Achievements The Consortium was successful in its endeavours.

• Generation of Market Analysis
• Generation of EP system level specification
• Performing of two SRR Milestones to converge on the EP system level specification.
• Generation of Specifications for the different sub units PSA, FCU, PPUs
• Creation and Delivery of LEO Preliminary Design and PDR data package and preparation of the Milestone
• Setup of a universal LEO Thruster Module
  optimized for Mass production
• Harmonization of Interfaces
• Start of Production of Flow control unit for LEO Breadboard
• Conduction of LEO PDR and successful completion
• Creation and Delivery of GEO Preliminary Design and PDR data package to REA and PSA and conduction of the Milestone
• Design Finalization of LEO Thruster module
• Continuation of environmental tests on LEO Thruster module
• Coupling testing with LEO FCU
• Coupling testing with LEO PPU
• Conduction of Final coupling test LEO (Dec. 2019)
• Conduction of VSR for LEO and GEO to collect actual status
• TRR for final coupling test GEO
• Preparation of Final coupling test GEO
• Qualification of FCU to Environmental loads (TRL6)
• Qualification tests on GEO PPU to demonstrate thermal environment.
• Conduction of Final Coupling Test GEO using GEO PPU EM, FCU EM, PSA EM and HTM EV1 bread board – demonstrating krypton/xenon and operation up to 5kW power for different operating voltages.

Work and main results covered by the report

• Thales Ulm

  The System Design for the both Application lines LEO and GEO (Telecom and Navigation) has been performed. Respective requirement definition has reached maturity to start creation of the hardware deliverables.

  A 700W Thruster module has been designed and will be ready for test soon, that evens out the performance difference to thrusters of the same power class on the market. The Module is designed for high volume production and is adequate in particular for mega constellations. It maintains the inherent advantages of the HEMPT-Technology such as flexibility, simplicity and high lifetime. The concept can be transferred to larger scaled thrusters of higher power in the GEO-Application inline within this program.

  A LEO-PPU optimized for Cost has been conceptuated. It will allow to use the 700W Thruster Module among others in the different LEO Applications together with the new innovative fluidic control elements.

  A Flow control system comprised by a high and a low pressure part has been designed and first models are currently in production. The units are reduced in size, Cost, mass in comparison with traditional Components and provide better control and manufacturability.

• TAS-D

  TAS in Germany has supported to the EP system level requirements specification and Fluidic Management System level specifications. The preliminary design of the FCU for the HEMPT-NG project was created. Tools (e.g. GSE), processes for manufacturing and test procedures have been completed. Lower level specifications are finished and piece parts production is ongoing.

• TAS-UK

  TAS-UK has brought its significant wealth of experience with regards to propulsion systems for space craft, to advise the consortium on the overall specification of the system and what will give the best results for the market and performance.

  In doing this, TASUK has also produced detailed specifications foe the “Electronic Pressure Regulator” (EPR) which is the heart of the Pressure Supply Assembly (PSA) and FCU (Flow Control unit) and will push the current industry standards and state of the art, while combining it with simple, reliable, known and robust off the shelf equipment (Fill Drain Valves) to ensure market competiveness.

• EMAU

  Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far The simulations aim at predicting the thruster parameters for different magnetic field topology and thereby reducing multiple experimental trials and cost.

  Basic physics studies suggest that an optimized design of a HEMP thruster requires a minimized wall contact at the exit region, also in the plume. This can be obtained by magnetic field shaping and/or geometric modification of the plasma-wall contact zone.

  The 3050 shows an earlier decay of neutral densities inside the acceleration channel which results in a shift of the potential drop into the acceleration channel compared with other configurations (e.g. DM3a), which improves the ion angular distribution and the thrust. The higher ionization efficiency implies a strong contribution of secondly charged ions, which will further increase for higher ionization efficiencies closer to the standard experimental operational point.

Progress beyond the state of the art

Expected results until the end of the project and potential impacts (including the socio-economic impact and the wider societal implications of the project so far)

• TAS-D

  The design includes the µFCU from AST, which is the heart of the FCU and pushed the current industry standards and state of the art, while combining it with simple, reliable, known and robust off the shelf equipment (SUB-D connector & gas purifier) to ensure market competiveness. The new design allows smaller volumes, less mass, equal to better performance and improved reliability compared to existing solutions, while also improving production time.

