Engineering topics
Publications and source records attributed to Davis, Daniel J..
These presentation slides review the progress in the development of the Ares I upper stage. The development includes development of a manufacturing and processing assembly that will reduce the time required over 100 days, development of a weld tool that is a robotic tool that is the largest welder of its kind in the United States, development of avionics and software, and development of logisitics and operations systems.
Since 2005, Ares has made substantial progress on designing, developing, and testing the Ares I crew launch vehicle and has continued its in-depth studies of the Ares V cargo launch vehicles. The combined Ares I/Ares V architecture was designed to reduce the complexity and labor intensity of ground operations for America s next journeys beyond low-Earth orbit (LEO). The Ares Projects goal is to instill operability as part of the vehicles requirements development, design, and operations. Since completing the Preliminary Design Review in 2008, work has continued to push the Ares I beyond the concept phase and into full vehicle development, while tackling fresh engineering challenges and performing pathfinding activities related to vehicle manufacturing and ground operations.
This slide presentation reviews the progress made on the Ares I and Ares V launch vehicles. Slides reviewing NASA's Mission, timetable and the Launch Vehicle comparisons between the shuttle and the Saturn V vehicles and the Ares I and V launch vehicles are shown. The elements of the Ares I is reviewed in detail with a slide showing Ares I Lunar mission profile. The Ares I-X test flight is reviewed. The Ares V elements are reviewed in a slide and the Ares V lunar profile is also shown. The progress made in this project is reviewed. Charts diagramming the production facilities at the Michoud Assembly Facility, and the manufacturing flow are displayed.
By incorporating rigorous engineering practices, innovative manufacturing processes and test techniques, a unique multi-center government/contractor partnership, and a clean-sheet design developed around the primary requirements for the International Space Station (ISS) and Lunar missions, the Upper Stage Element of NASA's Crew Launch Vehicle (CLV), the "Ares I," is a vital part of the Constellation Program's transportation system. Constellation's exploration missions will include Ares I and Ares V launch vehicles required to place crew and cargo in low-Earth orbit (LEO), crew and cargo transportation systems required for human space travel, and transportation systems and scientific equipment required for human exploration of the Moon and Mars. Early Ares I configurations will support ISS re-supply missions. A self-supporting cylindrical structure, the Ares I Upper Stage will be approximately 84' long and 18' in diameter. The Upper Stage Element is being designed for increased supportability and increased reliability to meet human-rating requirements imposed by NASA standards. The design also incorporates state-of-the-art materials, hardware, design, and integrated logistics planning, thus facilitating a supportable, reliable, and operable system. With NASA retiring the Space Shuttle fleet in 2010, the success of the Ares I Project is essential to America's continued leadership in space. The first Ares I test flight, called Ares 1-X, is scheduled for 2009. Subsequent test flights will continue thereafter, with the first crewed flight of the Crew Exploration Vehicle (CEV), "Orion," planned for no later than 2015. Crew transportation to the ISS will follow within the same decade, and the first Lunar excursion is scheduled for the 2020 timeframe.
By incorporating rigorous engineering practices, innovative manufacturing processes and test techniques, a unique multi-center government/contractor partnership, and a clean-sheet design developed around the primary requirements for the International Space Station (ISS) and Lunar missions, the Upper Stage Element of NASA s Crew Launch Vehicle (CLV), the "Ares I," is a vital part of the Constellation Program s transportation system.
No abstract available
Fielding an integrated launch vehicle system entails many challenges, not the least of which is the fact that it has been over 30 years since the United States has developed a human-rated vehicle - the venerable Space Shuttle. Over time, whole generations of rocket scientists have passed through the aerospace community without the opportunity to perform such exacting, demanding, and rewarding work. However, with almost 50 years of experience leading the design, development, and end-to-end systems engineering and integration of complex launch vehicles, the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center offers the in-house talent - both junior- and senior-level personnel - to shape a new national asset to meet the requirements for safe, reliable, and affordable space exploration solutions. The technical personnel are housed primarily in Marshall's Engineering Directorate and are matrixed into the programs and projects that reside at the rocket center. Fortunately, many Apollo-era and Shuttle engineers, as well as those who gained valuable hands-on experience in the 1990s by conducting technology demonstrator projects such as the Delta-Clipper Experimental Advanced, X-33, X-34, and X-37, as well as the short-lived Orbital Space Plane, work closely with industry partners to advance the nation's strategic capability for human access to space. The Ares Projects Office, resident at Marshall, is managing the design and development of America's new space fleet, including the Ares I, which will loft the Orion crew capsule for its first test flight in the 2013 timeframe, as well as the heavy-lift Ares V, which will round out the capability to leave low-Earth orbit once again, when it delivers the Altair lunar lander to orbit late next decade. This paper provides information about the approach to integrating the Ares I stack and designing the upper stage in house, using unique facilities and an expert workforce to revitalize the nation's space exploration resources.
