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At least 271 records · Page 15

Aerodynamic control, recovery, and sensor design for a first stage flyback booster

The mission of the flyback group is to control and recover the first stage of a commercially developed winged booster launched from a B-52 at 40,000 ft and Mach 0.8. First-stage separation occurs at 210,000 ft and Mach 8.7; the second and third stages will continue deployment of their 600 lb payload into low Earth orbit. The job of the flyback group begins at this point, employing a modified control system developed to stabilize and maneuver the separated first-stage vehicle to a suitable landing site approximately 130 miles from the launch point over the Pacific Ocean. This multidisciplinary design was accomplished by four subgroups: aerodynamic design/vehicle configuration (ADVC), trajectory optimization, controls, and thermal management.

Source record↗

Shuttle Reference Data

This collection of shuttle reference data contains the following information: shuttle abort history, shuttle abort modes, abort decisions, space shuttle rendezvous maneuvers, space shuttle main engines, space shuttle solid rocket boosters, hold-down posts, SRB (solid rocket boosters) ignition, electrical power distribution, hydraulic power units, thrust vector control, SBR rate gyro assemblies, SBR separation and Space Shuttle Super Super Light Weight Tank (SLWT).

Source record↗

Space Launch System Advanced Development Office, FY 2013 Annual Report

The Advanced Development Office (ADO), part of the Space Launch System (SLS) program, provides SLS with the advanced development needed to evolve the vehicle from an initial Block 1 payload capability of 70 metric tons (t) to an eventual capability Block 2 of 130 t, with intermediary evolution options possible. ADO takes existing technologies and matures them to the point that insertion into the mainline program minimizes risk. The ADO portfolio of tasks covers a broad range of technical developmental activities. The ADO portfolio supports the development of advanced boosters, upper stages, and other advanced development activities benefiting the SLS program. A total of 34 separate tasks were funded by ADO in FY 2013.

Crumbly, C. M.↗

Space Launch System Spacecraft/Payloads Integration and Evolution Office Advanced Development FY 2014 Annual Report

The Advanced Development Office (ADO), part of the Space Launch System (SLS) program, provides SLS with the advanced development needed to evolve the vehicle from an initial Block 1 payload capability of 70 metric tons (t) to an eventual capability Block 2 of 130 t, with intermediary evolution options possible. ADO takes existing technologies and matures them to the point that insertion into the mainline program minimizes risk. The ADO portfolio of tasks covers a broad range of technical developmental activities. The ADO portfolio supports the development of advanced boosters, upper stages, and other advanced development activities benefiting the SLS program. A total of 36 separate tasks were funded by ADO in FY 2014.

Crumbly, C. M.↗

Multibody Simulation of REMORA CubeSat Docking to and Pushing a Spent Rocket Booster

This paper details the multibody simulation of three phases of critical importance to the feasibility of the REMORA CubeSat space debris mitigation concept: the final approach of the CubeSat to a spent rocket booster; the grappling of the spent rocket booster using a robotic arm; and the pushing of the spent rocket booster to divert its course from another on-orbit asset. The extension of a robotic mobility and manipulation modeling toolkit (M3TK) from multibody dynamics simulation of manipulators and ground vehicles to simulation of orbital robotics is outlined. This includes the identification of the appropriate parameters required to concisely and generically describe thruster loads, thruster mixing, spacecraft control, and spacecraft navigation for the purpose of on-orbit robotics simulation. A high-level spacecraft navigator commands maneuvers to target spacecraft states. A PID spacecraft controller takes the target states and calculates desired forces and torques. A thruster mixer solves a quadratic program to determine the optimal thruster firing times for the propulsion system. Pulse width modulated actuation of eight canted cold gas thrusters is used in the simulated approach to a rocket nozzle from a distance of 200 m. A five degree of freedom robotic arm is controlled to position a pair of pincers to grasp the rocket nozzle. Contact dynamics are used to accurately simulate the grasping of the rocket nozzle by the pincers. A similar, but separate simulation is performed to assess the ability of the REMORA CubeSat to push the large spent rocket booster. This diversion maneuver makes use of an additional, larger thruster, and pushes the rocket booster in excess of 400 m. Appropriate motor control gains on the robotic arm are found to be higher during the pushing phase than those which are appropriate during free motion; this increase promotes rigidity of the arm and allows it to properly direct the pushing force. Challenges encountered in time step selection for numerical stability of the simulation are also discussed.

