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NASA NTRS2010

Ares I-X Flight Test Vehicle: Stack 5 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA's Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the first modal test that was performed on the top section of the vehicle referred to as Stack 5, which consisted of the spacecraft adapter, service module, crew module and launch abort system simulators. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 5 modal test.

Buehrle, Ralph D.↗

NASA NTRS2016

Efficiency Management in Spaceflight Systems

Efficiency in spaceflight is often approached as “faster, better, cheaper – pick two”. The high levels of performance and reliability required for each mission suggest that planners can only control for two of the three. True efficiency comes by optimizing a system across all three parameters. The functional processes of spaceflight become technical requirements on three operational groups during mission planning: payload, vehicle, and launch operations. Given the interrelationships among the functions performed by the operational groups, optimizing function resources from one operational group to the others affects the efficiency of those groups and therefore the mission overall. This paper helps outline this framework and creates a context in which to understand the effects of resource trades on the overall system, improving the efficiency of the operational groups and the mission as a whole. This allows insight into and optimization of the controlling factors earlier in the mission planning stage.

Murphy, Karen↗

NASA NTRS2016

Efficiency Management in Spaceflight Systems

Efficiency in spaceflight is often approached as "faster, better, cheaper - pick two". The high levels of performance and reliability required for each mission suggest that planners can only control for two of the three. True efficiency comes by optimizing a system across all three parameters. The functional processes of spaceflight become technical requirements on three operational groups during mission planning: payload, vehicle, and launch operations. Given the interrelationships among the functions performed by the operational groups, optimizing function resources from one operational group to the others affects the efficiency of those groups and therefore the mission overall. This paper helps outline this framework and creates a context in which to understand the effects of resource trades on the overall system, improving the efficiency of the operational groups and the mission as a whole. This allows insight into and optimization of the controlling factors earlier in the mission planning stage.

Murphy, Karen↗

NASA NTRS2004

Soft-Fault Detection Technologies Developed for Electrical Power Systems

The NASA Glenn Research Center, partner universities, and defense contractors are working to develop intelligent power management and distribution (PMAD) technologies for future spacecraft and launch vehicles. The goals are to provide higher performance (efficiency, transient response, and stability), higher fault tolerance, and higher reliability through the application of digital control and communication technologies. It is also expected that these technologies will eventually reduce the design, development, manufacturing, and integration costs for large, electrical power systems for space vehicles. The main focus of this research has been to incorporate digital control, communications, and intelligent algorithms into power electronic devices such as direct-current to direct-current (dc-dc) converters and protective switchgear. These technologies, in turn, will enable revolutionary changes in the way electrical power systems are designed, developed, configured, and integrated in aerospace vehicles and satellites. Initial successes in integrating modern, digital controllers have proven that transient response performance can be improved using advanced nonlinear control algorithms. One technology being developed includes the detection of "soft faults," those not typically covered by current systems in use today. Soft faults include arcing faults, corona discharge faults, and undetected leakage currents. Using digital control and advanced signal analysis algorithms, we have shown that it is possible to reliably detect arcing faults in high-voltage dc power distribution systems (see the preceding photograph). Another research effort has shown that low-level leakage faults and cable degradation can be detected by analyzing power system parameters over time. This additional fault detection capability will result in higher reliability for long-lived power systems such as reusable launch vehicles and space exploration missions.

Button, Robert M.↗

NASA NTRS2007

Crew Exploration Vehicle Launch Abort Controller Performance Analysis

This paper covers the simulation and evaluation of a controller design for the Crew Module (CM) Launch Abort System (LAS), to measure its ability to meet the abort performance requirements. The controller used in this study is a hybrid design, including features developed by the Government and the Contractor. Testing is done using two separate 6-degree-of-freedom (DOF) computer simulation implementations of the LAS/CM throughout the ascent trajectory: 1) executing a series of abort simulations along a nominal trajectory for the nominal LAS/CM system; and 2) using a series of Monte Carlo runs with perturbed initial flight conditions and perturbed system parameters. The performance of the controller is evaluated against a set of criteria, which is based upon the current functional requirements of the LAS. Preliminary analysis indicates that the performance of the present controller meets (with the exception of a few cases) the evaluation criteria mentioned above.

