Thermal Systems

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Our vision: Number one space product supplierRUAG Space’s vision is to be the leading supplier of space products. We laid the foundations for realizing this vision as a partner in institutional European space programs from the very beginning. RUAG Space has played a part in all major European missions, where we have acquired know-how that benefits our customers all over the world today.

Our values: Collaboration, high performance, visionary thinking Our corporate culture is based on the values of collab-oration, high performance and visionary thinking. These values determine our actions and characterize our relationships with our customers and partners. For more than four decades, RUAG Space has been an in-dustrial partner to national and European space agen-cies. And we have been supplying our products to man-ufacturers of satellites and launchers for just as long.

Outstanding product performance and consistency in meeting delivery deadlines are the yardsticks by which we measure success. Above all else, we are focused on reliability, as there is no scope for failure in space.

At the heart of RUAG Space’s strategy is a clearly struc-tured product portfolio, which we expand according to a definite plan. In expanding the portfolio, we place particular emphasis on space products that are attrac-tive in growth markets outside the institutional Europe-an sphere.

The cornerstone of our success: Our employees In Switzerland, Sweden, Austria, Finland, Germany and the USA, more than 1,300 employees of RUAG Space develop, manufacture and test products for satellites and launchers. Teamwork, trust and respect character-ize the work environment at RUAG Space. Our employ-ees work in close cooperation with customers and part-ners. The success of RUAG Space is based on the skills and commitment of our staff, on the accuracy and reli-ability of our mechanics, and on the creativity and know-how of our engineers.

RUAG Space: Part of an international technology group RUAG Space is a dedicated division within RUAG, an international technology group for aerospace and de-fense. RUAG has its sites in Switzerland, Germany, Austria, Hungary, Finland, Sweden and the USA. RUAG employs 9,100 people worldwide.

RUAG Space is the leading supplier of products for the space industry in Europe. Experience, outstanding reliability, customer focus and a comprehensive, clearly structured product portfolio make RUAG Space the partner of choice for manufac-turers of satellites and launchers across the globe.

Precision on earth. Reliability in space.

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Our vision is to be the leading competence center for vacuum thermal insulation solutions for space and cryogenic applications. Our mission is the development and production of multi-layer insulation for space and cryogenic industry to make our customers more com-petitive. To achieve this mission we focus on first-class products and reliable and long-standing partnerships with our customers.

Our development and production process comprises: • Thermal and mechanical engineering • Design and development • Production and integration

We are certified according to ISO9001, EN9100 and ISO14001.

Space applicationsRUAG Space activities for development and production of multi-layer insulation for space applications (satel-lites and launchers) started in 1991. Since then we have developed our competencies and skills in more than 150 projects to become the leading European supplier of multi-layer insulation for spacecraft.

RUAG Space is the leading European supplier of multi-layer insulation for spacecraft and market leader of super-insulation for cryogenic medical systems. The experience we have gained in more than two decades of thermal design and production enables us to increase your competitiveness with RUAG’s leading edge technology solutions.

Thermal Systems for space and cryogenic applications

Ongoing Space Programs CustomersSentinel 1 & 3 Thales Alenia Space, Italy; Casa SpainBiomass Airbus UKMETOP 2nd Generation Airbus FranceMeteosat Third Generation OHB GermanyGalileo OHB GermanyOneWeb OneWebHeinrich Hertz OHB GermanyAriane 6 Ariane GroupEarthCare AirbusNGSAR Airbus GermanyEUCLID Airbus France, SpainJUICE Airbus SpainSARah OHB Germany