Mukherjee, Rudranarayan↗

Aerodynamic results of a separation effects test on a 0.010-scale model (52-OTS) of the integrated SSV in the AEDC/VKF 40-by-40 inch supersonic wind tunnel A (IA111), volume 1

Graphical data obtained during experimental wind tunnel aerodynamic investigations of a 0.010 scale model (52-OTS) of the integrated space shuttle vehicle was presented. The purpose of this investigation was to obtain data with the solid rocket booster (SRB) in proximity to the orbiter/external tank (O/ET), over a large O/ET initial angle of attack and sideslip range, as well as data on the SRB alone (greatly separated from the O/ET). A captive trajectory system, which supported the SRB, was used with the tunnel primary sector (supporting the O/ET) to obtain grid type separation effects data. One symmetrical SRB model was used interchangeably to obtain right-hand and left-hand SRB data. The entire investigation was conducted at a free-stream Mach number of 4.5 at unit Reynolds number of 3.95 and 5.9 million per foot.

Chee, E.↗

Aerodynamic results of a separation effects test on a 0.010-scale model (52-OTS) of the integrated SSV in the AEDC/VKF 40-by-40 inch supersonic wind tunnel A (IA111), volume 2

Tabular data obtained during experimental wind tunnel aerodynamic investigations of a 0.010 scale model (52-OTS) of the integrated space shuttle vehicle was presented. The purpose of this investigation was to obtain data with the solid rocket booster (SRB) in proximity to the orbiter/external tank (O/ET), over a large O/ET initial angle of attack and sideslip range, as well as data on the SRB alone (greatly separated from the O/ET). A captive trajectory system, which supported the SRB, was used with the tunnel primary sector (supporting the O/ET) to obtain grid type separation effects data. One symmetrical SRB model was used interchangeably to obtain right-hand and left-hand SRB data. The entire investigation was conducted at free-stream Mach number of 4.5 at unit Reynolds number of 3.95 and 5.9 million per foot.

Chee, E.↗

Delta capability for launch of communications satellites

The evolution of capabilities and the current performance levels of the Delta launch vehicle are outlined. The first payload was the Echo I passive communications satellite, weighing 179 lb, and placed in GEO in 1960. Emphasis since then has been to use off-the-shelf hardware where feasible. The latest version in the 3924 first stage, 3920 second stage, and Pam D apogee kick motor third stage. The Delta is presently equipped to place 2800 lb in GEO, as was proven with the 2717 lb Anik-D1 satellite. The GEO payload placement performance matches the Shuttle's, and work is therefore under way to enhance the Delta performance to handle more massive payloads. Installation of the Castor-IV solid motor separation system, thereby saving mass by utilizing compressed nitrogen, rather than mechanical thrusters to remove the strap-on boosters, is indicated, together with use of a higher performance propellant and a wider nose fairing.

Grimes, D. W.↗

Coupled Analysis of an Inlet and Fan for a Quiet Supersonic Jet

A computational analysis of a Gulfstream isentropic external compression supersonic inlet coupled to a Rolls-Royce fan has been completed. The inlet was designed for a small, low sonic boom supersonic vehicle with a design cruise condition of M = 1.6 at 45,000 ft. The inlet design included an annular bypass duct that routed flow subsonically around an engine-mounted gearbox and diverted flow with high shock losses away from the fan tip. Two Reynolds-averaged Navier-Stokes codes were used for the analysis: an axisymmetric code called AVCS for the inlet and a three dimensional (3-D) code called SWIFT for the fan. The codes were coupled at a mixing plane boundary using a separate code for data exchange. The codes were used to determine the performance of the inlet/fan system at the design point and to predict the performance and operability of the system over the flight profile. At the design point the core inlet had a recovery of 96 percent, and the fan operated near its peak efficiency and pressure ratio. A large hub radial distortion generated in the inlet was not eliminated by the fan and could pose a challenge for subsequent booster stages. The system operated stably at all points along the flight profile. Reduced stall margin was seen at low altitude and Mach number where flow separated on the interior lips of the cowl and bypass ducts. The coupled analysis gave consistent solutions at all points on the flight profile that would be difficult or impossible to predict by analysis of isolated components.