• TAS-UK

  Inclusion of an EPR from Advanced Space Technologies GmbH (AST) to push the current industry standard, so to allow smaller volumes, less mass, equal to better performance and improved reliability compared to existing solutions, while also improving production time.

• EMAU

  Progress beyond the state of the art, expected results until the end of the project and potential impacts (including the socio-economic impact and the wider societal implications of the project so far).

  Successful development and application of modelling tools for EP systems can help to shorten the development time of new thrusters, and to avoid an experimental trial and error approach. The combination of basic physics understanding and engineering design optimization opens new chances for digitalization, also for space applications.

Objectives and Accomplishments

The Project has defined 4 main Objectives and accomplished them as follows:

Improvement and extension of performance of the EPS and its constituents to reach the capabilities demanded by the work programme and to satisfy the market need

• Thruster Module

  For the Leo Segment a high fidelity bread board 700W Thruster module has been tested for relevant environment. The underlying Constituents have demonstrated comparable performance to thrusters of the state of the art Thrusters of same power class on the market, while maintaining the HEMPT-Technology inherent advantages such as flexibility and simplicity and high lifetime.

  For the GEO segment a Thruster and Neutralizer has been designed capable to handle up to 5kW of EP power. Performance is consistent and in advance of previous models in line with the demands of the envisaged applications.

• Fluidic

  Satellite primes from the consortium have been included in the creation of the specific FMS requirements. Therefore ensuring market need is addressed and the required progression over current state of the art is addressed (and is achievable). Improved performance for the FCU has been achieved by reduced mass of FCU design and improved controllability (proportional control of Thruster and Neutraliser mass flow possible). For the GEO segment a Thruster and Neutralizer has been designed capable to handle up to 5kW of EP power. Performance is consistent and in advance of previous models in line with the demands of the envisaged applications.

• High Pressure Fluidic

  The GEO coupling test has demonstrated the capability of the high pressure fluidic elements to provide very low outlet pressure ripple and high pressure controllability. The very different flow demands are satisfied and the unit demonstrated to be a versatile unit.

Reduction of complexity on component and system level including testing and documentation to improve competitiveness in order to achieve significant cost reductions

• Thruster Module

  The LEO Thruster Module is designed for high volume production and is adequate in particular for mega constellations. It is designed to minimize production, handling and testing effort and as a standardized item it fits to many different applications without adjustments. Accordingly it allows the reduction of line items on the different system levels. An optimized strategy to drastically reduce the recurring testing and documentation effort has been elaborated.

  The same concept was applied to to larger scaled thrusters of higher power in the GEO-Application inline within this program. The module allows maintaining the technology inherent advantages of flexibility and simplicity. In addition to this, the module directly plugs into the PPU without additional harness and connectors. This minimizes the number of components and reduces effort on higher level.

• Fluidic

  Generic solution cover many mission platforms being developed, allowing an “off the shelf” system to be used minimising any NRE for a given system. Components are chosen that are reduced in complexity through technological development (for example the µFCU and the EPR in the FMS). These components are chosen as they are already demonstrated minimising the testing required. The successful coupling tests conducted with the FMS elements confirm the versatility and ease of use of the components.

Implementation of new features and technologies to enable better trade-offs at spacecraft level improving the overall performance and economic efficiency also on spacecraft level

• Thruster Module

  The HEMPT-Technology inherently supports a wide operational range and operational voltage, making it an ideal candidate for dual mode operation. This inherent capability however needs to be supported by the instantiations of designs, e.g. as specific constraints may limit the accessible area of operation. All the Thruster-Modules are specifically designed to support the operation with the innovative fluidic management system and by exploiting the FCUs flexibilities and the absence of other limitations, the full flexibility is provided.

• Fluidic

  The developed FCU design features improved controllability (proportional control of Thruster and Neutraliser mass flow possible) allowing more flexibility of the spacecraft bus while providing stable flow performance. The FCU design can cope with flow control needs to allow the HEMPT-NG “dual mode” operation, which is a discriminator compared to other electric propulsion systems.

