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NASA NTRS2019

A Streamlined Approach to Spatial Mapping of Complex 3D Thermal Boundary Condition Data

Spatial mapping of 1D, 2D, and particularly 3D thermal boundary condition data is essential for accurate thermal simulation of spacecraft and launch vehicles. This information typically is available in simple ASCII file format but can be problematic to use for thermal simulations. Difficulties that can be encountered include the ability to directly use the available file format, transformation of the data into the desired reference coordinate system in 3D space, and accurate interpolation of the data onto the thermal calculation domain. This paper presents a streamlined approach to spatial mapping of complex unsymmetrical 3D cold wall heat flux data using the fields’ capability in Simcenter3D. A recent example of 3D thermal plume simulation at MSFC will be employed to illustrate the use of text, csv, and Excel files, specifying coordinate systems for transformation of data in 3D space, and use of the various interpolation schemes available for spatial mapping. Spatial boundary condition verification is also very important, and the spacecraft thermal analyst needs effective visualization tools to develop confidence in the boundary condition definitions. Visualization of the spacecraft plume raw field data, the calculated field data, and the interpolated field data onto the thermal calculation domain will be discussed, with a particular focus on real-time viewing of the interpolated data for available interpolation schemes. The objective of this paper is to outline the modeling techniques used with the integrated thermal analysis of a terrestrial lunar lander demonstrator. Specifically, the techniques outlined herein focus on spatial mapping of convective and radiative exhaust plume results from a computational fluid dynamics (CFD) analysis. Two cases were investigated, however, the modeling techniques that were utilized translate to both cases seamlessly. Those two cases were as follows: • Lunar lander demonstrator firing on-pad (worst case). • Lunar lander demonstrator hovering at an elevated position above the launch pad. For the purposes of information control, this paper will focus on the modeling techniques only, using altered or dimensionless data where necessary. BACKGROUND The thermal model examined in this paper is of the lunar lander demonstrator known as XL-1T (terrestrial), born from a collaborative effort between Masten Space Systems (MSS) and NASA, under NASA’s Lunar CATALYST (also known as Lunar Cargo Transportation and Landing by Soft Touchdown) initiative. The lander is a reusable vertical takeoff/vertical landing (VTVL) test bed which is controlled by four throttleable main engines utilizing green hypergolic propellants.

Hawkins, Robert F.↗
NASA NTRS2008

Lunar Surface Access Module Descent Engine Turbopump Technology: Detailed Design

The need for a high specific impulse LOX/LH2 pump-fed lunar lander engine has been established by NASA for the new lunar exploration architecture. Studies indicate that a 4-engine cluster in the thrust range of 9,000-lbf each is a candidate configuration for the main propulsion of the manned lunar lander vehicle. The lander descent engine will be required to perform minor mid-course corrections, a Lunar Orbit Insertion (LOI) burn, a de-orbit burn, and the powered descent onto the lunar surface. In order to achieve the wide range of thrust required, the engines must be capable of throttling approximately 10:1. Working under internal research and development funding, NASA Marshall Space Flight Center (MSFC) has been conducting the development of a 9,000-lbf LOX/LH2 lunar lander descent engine testbed. This paper highlights the detailed design and analysis efforts to develop the lander engine Fuel Turbopump (FTP) whose operating speeds range from 30,000-rpm to 100,000-rpm. The capability of the FTP to operate across this wide range of speeds imposes several structural and dynamic challenges, and the small size of the FTP creates scaling and manufacturing challenges that are also addressed in this paper.

Alarez, Erika↗
NASA NTRS2010

Lunar Surface Access Module Descent Engine Turbopump Technology: Detailed Design

The need for a high specific impulse LOX/LH2 pump-fed lunar lander engine has been established by NASA for the new lunar exploration architecture. Studies indicate that a 4-engine cluster in the thrust range of 9,000-lbf each is a candidate configuration for the main propulsion of the manned lunar lander vehicle. The lander descent engine will be required to perform multiple burns including the powered descent onto the lunar surface. In order to achieve the wide range of thrust required, the engines must be capable of throttling approximately 10:1. Working under internal research and development funding, NASA Marshall Space Flight Center (MSFC) has been conducting the development of a 9,000-lbf LOX/LH2 lunar lander descent engine technology testbed. This paper highlights the detailed design and analysis efforts to develop the lander engine Fuel Turbopump (FTP) whose operating speeds range from 30,000-rpm to 100,000-rpm. The capability of the FTP to operate across this wide range of speeds imposes several structural and dynamic challenges, and the small size of the FTP creates scaling and manufacturing challenges that are also addressed in this paper.