Chima, Rodrick V.↗

Coupled Analysis of an Inlet and Fan for a Quiet Supersonic Aircraft

A computational analysis of a Gulfstream isentropic external compression supersonic inlet coupled to a Rolls-Royce fan was completed. The inlet was designed for a small, low sonic boom supersonic vehicle with a design cruise condition of M = 1.6 at 45,000 feet. The inlet design included an annular bypass duct that routed flow subsonically around an engine-mounted gearbox and diverted flow with high shock losses away from the fan tip. Two Reynolds-averaged Navier-Stokes codes were used for the analysis: an axisymmetric code called AVCS for the inlet and a 3-D code called SWIFT for the fan. The codes were coupled at a mixing plane boundary using a separate code for data exchange. The codes were used to determine the performance of the inlet/fan system at the design point and to predict the performance and operability of the system over the flight profile. At the design point the core inlet had a recovery of 96 percent, and the fan operated near its peak efficiency and pressure ratio. A large hub radial distortion generated in the inlet was not eliminated by the fan and could pose a challenge for subsequent booster stages. The system operated stably at all points along the flight profile. Reduced stall margin was seen at low altitude and Mach number where flow separated on the interior lips of the cowl and bypass ducts. The coupled analysis gave consistent solutions at all points on the flight profile that would be difficult or impossible to predict by analysis of isolated components.

Chima, Rodrick V.↗

Wind Tunnel Investigation of the Supersonic Stage Separation Aerodynamics of a Generic 0.0175-Scale Bimese Two-Stage-to-Orbit Reusable Launch Vehicle Configuration

A wind tunnel investigation was conducted of the supersonic stage separation aerodynamics of a generic two-stage-to-orbit bimese wingbody configuration in the NASA Langley Research Center Unitary Plan Wind Tunnel. Proximity and isolated model testing was conducted at Mach numbers of 2.3, 3.0, and 4.5 and a unit Reynolds number of 2.0 million per foot using 0.0175-scale models of the Langley Glide-Back Booster concept designated as the orbiter and booster in belly-to-belly and back-to-belly configurations. Longitudinal forces and moments were obtained on both models and surface static pressure measurements were obtained on the orbiter model at 328 relative proximity locations and at relative angles of attack of 0 degrees and 5 degrees. The test results supported a larger effort to develop and validate experimental and computational tools applicable to the design and simulation of stage separation and abort procedures for reusable launch vehicles composed of multiple bodies, including winged bodies. An initial proof-of-concept experiment featuring low-cost uninstrumented models was conducted to verify an emerging automated model control system and new support system hardware, and to identify potential model and support system blockage and unsteady aerodynamics/model dynamics prior to committing to higher-fidelity instrumented models. This investigation led to upgrades in the facility stage separation hardware, calibration and testing techniques and capabilities, and data analysis and documentation methodologies that have been extended to the more recent NASA Constellation and Space Launch System crew and cargo launch vehicle programs. A virtual diagnostics interface methodology was used to facilitate the design of the stage separation support hardware, to position the models in the test section, and to define the experimental test space. Advances in the facility automated model positioning system established a foundation for the development of a continuous-sweep data acquisition technique that is responsible for significant productivity improvements to the current NASA Space Launch System test program. The automated model positioning capability was leveraged to conduct a companion statistically-designed stage separation experiment requiring randomization of the relative proximity positions of the orbiter and booster models. The respective zones of influence and interference effects of the orbiter and booster were identified from three-dimensional scatter plots, contour and influence maps, and two-dimensional plotting methods. The highly-nonlinear, shock-dominated aerodynamic characteristics of the orbiter and booster in the Unitary Plan Wind Tunnel exhibited good agreement with independent test data obtained in a NASA Marshall Space Flight Center wind tunnel and with computational fluid dynamics predictions using a compressible, three-dimensional flow solver and an inviscid, unstructured Cartesian method.