The Crew Launch Vehicle (CLV), a key component of NASA's blueprint for the next generation of spacecraft to take humans back to the moon, is being designed and built by engineers at NASA s Marshall Space Flight Center (MSFC). The vehicle s design is based on the results of NASA's 2005 Exploration Systems Architecture Study (ESAS), which called for development of a crew-launch system to reduce the gap between Shuttle retirement and Crew Exploration Vehicle (CEV) Initial Operating Capability, identification of key technologies required to enable and significantly enhance these reference exploration systems, and a reprioritization of near- and far-term technology investments. The Upper Stage Element (USE) of the CLV is a clean-sheet approach that is being designed and developed in-house, with element management at MSFC. The USE concept is a self-supporting cylindrical structure, approximately 115' long and 216" in diameter, consisting of the following subsystems: Primary Structures (LOX Tank, LH2 Tank, Intertank, Thrust Structure, Spacecraft Payload Adaptor, Interstage, Forward and Aft Skirts), Secondary Structures (Systems Tunnel), Avionics and Software, Main Propulsion System, Reaction Control System, Thrust Vector Control, Auxiliary Power Unit, and Hydraulic Systems. The ESAS originally recommended a CEV to be launched atop a four-segment Space Shuttle Main Engine (SSME) CLV, utilizing an RS-25 engine-powered upper stage. However, Agency decisions to utilize fewer CLV development steps to lunar missions, reduce the overall risk for the lunar program, and provide a more balanced engine production rate requirement prompted engineers to switch to a five-segment design with a single Saturn-derived J-2X engine. This approach provides for single upper stage engine development for the CLV and an Earth Departure Stage, single Reusable Solid Rocket Booster (RSRB) development for the CLV and a Cargo Launch Vehicle, and single core SSME development. While the RSRB design has changed since the CLV Project's inception, the USE design has remained essentially a clean-sheet approach. Although a clean-sheet upper stage design inherently carries more risk than a modified design, it does offer many advantages: a design for increased reliability; built-in extensibility to allow for commonality/growth without major redesign; and incorporation of state-of-the-art materials, hardware, and design, fabrication, and test techniques and processes to facilitate a potentially better, more reliable system. Because consideration was given in the ESAS to both clean-sheet and modified USE designs, this paper will highlight the advantages and disadvantages of both approaches and provide a detailed discussion of trades/selections made that led to the final upper stage configuration.
When manned and unmanned space flight first began, the clear and overriding design consideration was performance. Consequently, propellant combinations of all kinds were considered, tested, and, when they lifted the payload a kilometer higher, or an extra kilogram to the same altitude, they became part of our operational inventory. Cost was not considered. And with virtually all of the early work being performed by the military, safety was hardly a consideration. After all, fighting wars has always been dangerous. Those days are past now. With space flight, and the products of space flight, a regular part of our lives today, safety and cost are being reexamined. NASA's focus turns naturally to its Shuttle Space Transportation System. Designed, built, and flown for the first time in the 1970s, this system remains today America's workhorse for manned space flight. Without its tremendous lift capability and mission flexibility, the International Space Station would not exist. And the Hubble telescope would be a monument to shortsighted management, rather than the clear penetrating eye on the stars it is today. But the Shuttle system fully represents the design philosophy of its period: it is too costly to operate, and not safe enough for regular long term access to space. And one of the key reasons is the utilization of toxic propellants. This paper will present an overview of the utilization of toxic propellants on the current Shuttle system.