Alvarez, Erika↗
NASA NTRS1984

Impact of lunar and planetary missions on the space station

The impacts upon the growth space station of several advanced planetary missions and a populated lunar base are examined. Planetary missions examined include sample returns from Mars, the Comet Kopff, the main belt asteroid Ceres, a Mercury orbiter, and a saturn orbiter with multiple Titan probes. A manned lunar base build-up scenario is defined, encompassing preliminary lunar surveys, ten years of construction, and establishment of a permanent 18 person facility with the capability to produce oxygen propellant. The spacecraft mass departing from the space station, mission Delta V requirements, and scheduled departure date for each payload outbound from low Earth orbit are determined for both the planetary missions and for the lunar base build-up. Large aerobraked orbital transfer vehicles (OTV's) are used. Two 42 metric ton propellant capacity OTV's are required for each the the 68 lunar sorties of the base build-up scenario. The two most difficult planetary missions (Kopff and Ceres) also require two of these OTV's. An expendable lunar lander and ascent stage and a reusable lunar lander which uses lunar produced oxygen are sized to deliver 18 metric tons to the lunar surface. For the lunar base, the Space Station must hangar at least two non-pressurized OTV's, store 100 metric tons of cryogens, and support an average of 14 OTV launch, return, and refurbishment cycles per year. Planetary sample return missions require a dedicated quarantine module.

Source record↗
NASA NTRS2019

Guidance and Navigation Design Trades for the Lunar Pallet Lander

This paper provides an overview of a series of design trades in support of the NASA Lunar Pallet Lander (LPL) project. The vehicle is being designed to enable a high mass landing capability on the Lunar surface with a high precision. In order to provide clear requirements definition and preliminary design, the Guidance and Navigation Teams are assessing areas such as algorithm development, sensor architectures, and system-level sensitivities. These trades are enabled by the de-tailed six degree of freedom analysis tools. This mature simulation with the capability for closed- and open-loop simulation modes allows for high fidelity modeling and understanding of the system under design. The results show the feasibility and performance of the current vehicle to meet high accuracy landing requirements.

Anzaline, Evan↗
NASA NTRS2015

Lander Technologies

Since 2006 NASA has been formulating robotic missions to the lunar surface through programs and projects like the Robotic Lunar Exploration Program, Lunar Precursor Robotic Program, and International Lunar Network. All of these were led by NASA Marshall Space Flight Center (MSFC). Due to funding shortfalls, the lunar missions associated with these efforts, the designs, were not completed. From 2010 to 2013, the Robotic Lunar Lander Development Activity was funded by the Science Mission Directorate (SMD) to develop technologies that would enable and enhance robotic lunar surface missions at lower costs. In 2013, a requirements-driven, low-cost robotic lunar lander concept was developed for the Resource Prospector Mission. Beginning in 2014, The Advanced Exploration Systems funded the lander team and established the MSFC, Johnson Space Center, Applied Physics Laboratory, and the Jet Propulsion Laboratory team with MSFC leading the project. The lander concept to place a 300-kg rover on the lunar surface has been described in the New Technology Report Case Number MFS-33238-1. A low-cost lander concept for placing a robotic payload on the lunar surface is shown in figures 1 and 2. The NASA lander team has developed several lander concepts using common hardware and software to allow the lander to be configured for a specific mission need. In addition, the team began to transition lander expertise to United States (U.S.) industry to encourage the commercialization of space, specifically the lunar surface. The Lunar Cargo Transportation and Landing by Soft Touchdown (CATALYST) initiative was started and the NASA lander team listed above is partnering with three competitively selected U.S. companies (Astrobotic, Masten Space Systems, and Moon Express) to develop, test, and operate their lunar landers.