Erickson, Gary E.↗

Lithium cell tests at Marshall Space Flight Center

Three 18 AH Li-CF batteries with a polypropylene separator and using dimethyl sulfite in Li as F6 for the electrolyte will be placed in each shuttle solid rocket booster for range safety and frustrum location aid. Mechanical vibration, acceleration, random and design vibration, and discharge evaluation tests are discussed.

Paschal, L. E.↗

Recommendations for Safe Separation Distances from the Kennedy Space Center (KSC) Vehicle Assembly Building (VAB) Using a Heat-Flux-Based Analytical Approach (Abridged)

The NASA Engineering and Safety Center (NESC) was requested to provide computational modeling to support the establishment of a safe separation distance surrounding the Kennedy Space Center (KSC) Vehicle Assembly Building (VAB). The two major objectives of the study were 1) establish a methodology based on thermal flux to determine safe separation distances from the Kennedy Space Center's (KSC's) Vehicle Assembly Building (VAB) with large numbers of solid propellant boosters containing hazard division 1.3 classification propellants, in case of inadvertent ignition; and 2) apply this methodology to the consideration of housing eight 5-segment solid propellant boosters in the VAB. The results of the study are contained in this report.

Cragg, Clinton H.↗

Flight Performance and Stability of Space Launch System Core Stage Thrust Vector Control

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. The Core Stage TVC shares vehicle control authority with the SLS 5-segment Solid Rocket Boosters (SRBs) during boost phase flight, and is the sole means of vehicle flight control during in exoatmospheric flight following SRB separation. TVC responses during Green Run Hot Fire (GRHF) testing revealed that the TVC did not meet its performance specifications. Step and frequency responses exhibited unexpected departures from prior laboratory data and modeled behavior. Post-test analysis determined that the characteristics of the structure and gimbal friction are significantly influenced by the thrust-loaded conditions, and the command avionics exhibited a small but important gain nonlinearity. Using the available test data, the design team augmented the flight control TVC models to bound the observed results and include the additional fidelity needed for vehicle flight control analysis so as to build sufficient rationale for flight certification. Prior to the Green Run tests, “simplex” linear models typically used for flight control analysis did not include gimbal friction and other nonlinearities owing to long-standing assumptions that these effects were negligible in the Shuttle Orbiter TVC system. Following the Green Run findings, simulation analysis of the flight dynamics in the time and frequency domain revealed the propensity for a flight control limit cycle oscillation (LCO) if friction and structural compliances fell near the edges of test-predicted bounds. While the “most probable” models did not predict an in-flight LCO, the SLS Program conservatively proceeded with a system-wide evaluation and ultimate acceptance of the possibility for a small amplitude, low-frequency TVC LCO in flight. A final validation of the extensive test and modeling effort occurred when the first flight of SLS successfully demonstrated the fully integrated performance of the vehicle’s TVC system This paper is the final installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the development of flight rationale in light of the TVC responses observed in Green Run is discussed, along with a review of the flight telemetry illustrating the correlation of the preflight predictions with the observed performance.

John H. Wall↗

A Deformed Geometry Synthesis Technique for Determining Stacking and Cryogenically Induced Preloads for the Space Launch System