Completed Space Programs CustomersCluster Airbus, Netherlands & GermanySoho Payload Module Airbus, UKHuygens Airbus, GermanyEnvisat Instruments Airbus; Thales Alenia Space, ItalyMechanisms ITF, AustriaOdin RUAG Space, SwedenMeteosat 2nd Generation Thales Alenia Space, FranceSeviri Airbus, FranceXMM Payload Module RUAG Space, SwitzerlandIntegral Payload Module Thales Alenia Space, ItalyAbrixas OHB, GermanyMetop Airbus, Germany & UKRosetta Airbus, FranceMars Express Airbus, FranceVenus Express Airbus, FranceRapid Eye Jena Optronics, Germany; NASA, USAHerschel Dawn Field Camera Airbus, GermanyHerschel & Planck Service Modules, Thales Alenia SpaceGoce Airbus, GermanySAR-Lupe OHB, GermanyGAIA Airbus, Germany & France, SENER, SpainLisa Pathfinder Airbus, UKSwarm Airbus, UKSmall GEO OHB, GermanyEDRS-C OHN, GermanyIridium Next Thales Alenia SpaceBepi Colombo Thales Alenia SpaceJames Webb Space Telescope RUAG Sweden Antenna MLI

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Cryogenic applicationsMoreover, RUAG Space has developed great expertise in the field of cryogenic super-insulation within the last 30 years.

Today RUAG also offers the development and production of cryogenic super-insulation for various applications such as helium liquefiers or superconducting magnets.

Typical industrial sectors are:• Medical Imaging• Nuclear Magnetic Resonance• Technical Gases• Accelerators• Superconductor Technology

Cryogenic super-insulation from RUAG Space is sup-plied for, however not restricted to, the following ap-plications: • Nitrogen and Helium Cryostats • Cryogenic Piping and Storage Tanks • Superconducting Magnets • Particle Accelerators and Detectors • Helium Liquefiers • Test Chambers• Superconducting Cables We can offer a broad range of vacuum super-insulation pack-ages with polyester or aluminium foils and different spacer materials. We have also developed the procedures for pro-duction on a larger industrial scale. Multi-layer super-insula-tion for cryogenic applications is covered by the COOLCAT Line of multi-layer super-insulation products.

COOLCAT 2 NWMulti-layer super-insulation made of double side aluminized, perforated polyester foil and non-woven polyester spacer

COOLCAT 2 NFNon-flammable multi-layer super-insulation made of pure al-uminium foil and glass fibre fleece

COOLCAT 2 LOXNon-flammable, liquid oxygen compatible multi-layer su-per-insulation made of pure aluminium foil and glass fibre cloth

COOLCAT 2 NINon-inductive multi-layer super-insulation for minimizing eddy currents, made of polyester foil aluminized in squares and non-woven polyester spacer

COOLCAT 4KLow absorptance helium can laminate

COOLCAT B-R50Low emissivity double sided aluminized adhesive tape with polyester carrier, optimized for use under cryogenic environ-ment

COOLCAT 1050Low absorptivity adhesive tape with aluminium carrier for in-sulating surfaces at 4K and for installing COOLCAT 4K

COOLCAT H Welding protection made of aluminium foil and fibre-glass cloth

For detailed product description and performance data please refer to our Thermal Insulation Products brochure.

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The design of the (super-) insulation blankets includes all slits, fixations and grounding points necessary for the appli-cation. The design is based on electronic 3D models of the application, e.g. helium can, Nitrogen tank, satellite and/or instrument shape. For very complex shapes, 3D mock-ups can be built or a templates fit-check on the application will be performed.

For easy shapes only 2D design can also be sufficient, which is especially common in the cryogenic field.

Thermal Systems management, engineering, design and ad-ministration is located in RUAG Space Austria’s head office in Vienna.

Design tools CAD programs Siemens NX Data formats DXF, STEP FEM software NX Nastran, Ansys Thermal software Thermica, ESATAN

Space applicationsThe configuration of the individual insulation is designed and manufactured according to customer requirements. The blankets are then tested against verification requirements. RUAG Space also integrates the blankets on the instruments and satellites at the customers’ premises.

Based on the geometrical inputs and the set of thermal, me-chanical and other mission requirements, we provide three-dimensional design of insulation on CAD models for further development to the two-dimensional shape of insula-tion blankets which will be produced in our production facil-ity. Optimum fit, well defined interfaces, minimum mass and the desired thermal performance are the design drivers for our engineering and design process.