Chavers, Greg↗
NASA NTRS2014

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

This paper presents a design automation process using optimization via a genetic algorithm to design the conceptual structure of a Lunar Pallet Lander. The goal is to determine a design that will have the primary natural frequencies at or above a target value as well as minimize the total mass. Several iterations of the process are presented. First, a concept optimization is performed to determine what class of structure would produce suitable candidate designs. From this a stiffened sheet metal approach was selected leading to optimization of beam placement through generating a two-dimensional mesh and varying the physical location of reinforcing beams. Finally, the design space is reformulated as a binary problem using 1-dimensional beam elements to truncate the design space to allow faster convergence and additional mechanical failure criteria to be included in the optimization responses. Results are presented for each design space configuration. The final flight design was derived from these results.

Burt, Adam O.↗
NASA NTRS1989

Design of an unmanned lunar cargo lander that reconfigures into a shelter for a habitation module or disassembles into parts useful to a permanent manned lunar base

NASA plans to establish a permanent manned lunar base by the first decade of the twenty-first century. It is extremely expensive to transport material from earth to the moon. Therefore, expense would be reduced if the vehicle that lands cargo on the moon could itself meet some of the material needs of establishing the lunar base. The design of a multi-functional lander that is entirely useful to the base after landing is described. Alternate designs of the overall lander configuration and possible uses of the lander and its components after landing are contained. The design solution is a lander employing the Saddlebagged Fuel Tank Configuration. After landing, its structure will be converted into a habitation module shelter that supports a protective layer of regolith. The fuel tanks will be cleaned and used as storage tanks for the lunar base. The engines and instrumentation will be saved as stock parts. Recommendations for further research and technology development to enhance future lander designs are given.

Davanay, Lisa↗
NASA NTRS2011

Liquid Oxygen/Liquid Methane Propulsion and Cryogenic Advanced Development

Exploration Systems Architecture Study conducted by NASA in 2005 identified the liquid oxygen (LOx)/liquid methane (LCH4) propellant combination as a prime candidate for the Crew Exploration Vehicle Service Module propulsion and for later use for ascent stage propulsion of the lunar lander. Both the Crew Exploration Vehicle and Lunar Lander were part the Constellation architecture, which had the objective to provide global sustained lunar human exploration capability. From late 2005 through the end of 2010, NASA and industry matured advanced development designs for many components that could be employed in relatively high thrust, high delta velocity, pressure fed propulsion systems for these two applications. The major investments were in main engines, reaction control engines, and the devices needed for cryogenic fluid management such as screens, propellant management devices, thermodynamic vents, and mass gauges. Engine and thruster developments also included advanced high reliability low mass igniters. Extensive tests were successfully conducted for all of these elements. For the thrusters and engines, testing included sea level and altitude conditions. This advanced development provides a mature technology base for future liquid oxygen/liquid methane pressure fed space propulsion systems. This paper documents the design and test efforts along with resulting hardware and test results.

Klem, Mark D.↗
NASA NTRS2014

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

In this paper, a unique system level spacecraft design optimization will be presented. A Genetic Algorithm is used to design the global pattern of the reinforcing structure, while a gradient routine is used to adequately stiffen the sub-structure. The system level structural design includes determining the optimal physical location (and number) of reinforcing beams of a lunar pallet lander deck structure. Design of the substructure includes determining placement of secondary stiffeners and the number of rivets required for assembly.. In this optimization, several considerations are taken into account. The primary objective was to raise the primary natural frequencies of the structure such that the Pallet Lander primary structure does not significantly couple with the launch vehicle. A secondary objective is to determine how to properly stiffen the reinforcing beams so that the beam web resists the shear buckling load imparted by the spacecraft components mounted to the pallet lander deck during launch and landing. A third objective is that the calculated stress does not exceed the allowable strength of the material. These design requirements must be met while, minimizing the overall mass of the spacecraft. The final paper will discuss how the optimization was implemented as well as the results. While driven by optimization algorithms, the primary purpose of this effort was to demonstrate the capability of genetic algorithms to enable design automation in the preliminary design cycle. By developing a routine that can automatically generate designs through the use of Finite Element Analysis, considerable design efficiencies, both in time and overall product, can be obtained over more traditional brute force design methods.