The Space Launch System (SLS) stacking and Core Stage (CS) fueling induce significant preloads that contribute to the liftoff pad separation “twang”. To accurately capture this, an approach is required that can replicate the physics of all SLS physical stacking steps, CS cryogenic shrinkage, associated geometric nonlinearities, and the transient behavior and decay of the preloads with changing boundary conditions as the vehicle separates from the pad. The Deformed Geometry Synthesis (DGS) approach presented here satisfies the above requirements. DGS determines induced preloads by modeling components in their deformed geometry states and then enforcing compatibility by closing the resulting “deadbands”. DGS seamlessly integrates into the multibody modal synthesis framework and does not require the use of artificial external loads to enforce preloads or post-processing steps to remove their influence. Since DGS iterates to solve for the deformed state inclusive of geometric nonlinearities, running linearized parametrics to exercise different potential orientations of ball jointed struts that connect the CS to Boosters for cryo-shrinkage analyses is entirely avoided. Relative to the transient behavior and decay of stacking and cryo-induced preloads with SLS liftoff pad separation, this is an area of considerable interest to the SLS program. To capture this in the most accurate way possible, DGS algorithms are designed to work with Henkel-Mar nonlinear pad separation algorithms which operate on the separating longitudinal and lateral degrees of freedom (DoFs) between the vehicle and the pad. As the separating DoFs release, in whatever manner as dictated by the interface geometries, interface loads and interface flexibilities as well as the external loading on the vehicle, the subject preloads generate a complex twang/decay time-trace as dictated by the physics of the problem. This paper presents DGS numerical verification against the closed-form solution for Timoshenko’s 3 ball-jointed strut preload problem. This problem is then extended by the authors to the geometric nonlinear case where DGS is compared to the Newton-Raphson solution of the nonlinear equations. Next, DGS is utilized to solve the SLS stacking and cryogenic shrinkage coupled loads analyses. Finally, Henkel-Mar pad separation simulations are executed that isolate the impact of the induced preloads’ twang and decay characteristics.

Space Launch System↗

High gradient directional solidification furnace

A high gradient directional solidification furnace is disclosed which includes eight thermal zones throughout the length of the furnace. In the hot end of the furnace, furnace elements provide desired temperatures. These elements include Nichrome wire received in a grooved tube which is encapsulated y an outer alumina core. A booster heater is provided in the hot end of the furnace which includes toroidal tungsten/rhenium wire which has a capacity to put heat quickly into the furnace. An adiabatic zone is provided by an insulation barrier to separate the hot end of the furnace from the cold end. The old end of the furnace is defined by additional heating elements. A heat transfer plate provides a means by which heat may be extracted from the furnace and conducted away through liquid cooled jackets. By varying the input of heat via the booster heater and output of heat via the heat transfer plate, a desired thermal gradient profile may be provided.

Aldrich, B. R.↗

Aerodynamic flight evaluation analysis and data base update

Research was conducted to determine the feasibility of replacing the Solid Rocket Boosters on the existing Space Shuttle Launch Vehicle (SSLV) with Liquid Rocket Boosters (LRB). As a part of the LRB selection process, a series of wind tunnel tests were conducted along with aero studies to determine the effects of different LRB configurations on the SSLV. Final results were tabulated into increments and added to the existing SSLV data base. The research conducted in this study was taken from a series of wind tunnel tests conducted at Marshall's 14-inch Trisonic Wind Tunnel. The effects on the axial force (CAF), normal force (CNF), pitching moment (CMF), side force (CY), wing shear force (CSR), wing torque moment (CTR), and wing bending moment (CBR) coefficients were investigated for a number of candidate LRB configurations. The aero effects due to LRB protuberances, ET/LRB separation distance, and aft skirts were also gathered from the tests. Analysis was also conducted to investigate the base pressure and plume effects due to the new booster geometries. The test results found in Phases 1 and 2 of wind tunnel testing are discussed and compared. Preliminary LRB lateral/directional data results and trends are given. The protuberance and gap/skirt effects are discussed. The base pressure/plume effects study is discussed and results are given.

Boyle, W. W.↗

Hyper-X Stage Separation Trajectory Validation Studies

An independent twelve degree-of-freedom simulation of the X-43A separation trajectory was created with the Program to Optimize Simulated trajectories (POST II). This simulation modeled the multi-body dynamics of the X-43A and its booster and included the effect of two pyrotechnically actuated pistons used to push the vehicles apart as well as aerodynamic interaction forces and moments between the two vehicles. The simulation was developed to validate trajectory studies conducted with a 14 degree-of-freedom simulation created early in the program using the Automatic Dynamic Analysis of Mechanics Systems (ADAMS) simulation software. The POST simulation was less detailed than the official ADAMS-based simulation used by the Project, but was simpler, more concise and ran faster, while providing similar results. The increase in speed provided by the POST simulation provided the Project with an alternate analysis tool. This tool was ideal for performing separation control logic trade studies that required the running of numerous Monte Carlo trajectories.

Tartabini, Paul V.↗