Materials & special products for space• Polyester (Mylar) blankets (aluminized polyester foils

with polyester interleaving spacer)• Polyimide (Kapton) blankets (aluminized polyimide foils,

embossed or high temperature polyimide, spacered)• High temperature shielding (Titanium)• High radiation shielding• Mechanism multi-layer insulation• Teflon blankets and Second Surface Mirrors (SSM)• Optical Surface Reflectors (OSR)• Heaters, thermistors, thermostats, doublers, interfillers

Our design and development of thermal hardware is based on proven and efficient processes and aided by state-of-the-art design software tools. It can be applied to a wide range of materials.

Design and development

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Cryogenic applications Based on our customers’ specific geometrical and thermal requirements, two-dimensional and/or three-dimensional design data will be generated by us and provided to the customer.

We can work out the composition and the design of specific pre-cut and pre-assembled super-insulation. E.g. for Helium and Nitrogen systems we can define the number of reflective layers, optimize the shape of blankets and overlaps, we cut and pre-assemble the blankets for minimized installation ef-fort and maximize the insulation performance as well as op-timize the repeatability in a serial production.

Blankets can be made of aluminized polyester or aluminium foil, with polyester or glass fibre spacer, including helium can foils, welding protection, tapes and Velcros for installation and even more features. The customer can define super-insu-lation kits with all thermal components needed, even with heaters or temperature sensors.

We supply prototype kits and kits for serial production, if re-quired to consignment stock or according to customers’ lo-gistics demand, for example just in time delivery or Kanban.

Beside these customer specific super-insulation blankets, RUAG Space offers for cryogenic applications also standard material which includes rolls and sheets of predefined layups (narrow rolls on request), special single layer foils, cryogenic tape and welding protection material.

See listing of COOLCAT line above and for detailed product description and performance data please refer to our Ther-mal Insulation Product brochure including COOLCAT line datasheet information.

Materials & special products for cryogenics• Polyester (Mylar) layups (aluminized polyester foils with

polyester interleaving spacer)• Aluminium layups (pure aluminium foils with glass fibre

interleaving spacer)• Special single layers for reduction of magnetic thermal

noise• Special laminates for insulation at 4K• Welding protection (aluminium foil with glass fibre

cloth)• Aluminized polyester tape• Pure aluminium tape

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Production Facility Berndorf The production facility for space and cryogenic insulation is located in Berndorf, 50 km south of Vienna. It features:

• 300 m2 of an ISO class 7 cleanroom for space insulation including

• 1200 m2 production hall for cryogenic super-insulation, • lay-up facility, laser cutting and cold cutting • 500 m² for high temperature insulation areas

Environmental Test Facility ViennaThermal Vacuum ChamberChamber dimensions: Usable length 800 mm, width 600 mm, height 600 mm Vacuum system: Operating pressure 10E-5 mbar

Temperature range: • Thermal wall -85 °C to +95 °C - Optional -170 °C to +170 °C• Thermal platform -60 °C to +95 °C

Space applicationsOur production processes for the cutting of blankets, electri-cal grounding and assembly of multi-layer insulation, Velcros/Stand-offs, attachments as well as advanced cleanliness are proven by many tests and several flight heritages. Advanced solutions have been worked out e.g. for high temperatures multi-layer insulation around thrusters with Titanium foils and multi-layer insulation at mechanisms.

RUAG Space manufactures and integrates thermal insulation in-house or at the customers’ sites. Based on our worldwide connections to material suppliers, we have on stock a great range of multi-layer insulation reflective foils (Mylar, Kapton, Teflon, etc.) and interleaving spacers (polyester, glass, ceram-ics) for the specific requirements of most projects.

2017 RUAG Space started the design and development of flexible insulation for launch vehicles and in 2019 imple-mented a production line for this type of thermal hardware in a newly built facility connected to the existing MLI produc-tion plant at our Berndorf site.