Burt, Adam↗
NASA NTRS2016

Rocket Propulsion (RP) 21 Steering Committee Meeting - NASA Spacecraft Propulsion Update

Lander Tech is three separate but synergistic efforts: Lunar CATALYST (Lunar Cargo Transportation and Landing by Soft Touchdown) Support U.S. industry led robotic lunar lander development via three public-private efforts. Support U.S. industry led robotic lunar lander development via three public-private partnerships. Infuse or transfer landing technologies into these public private partnerships. Advanced Exploration Systems-Automated Propellant Loading (APL) -Integrated Ground Operations. Demonstrate LH2 zero loss storage, loading and transfer operations via testing on a large scale in a relevant launch vehicle servicing environment. (KSC, GRC). Game Changing Technology-20 Kelvin -20 Watt Cryocooler Development of a Reverse Turbo-Brayton Cryocooler operating at 20 Kelvin with 20 Watts of refrigeration lift.

Propellant↗
NASA NTRS2005

Integration of Launch Vehicle Simulation/Analysis Tools and Lunar Cargo Lander Design

Simulation and analysis of vehicle performance is essential for design of a new launch vehicle system. It is more and more demand to have an integrated, highly efficient, robust simulation tool with graphical user interface (GUI) for vehicle performance and simulations. The objectives of this project are to integrate and develop launch vehicle simulation and analysis tools in MATLAB/Simulink under PC Platform, to develop a vehicle capable of being launched on a Delta-IV Heavy Launch Vehicle which can land on the moon with the goal of pre-implanting cargo for a new lunar mission, also with the capability of selecting other launch vehicles that are capable of inserting a payload into Trans-Lunar Injection (TLI). The vehicle flight simulation software, MAVERIC-II (Marshall Aerospace VEhicle Representation In 'C'), developed by Marshall Space Flight Center was selected as a starting point for integration of simulation/analysis tools. The goals are to convert MAVERIC-II from UNIX to PC platform and build input/output GUI s in the MATLAB environment, and then integrate them under MATLAB/Simulink with other modules. Currently, MAVERIC-II has been successfully converted from UNIX to PC using Microsoft Services for UNIX subsystem on PC. Input/Output GUI's have been done for some key input/output files. Calling MAVERIC-II from Simulink has been tested. Details regarding Lunar Cargo Lander Design are described in Part 2/2 of the paper on page X-1.

Shiue, Yeu-Sheng Paul↗
NASA NTRS2012

Small Radioisotope Power System at NASA Glenn Research Center

In April 2009, NASA Glenn Research Center (GRC) formed an integrated product team (IPT) to develop a Small Radioisotope Power System (SRPS) utilizing a single Advanced Stirling Convertor (ASC) with passive balancer for possible use by the International Lunar Network (ILN) program. The ILN program is studying the feasibility of implementing a multiple node seismometer network to investigate the internal lunar structure. A single ASC produces approximately 80 W(sub e) and could potentially supply sufficient power for that application. The IPT consists of Sunpower, Inc., to provide the single ASC with balancer, The Johns Hopkins University Applied Physics Laboratory (JHU/APL) to design an engineering model Single Convertor Controller (SCC) for an ASC with balancer, and NASA GRC to provide technical support to these tasks and to develop a simulated lunar lander test stand. A controller maintains stable operation of an ASC. It regulates the alternating current produced by the linear alternator of the convertor, provides a specified output voltage, and maintains operation at a steady piston amplitude and hot end temperature. JHU/APL also designed an ASC dynamic engine/alternator simulator to aid in the testing and troubleshooting of the SCC. This paper describes the requirements, design, and development of the SCC, including some of the key challenges and the solutions chosen to overcome those issues. In addition, it describes the plans to analyze the effectiveness of a passive balancer to minimize vibration from the ASC, characterize the effect of ASC vibration on a lunar lander, characterize the performance of the SCC, and integrate the single ASC, SCC, and lunar lander test stand to characterize performance of the overall system.

Dugala, Gina M.↗
NASA NTRS2017

Global Exploration Roadmap Derived Concept for Human Exploration of the Moon

Taking advantage of the development of Mars-forward assets in cislunar space, a human lunar surface concept is proposed to maximize value for both lunar exploration and future deep space missions. The human lunar surface missions will be designed to build upon the cislunar activities that precede them, providing experience in planetary surface operations that cannot be obtained in cislunar space. To enable a five-mission limited campaign to the surface of the Moon, two new elements are required: a human lunar lander and a mobile surface habitat. The human lunar lander will have been developed throughout the cislunar phase from a subscale demonstrator and will consist of a descent module alongside a reusable ascent module. The reusable ascent module will be used for all five human lunar surface missions. Surface habitation, in the form of two small pressurized rovers, will enable 4 crew to spend up to 42 days on the lunar surface.

