Design, simulation, and testing of an electric propulsion cluster frame

Sammanfattning: In general, electric propulsion offers very high efficiency but relatively low thrust. To remedy this, several ion engines can be assembled in a clustered configuration and operated in parallel. This requires the careful design of a frame to accommodate the individual propulsion systems. This frame must be modular to be used in different cluster sizes, and verify thermal and mechanical requirements to ensure the nominal operation of the thrusters. The present report aims to show the design process of such a frame, from preliminary modelling to the experimental study of a prototype. This document features an overview of the iterative design process driven by thermal simulations rendered on COMSOL Multiphysics. This process led to the conception of a 2-thruster and 4-thruster cluster frame. A lumped-parameter model of the electric propulsion system was also created to model its complex thermal behaviour. In addition, the 2-thruster frame was studied mechanically with analytical calculations and simulations of simple load cases on SolidWorks. Lastly, a prototype based on the 2-thruster frame model was assembled. The prototype was used to conduct temperature measurements while hosting two operating thrusters inside a vacuum chamber. The temperature distribution in the cluster was measured, and compared to simulation results. Thermal simulations of the 2-thruster and 4-thruster frame showed promising results, while mechanical simulations of the 2-thruster version met all requirements. Moreover, experimental results largely agreed with thermal simulations of the prototype. Finally, the lumped-element model proved instrumental in calibrating the models, with its high flexibility and quick computation time.