3P), VCR, valves, manifolds and complex components.

Each delivery system is specific to the customer process.

That was the challenge for THERMOCOAX ISOPAD.

Another limitation of this application is the use of jackets that must be installed, positioned as easily as possible in an environment with limited space.

ISOPAD has a lot of experience in high performance silicon jackets.

The silicone jacket is a well-known product for our company, all the expertise we have gained from working with our other OEM customers have been used to design and construct a high volume production solution.

All core competencies are in house, only the raw materials are bought in.

Many years ago, we developed filter heating jackets for the biotechnology industries, built with seamless silcone rubber that does not need affixing.

Silicone Jacket

These jackets have a real advantage on the market because of the flexibility they provide in terms of positioning and ease of cleaning.

The one-piece molded design is formed out of a two-component silicone rubber compound that fits around the filter housings without any affixing methods that may not be compliant for use in those production processes.

The target for THERMOCOAX ISOPAD to adapt this solution to the SEMICON applications was:

to adapt this technology to smaller diameters, and to complex shapes.
To achieve the customer specifications on uniformity over the full line assembly
To find good materials for clean-room use and respond to the SEMICONDUCTOR requirements in term of low contamination properties.

Due to our expertise, we quickly managed to design and prototype a full line assembly responding to our customers’ demanding specifications.

The advantages of our solution:

These heating jackets provide an innovative design on the market with short delivery time.

Built with seamlessly-molded silicone rubber, these jackets offer a better thermal performance due to a close-fitting design and a high uniformity over the complete line.

With a product that has demonstrated a longer service life than existing solutions, we can deal with any installations of new deposition systems, but also spare parts for installed systems.

Applications that addresses our offer:

PeCVD, PVD, ALD, Epitaxy, ETCH, Wafer packaging, cleaning chamber processes etc.

THERMOCOAX KEY DIFFERENTIATION FACTORS:

Technical Performance

. Custom-built line assembly

. Seamlesly-molded silicone

. Close-fitting design

. Better thermal performance, heat 68°F (20°C) up to 275°F (135°C)

. Reduced installation faults

. Lower overall risk of production downtimes

. Longer service life

. Easy to install & remove

. Outgassing according NASA standards

THERMOCOAX is a certified for Copy Exact:

Specifications

Thermal gas flow uniformity: ± 5°C in the complete line assembly
Better thermal performance, heat 68°F (20°C) up to 275°F (135°C)

(minimum 1 meter of length)

Reduces installation faults
Lower overall risk of production downtimes

Jacket: silicone rubber, seamlessly molded, easy to clean, IP68 standard
Minimum gas line diameter: ¼ inch OD
Affixing technology: ” snap-on ” design by molding, easy to install and remove
temperature: 200 °C
UL-V0 standard, FDA-approved ultra-low emission material

Heater design to fit standard components used in weldments

Straight tube
Elbows (2p, 3p)
Tee
VCR fitting, etc.
Specially-formed and customised heaters for valves, manifolds and complex components

This high purity gas line heater development has been combined with the development of ampoule and canister heaters which are used in all deposition processes and with RF thermocouples used in the plasma environment to control the temperature in the deposition chamber.

Ampoule heater

THERMOCOAX meets the requirements of the SEMICON market in terms of repeatability, temperature uniformity, production control, quality monitoring, and COPY EXACT high volume manufacturing.

For high volume manufacturing, THERMOCOAX works with a continuous improvement strategy for:

Design
Manufacturing process
Cost reduction

THERMOCOAX is highly adaptable to specific customer requests

Heating System for SMA actuators

September 26, 2018SpaceNadine LAURET

You are looking to replace your pyrotechnic actuators with shape memory alloy technology for your space applications ? We have the most advanced industry-proven solutions.

Spacecrafts require variety of mechanisms to accomplish the mission. The typical functions are deployment, articulation, positioning, displacement.

Pyrotechnic separation nuts, paraffin actuators and others devices are hazardous for the satellite, regarding shocks waves generation and potential risk of contamination.

Shape Memory Alloy ( SMA ) technology equipped with inner heating element, offers smooth and slow behavour, higher cleanliness result and good vibration & shock resistance.

Thermocoax addresses this new market with miniature and powerfull heating element, same components already demonstrated on propulsion and thermal management on board satellite.

Main applications are single one time used valve, Hold Down & Relieve Mechanism (HDRM), Pin Puller, deployment Hinge.

[showhide type=”links” more_text=”To receive the entire White paper on SMA application please click here” less_text=”Hide”]

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Heating coil

THERMOCOAX heating space products with Spacecraft Electrical Propulsion System

August 31, 2018UncategorizedNadine LAURET

New Generation of Pre-Heating Solution for : Hall-Effect Propulsion Thruster

ring

THERMOCOAX Pedigree

For 15 years, THERMOCOAX has been a worldwide key player in designing, developing and manufacturing heating systems for the space market.