Whitley, Ryan↗
NASA NTRS2007

Plume Impingement to the Lunar Surface: A Challenging Problem for DSMC

The President's Vision for Space Exploration calls for the return of human exploration of the Moon. The plans are ambitious and call for the creation of a lunar outpost. Lunar Landers will therefore be required to land near predeployed hardware, and the dust storm created by the Lunar Lander's plume impingement to the lunar surface presents a hazard. Knowledge of the number density, size distribution, and velocity of the grains in the dust cloud entrained into the flow is needing to develop mitigation strategies. An initial step to acquire such knowledge is simulating the associated plume impingement flow field. The following paper presents results from a loosely coupled continuum flow solver/Direct Simulation Monte Carlo (DSMC) technique for simulating the plume impingement of the Apollo Lunar module on the lunar surface. These cases were chosen for initial study to allow for comparison with available Apollo video. The relatively high engine thrust and the desire to simulate interesting cases near touchdown result in flow that is nearly entirely continuum. The DSMC region of the flow field was simulated using NASA's DSMC Analysis Code (DAC) and must begin upstream of the impingement shock for the loosely coupled technique to succeed. It was therefore impossible to achieve mean free path resolution with a reasonable number of molecules (say 100 million) as is shown. In order to mitigate accuracy and performance issues when using such large cells, advanced techniques such as collision limiting and nearest neighbor collisions were employed. The final paper will assess the benefits and shortcomings of such techniques. In addition, the effects of plume orientation, plume altitude, and lunar topography, such as craters, on the flow field, the surface pressure distribution, and the surface shear stress distribution are presented.

Lumpkin, Forrest↗
NASA NTRS2009

Overview of Altair's Thermal Control System and the Associated Technology Development Efforts

Abstract In early 2004, President Bush announced a bold vision for space exploration. One of the goals included in this vision is a return to the moon by 2020. In response to this vision, NASA established the Constellation Program, which includes several project offices. One of the Constellation projects is Altair, which is the next generation Lunar Lander. The future Altair missions are very different than the Lunar missions accomplished during the Apollo era. As such, there are several project risks and design challenges that have never before been addressed. Due to the unique thermal environment associated with this mission, many of these risks and design challenges are associated with the vehicle's thermal control system. NASA's Exploration Systems Mission Directorate (ESMD) includes the Exploration Technology Development Program (ETDP). ETDP consists of several technology development projects. The project chartered with mitigating the aforementioned risks and design challenges is the Thermal Control System Development for Exploration Project. The current paper will summarize the Altair mission profile, the operational phases, and the thermal design challenges unique to this particular vehicle. The paper will also describe the technology development efforts being performed to mitigate the risks and design challenges. The technology development project is performing a rigorous development effort that includes thermal control system fluids, evaporators, heat exchangers, and Lunar surface radiators. Constellation Program, there are several project offices. One of these projects includes the development of NASA's new lunar lander vehicle. The overall mission architecture for this vehicle, Altair, is very similar to Apollo's architecture. This paper will provide the reader with an overview of the Altair vehicle. In addition, Altair's thermal control system, including the functionality and the hardware, will be discussed. The paper will also describe the technology development process and the various technology developments currently underway.

Stephan, Ryan A.↗
NASA NTRS2011

GENIE Flight Test Results and System Overview

NASA has envisioned a suite of lander test vehicles that will be flown in Earth s atmosphere to incrementally demonstrate applicable lunar lander performance in the terrestrial environment. As each terrestrial rocket progresses in maturity, relevant space flight technology matures to a higher technology readiness level, preparing it for inclusion on a future lunar lander design.. NASA s "Project M" lunar mission concept flew its first terrestrial rocket, RR1, in June 2010 in Caddo Mills, Texas. The Draper Laboratory built GENIE (Guidance Embedded Navigator Integration Environment) successfully demonstrated accurate, real time, embedded performance of Project M navigation and guidance algorithms in a highly dynamic environment. The RR1 vehicle, built by Armadillo Aerospace, performed a successful 60 second free flight and gave the team great confidence in Project M s highly reliable and robust GNC system design and implementation. This paper provides an overview of the GENIE system and describes recent flight performance test results onboard the RR1 terrestrial rocket.