• High Pressure Fluidic

  Equipment’s and designs are chosen to improve operational needs, such as power requirements mass, etc. while simplifying operation and interface needs

Improving technology maturity (TRL4-6) and preparing to reach the technological maturity of TRL7-8 and the market entry by the end of the second phase H2020 call for LEO and telecom/navigation application

• Thruster Module

  For the Leo Segment a high fidelity bread board 700W Thruster module has been tested for relevant environment. The tests confirmed compliance to the most demanding requirements such as vibration and radiation for the developed design. This breadboard reached through environmental testing TRL5. The experience gathered with the LEO model has been used for upscaling to the GEO thruster module in order to support technology advancement and to communalise materials and processes.

• Fluidic

  one FCU EM is planned to be tested to qualification levels in the relevant environment in the frame of the project. Starting at TRL 4-5 at the beginning of the project, the project reached TRL 6 for the FCU. The FCU components already have demonstrated compliance to the relevant environment for the GEO environment and demonstrated life capabilities in line with the requirement needs, making a life test on the FCU obsolete.

• High Pressure Fluidic

  System designed to be high TRL from outset, with final level testing to reach final needed TRL by end of second phase. System is designed by end user, ensuring required market need is met.

• System

  LEO and GEO system components where tested in final coupling tests demonstrating the interoperability of the components with excellent controllability and flexibility. The novel control concept for the commanding was demonstrated and allows significant simplification on the control side.

Impact The Project has reached the following impact elements

To develop, in the mid-term, the European capacity to compete in the worldwide arena of EP satellites.

We managed to develop a portfolio of products, that can be assembled into different topologies of EP-Solutions. When further developed and maturated these products enable our companies to offer attractive solutions able to compete with other companies.

To substantially increase medium and long term competitiveness of existing EP system technologies with a technology/application-driven approach.

Strong cost reduction efforts where conducted and have proven to be successful. For instance we have reached costs that allow us to offer solutions, that are considered by potential customers for their offers.

To pursue developments which shall be mainly market-oriented, beneficial at system level and with a strategic view to long term needs.

The system was developed in a holistic view involving all the partners to agree on the cost driver elements. The modularity of the individual elements allows to remain flexible within changing market demands. The used concepts are compatible to be upscaled in particular in view of long-term market evolution e.g. such as scientific applications or lunar industry concepts

To enable medium and longer term applications: Telecom, Space Transportation, LEO, MEO, Exploration and Science. To anticipate ambitious long-term market evolution and strategic opportunities

The system was developed in a holistic view involving all the partners to agree on the cost driver elements. The modularity of the individual elements allows to remain flexible within changing market demands. The used concepts are compatible to be upscaled in particular in view of long-term market evolution e.g. such as scientific applications or lunar industry concepts

To anticipate ambitious long-term market evolution and strategic opportunities, so that the developed systems create new markets and shape existing ones.

The market of space, due to the rapid evolution of constellations, is undergoing the most drastic changes in the past centuries. To cope with this market needs, we had to leave the orientation on customer tailored products onto standardized products, that remain sufficiently universal and flexible to meet the different customer expectations without modifications or requalification. This is facilitated by the currently developed products.

Environmental Impacts

The EP technologies generally improve the environmental Impacts by the avoidance of chemically hazardous materials such as hydrazine. The used propellants for EP are generally unproblematic in contrast to the chemical propellant baseline.

Socio Economic Impacts – Employment

All the companies involved in the program gained experience and know how enabling them to progress in the development of products and services to offer to potential customers. Some Companies have already offered products to final customers. Accordingly the chances for them to sustain in the market and to secure employment have been increased.

Socio Economic Impacts – Reduction of urbanization effects

Several interests from customer side exist in the domain of LEO Constellations. When these products are sold, the final operators can provide world wide internet in particular in weakly developed areas, that otherwise would be left by the inhabitants, as they can not do home office or raise small companies involving teleworking jobs, as they would have to commute long distance otherwise.

Conferences and Workshops

Scientific Publications