Further, we offer the procurement and assembly of heaters, thermistors, thermostats, Optical Surface Reflectors (OSRs) and Second Surface Mirror (SSM) Tapes.

Since the beginning of 2012, RUAG Space has been offering the bonding of Optical Surface Reflectors on an NC con-trolled pick and place facility for a maximum panel size of 2400 mm to 2600 mm.

Cryogenic applicationsThe production line of customized super-insulation for cryo-genics is organized in laser- and cold-cutting devices fol-lowed by manual assembly, quality check and commission-ing/packing stations.

RUAG Space also offers support for initial installations on customer hardware to assure an efficient and high quality insulation process.

Production and integration

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Product areas Product lines

Electronics Navigation Receivers & Signal Processing

Satellite & Launcher Computers

Microwave

Antenna

Spacecraft Satellite Structures

Satellite Mechanisms (OSR with ITO and low UV coating)

Slip Rings

Mechanical Ground Support Equipment

Multi-Layer Insulation

Launcher Launcher Fairings & Structures

Adapters & Separation Systems

Sounding Rocket Guidance Systems

Dispensers

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RUAG Space Austria provides design, analysis, development, production, testing and qualification of electro-, or pure mechanical space equipment according the program specific requirements and space standards, stipulated by ESA, NASA or other agen-cies. With company-owned test equipment such as vibration tables and thermo-vacu-um chambers the requisite tests and qualification procedures are executed. As Ther-mal systems are one of the core competencies, Satellite Mechanisms and Mechanical Ground Support Equipment are other heritage products.

More interesting areas of RUAG Space: Mechanical Ground Support Equipment and Satellite Mechanisms

Mechanical Ground Support Equipment (MGSE)Over the past decades RUAG Space Austria has successfully developed, manufactured and delivered Mechanical Ground Support Equipment (MGSE) for a substantial number of ESA Spacecraft (S/C), satellites and instruments as well as for Commercial Spacecraft in Europe, U.S. and Israel.Apart from providing the complete range of MGSE for inte-grating, testing and transporting a satellite, RUAG has been focusing on the high value MGSE items such as Transport Containers (more than 50 large Containers built and deliv-ered, sizes up to 12 x 5.5 x 4.2 m) and Satellite Handling Trolleys (more than 80 Trolleys built and delivered). Spacecraft Handling Dolly, different sizes possible

Specific Test and Handling AdaptersSpacecraft Transport Container, IATA compatible, climate, mechanical damping and environment control + recording, including lifting devices

Heavy Duty & Test Clamp-Bands for S/C handling, assembling

50+ Spacecraft Transport Containers, here equipped with a built-in tilt-unit

50+ Trolleys built

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Satellite MechanismsRUAG Space Austria is a leading company in the field of mechanisms for space. In this field a particular focus is put on offering a very wide range of Electrical Propulsion Point-ing Mechanism (EPPM) with 2-axis and 3-axis systems sup-porting all commercially available Thrusters-Types. Deploy-ment systems and mechanism components (e.g. actuators) are complementing this product line. Our specialized engi-neering capability covers aspects such as mechanisms at cryogenic temperatures down to 5K, the selection of space-usable material, corrosion, tribology, the use of elec-tric motors and release systems, testing at cryogenic tem-perature.

Instrument Refocusing Mechanism

Herschel Cryo Cover (60° Kelvin)

Scientific Mission, ExoMars Rover Deployable

with 23 Nm torque at -40 to 115 °C

SA15 Geared Actuator

VINCI Engine Cardan-Mechanism for ARIANE-6 engine (120 Kelvin) Telecommunication Satellite, 2 axis EPPM for orbiting + station keeping

Heavy Duty & Test Clamp-Bands for S/C handling, assembling

RUAG Space GmbH Stachegasse 16 1120 Vienna | Austria

Phone +43 1 80199 0 Fax +43 1 80199 30 60 cryo.at.space@ruag.com www.ruag.com/thermal 01/2020