Brady, Tye↗
NASA NTRS2009

Ares V: Game Changer for National Security Launch

NASA is designing the Ares V cargo launch vehicle to vastly expand exploration of the Moon begun in the Apollo program and enable the exploration of Mars and beyond. As the largest launcher in history, Ares V also represents a national asset offering unprecedented opportunities for new science, national security, and commercial missions of unmatched size and scope. The Ares V is the heavy-lift component of NASA's dual-launch architecture that will replace the current space shuttle fleet, complete the International Space Station, and establish a permanent human presence on the Moon as a stepping-stone to destinations beyond. During extensive independent and internal architecture and vehicle trade studies as part of the Exploration Systems Architecture Study (ESAS), NASA selected the Ares I crew launch vehicle and the Ares V to support future exploration. The smaller Ares I will launch the Orion crew exploration vehicle with four to six astronauts into orbit. The Ares V is designed to carry the Altair lunar lander into orbit, rendezvous with Orion, and send the mated spacecraft toward lunar orbit. The Ares V will be the largest and most powerful launch vehicle in history, providing unprecedented payload mass and volume to establish a permanent lunar outpost and explore significantly more of the lunar surface than was done during the Apollo missions. The Ares V consists of a Core Stage, two Reusable Solid Rocket Boosters (RSRBs), Earth Departure Stage (EDS), and a payload shroud. For lunar missions, the shroud would cover the Lunar Surface Access Module (LSAM). The Ares V Core Stage is 33 feet in diameter and 212 feet in length, making it the largest rocket stage ever built. It is the same diameter as the Saturn V first stage, the S-IC. However, its length is about the same as the combined length of the Saturn V first and second stages. The Core Stage uses a cluster of five Pratt & Whitney Rocketdyne RS-68B rocket engines, each supplying about 700,000 pounds of thrust. Its propellants are liquid hydrogen and liquid oxygen. The two solid rocket boosters provide about 3.5 million pounds of thrust at liftoff. These 5.5-segment boosters are derived from the 4-segment boosters now used on the Space Shuttle, and are similar to those used in the Ares I first stage. The EDS is powered by one J-2X engine. The J-2X, which has roughly 294,000 pounds of thrust, also powers the Ares I Upper Stage. It is derived from the J-2 that powered the Saturn V second and third stages. The EDS performs two functions. Its initial suborbital burns will place the lunar lander into a stable Earth orbit. After the Orion crew vehicle, launched separately on an Ares I, docks with the lander/EDS stack, EDS will ignite a second time to put the combined 65-metric ton vehicle into a lunar transfer orbit. When it stands on the launch pad at Kennedy Space Center late in the next decade, the Ares V stack will be approximately 381 feet tall and have a gross liftoff mass of 8.1 million pounds. The current point-of-departure design exceeds Saturn V s mass capability by approximately 40 percent. Using the current payload shroud design, Ares V can carry 315,000 pounds to 29-degree low Earth orbit (LEO) or 77,000 pounds to a geosynchronous orbit. Another unique aspect of the Ares V is the 33-foot-diameter payload shroud, which encloses approximately 30,400 cubic feet of usable volume. A larger hypothetical shroud for encapsulating larger payloads has been studied. While Ares V makes possible larger payload masses and volumes, it may alternately make possible more cost-effective mission design if the relevant payload communities are willing to consider an alternative to the existing approach that has driven them to employ complexity to solve current launch vehicle mass and volume constraints. By using Ares V s mass and volume capabilities as margin, payload designers stand to reduce development risk and cost. Significant progress has been made on the Ares V to support a plaed fiscal 2011 authority-to-proceed (ATP) milestone. The Ares V team is actively reaching out to external organizations during this early concept phase to ensure that the Ares V vehicle can be leveraged for national security, science, and commercial development needs. This presentation will discuss Ares V vehicle configuration, the path to the current concept, accomplishments to date, and potential payload utilization opportunities.

Sumrall, Phil↗