Space Hardware to Enhance Hall-effect Thruster Performance

Cycle Automated Mass Flow Controller (CAMFlow)

Low-cost precision flow control for optimum performance with sub-kilowatt Hall/ion thrusters

The Cycle Automated Mass Flow (CAMFlow) system provides reliable and well-regulated flow control for electric propulsion systems. CAMFlow uses an innovative control scheme that enables stable operation using fixed frequency Boolean valve states, even for the low flow rates necessary for sub-kiloWatt Hall-effect thrusters. This methodology removes system complexity, places the onus of reliability on valve cycle life, and, combined with the fixed operational frequency, allows for a direct correlation between system life and valve cycle life.

The CAMFlow control scheme was successfully tested and validated on a 600-Watt Hall-effect thruster. This included open loop, closed loop, and cold ‘hard’ start operations. The control valves were cycled greater than 120 million pulses while maintaining a very low leak rate, thereby demonstrating long-life potential. CAMFlow units are presently focused on smaller Hall-effect or gridded-ion electric propulsion systems, however, the technology is widely applicable over a larger range of flow rates for a broader commercial market. The CAMFlow system controls the output flow rate to less than ±3%. Through the use of less expensive space-rated components, CAMFlow technology provides a reliable, low-cost flow controller that is well-suited for sub-kiloWatt Hall/ion thrusters.

CAMFlow Status Non-Recurring Engineering (NRE) required for final design and qualification. Lead time will depend upon qualification level. Non-flight Engineering Model (EM) ~ 7 months lead time

CAMFlow Propellant Options: Xenon, Krypton, Argon, Nitrogen, other inert gases

Cycle Automated Mass Flow Controller (CAMFlow)
Advantages Include:

Advantages Include:

Low-cost flow controller well-suited for sub-kiloWatt Hall/ion thrusters

Can accept up to 2,500 psia (per square inch absolute) pounds input pressure

Flow control of less than plus or minus 3% demonstrated

Hard startup on Hall thruster demonstrated

Demonstrated greater than 120 million valve actuations @ less than 1x10-4 sccs (standard cubic centimeters per second) Helium leak rate

Interested in CAMFlow?

Are you looking to get more reliable performance from your Hall-effect or gridded-ion thruster? CAMFlow will help, contact Dr. David Carroll with inquiries.
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C. A. Woodruff, M. M. Parta, R. T. Fox, D. L. Carroll, L. Su, T. Gill, C. Sercel, W. Hurley, P. Roberts, M. Allen, J. V. Noord, B. Jorns, “CAMFlow-3 Flow Controller and Hall Thruster Testing” 37th International Electric Propulsion Conference, P. Baudis Convention Center, Toulouse, France, June 23-28, 2024, DOI n/a, (2024)
C. A. Woodruff, M. M. Parta, R. T. Fox, D. L. Carroll, “Advanced Flow Control System for In-Space Electric Propulsion” 71st JANNAF Propulsion Meeting, Sheraton Oklahoma City Downtown, Oklahoma City, Oklahoma, May 6-10, 2024, DOI n/a, (2024)
C. A. Woodruff, M. M. Parta, N. Hejmanowski, D. L. Carroll, L. Su, C. Sercel, C. Whittaker, E. Viges, M. Byrne, B. Jorns, “Cycle Automated Mass Flow (CAMFlow) System for Hall Thrusters” 37th International Electric Propulsion Conference Massachusetts Institute of Technology, Cambridge, MA USA, Cambridge, MA, June 19-23, 2022, DOI n/a, (2022)

Datasheet Downloads
CAMFlow Controller

Hall and ion thrusters (July 2025)