We provide solutions for :

Ground applications :

R&D programmes with institutes
Ground equipment

Flying models :

Heating management systems at 50 & 100 volts for Satcom
Catalyst bed heaters for chemical propulsion
Heating solutions for Hall-effect thrusters

Scientific Mission :

Heating systems on Curiosity Rover
Heating elements on ISS for MSL
Heating elements for pyrolysor on Cassini-Huygens Titan probe

THERMOCOAX heating solution

Technical Application of pre-heating ring

The new generation of communication satellites is improved with more power available (13kW for E3000 platform) and allows the use of electrical propulsion systems for orbit raising and for all station-keeping manoeuvres, wheel offloading, station relocation and final re-orbiting for disposal.

The electrical propulsion system allows a significant reduction in spacecraft mass. A disadvantage is the average length of 8 months to raise the final orbit in comparison to a few days for chemical propulsion.

The first platform to be equipped with the THERMOCOAX pre-heating ring is the EUTELSAT172B, produced by Airbus Defense and Space, equipped with Russian FAKEL EPS.

hall effect thruster

For faster startup and to protect the thruster from premature erosion, a pre-heating system is installed around the electrical thruster. Each pre-heating ring supplies 28 watts.

Technical Description of heated Ring

We use our best mineral-insulated cable.

Mineral-insulated cable with 2 resistive wires welded together at the tip to make one electrical loop.

Redundancy can be reached by using 2 separate heating cables with an outer diameter of 1mm or only 1 cable with 4 wires for 2 heating loops with a minimum outer diameter of 1.5mm.

heating element

The cables are installed and brazed in the metallic ring.

To get the perfect dimensions and tolerance, the ring is reworked and then polished.

ring

Finished product cleanless

Catalyst Bed Heater :

2 redundant electrical loops
Nominal power supply: 28 to 55 volts
Power version per loop:

30 watts under 70VDC
60 watts with 2 loops activated

Max exposed temperature:

1000°C with Inconel

Other power and voltage available.

Mineral-Insulated Cable :

Version exposed to 1000°C :

Inconel 600 sheath
4 nickel-chromium wires

Xray four wires heater

Lead Wires :

4 wires
Color code for each loop
AWG24 or 26
Strength 1.4kg

Acceptance Test Criteria of the catalyst bed heater :

Helium Leak Test
X-ray of the ring
X-ray of the junction MIC/lead wires
Lead attachment strength test
Visual and mechanical examination
Overvoltage
Line resistance
Insulation resistance under 500 volts
Burn-in test
Dielectric 100/300/500VAC, 60Hz/60s
Weight
Final Manufacturing Report

Test List for Qualification Program

THERMOCOAX manages and conducts the qualification test programme in accordance with our customer’s specification.

Our engineers write the QTP for customer approval prior to running the test.

Most of the tests (thermal, humidity, electrical, etc.) on the space grade heating solutions are performed in THERMOCOAX’s labs.

Tests requiring heavy equipment (vibration, acceleration, shocks, etc.) are subcontracted to external laboratories or supported by our customers with the complete propulsion system.

List of Typical Qualification Tests on Catalyst Bed Heater :

Vibration
Acceleration
Mechanical shock
Pyrotechnic shock
Helium leak
Burn-in
Humidity
Hot firing
Electrical cycling
Thermal cycling
Lead attachment
Dielectric
Destructive physical analysis
X-ray Examination

Example of vibration spectral

Packaging and Cleanness :

Packaging is designed specifically to ensure excellent condition of the catalyst bed heater during transportation and storage :

vacuum packaging

marking packaging

THERMOCOAX supplies the new Hall-effect thruster with 1500 and 5000 watts, here are a few examples :

SMART1
Alphabus
Alphasat

To come :

SSL1300
E3000e
Boeing 702 platform

THERMOCOAX is the major player for onboard heating solutions for electrical thrusters and is proud to participate in challenging international space programmes.

THERMOCOAX’s focuses on high-quality heating products for maximum stability and repeatability during operation. We have understood our customers’ challenge to manufacture spacecrafts for over 20 years for a better life for human beings.

New large constellation programmes are currently in construction, THERMOCOAX is now ready to support the market with high-reliability and high efficiency heating ring for electrical thruster.

In-Core water level detector

June 18, 2018NuclearNadine LAURET

Over the last decade, THERMOCOAX has developed a range of Ex-Core accident resistant cabling systems and In-Core instrumentation assemblies for Gen 3 reactors.

Based on THERMOCOAX unique expertise and taking profit of the extreme robustness of its MIneral Cable technology, THERMOCOAX has developed, tested and qualified a Reactor Pressure Vessel Level (RPVL) detector.

Before making the detector commercially available, THERMOCOAX has partnered with SIET (www.siet.it) to verify detector functionality at normal and abnormal conditions.

Some results have been published during the latest BEPU 2018 Conference. Click here to read an abstract

THERMOCOAX Nuclear team remains available for further information.