Sparks, Dean W., Jr.↗

NASA NTRS2010

Design for Safety - The Ares Launch Vehicles Paradigm Change

The lessons learned from the S&MA early involvement in the Ares I launch vehicle design phases proved that performing an in-line function jointly with engineering is critical for S&MA to have an effective role in supporting the system, element, and component design. These lessons learned were used to effectively support the Ares V conceptual design phase and planning for post conceptual design phases. The Top level Conceptual LOM assessment for Ares V performed by the S&MA community jointly with the engineering Advanced Concept Office (ACO) was influential in the final selection of the Ares V system configuration. Post conceptual phase, extensive reliability effort should be planned to support future Heavy Lift Launch Vehicles (HLLV) design. In-depth reliability analysis involving the design, manufacturing, and system engineering communities is critical to understand design and process uncertainties and system integrated failures.

Safie, Fayssal M.↗

NASA NTRS2006

NASA Exploration Launch Projects Overview: The Crew Launch Vehicle and the Cargo Launch Vehicle Systems

The U.S. Vision for Space Exploration (January 2004) serves as the foundation for the National Aeronautics and Space Administration's (NASA) strategic goals and objectives. As the NASA Administrator outlined during his confirmation hearing in April 2005, these include: 1) Flying the Space Shuttle as safely as possible until its retirement, not later than 2010. 2) Bringing a new Crew Exploration Vehicle (CEV) into service as soon as possible after Shuttle retirement. 3) Developing a balanced overall program of science, exploration, and aeronautics at NASA, consistent with the redirection of the human space flight program to focus on exploration. 4) Completing the International Space Station (ISS) in a manner consistent with international partner commitments and the needs of human exploration. 5) Encouraging the pursuit of appropriate partnerships with the emerging commercial space sector. 6) Establishing a lunar return program having the maximum possible utility for later missions to Mars and other destinations. In spring 2005, the Agency commissioned a team of aerospace subject matter experts to perform the Exploration Systems Architecture Study (ESAS). The ESAS team performed in-depth evaluations of a number of space transportation architectures and provided recommendations based on their findings? The ESAS analysis focused on a human-rated Crew Launch Vehicle (CLV) for astronaut transport and a heavy lift Cargo Launch Vehicle (CaLV) to carry equipment, materials, and supplies for lunar missions and, later, the first human journeys to Mars. After several months of intense study utilizing safety and reliability, technical performance, budget, and schedule figures of merit in relation to design reference missions, the ESAS design options were unveiled in summer 2005. As part of NASA's systems engineering approach, these point of departure architectures have been refined through trade studies during the ongoing design phase leading to the development phase that begins in 2008. Comprehensive reviews of engineering data and business assessments by both internal and independent reviewers serve as decision gates to ensure that systems can fully meet customer and stakeholder requirements. This paper provides the current CLV and CaLV configuration designs and gives examples of the progress being made during the first year of this significant effort. Safe, reliable, cost-effective space transportation systems are a foundational piece of America s future in space and the next step in realizing the plan for revitalizing lunar capabilities on the passageway to the human exploration of Mars. While building on legacy knowledge and heritage hardware for risk reduction, NASA will apply lessons learned from developing these new launch vehicles to the growth path for future missions. The elements for mission success and continued U.S. leadership in space have been assembled over the past year. As NASA designs and develops these two new systems over the next dozen years, visible progress, such as that reported in this paper, may sustain the national will to stay the course across political administrations and weather the inevitable trials that will be experienced during this challenging endeavor.

Snoddy, Jimmy R.↗

NASA NTRS2014

Conceptual Launch Vehicle and Spacecraft Design for Risk Assessment

One of the most challenging aspects of developing human space launch and exploration systems is minimizing and mitigating the many potential risk factors to ensure the safest possible design while also meeting the required cost, weight, and performance criteria. In order to accomplish this, effective risk analyses and trade studies are needed to identify key risk drivers, dependencies, and sensitivities as the design evolves. The Engineering Risk Assessment (ERA) team at NASA Ames Research Center (ARC) develops advanced risk analysis approaches, models, and tools to provide such meaningful risk and reliability data throughout vehicle development. The goal of the project presented in this memorandum is to design a generic launch 7 vehicle and spacecraft architecture that can be used to develop and demonstrate these new risk analysis techniques without relying on other proprietary or sensitive vehicle designs. To accomplish this, initial spacecraft and launch vehicle (LV) designs were established using historical sizing relationships for a mission delivering four crewmembers and equipment to the International Space Station (ISS). Mass-estimating relationships (MERs) were used to size the crew capsule and launch vehicle, and a combination of optimization techniques and iterative design processes were employed to determine a possible two-stage-to-orbit (TSTO) launch trajectory into a 350-kilometer orbit. Primary subsystems were also designed for the crewed capsule architecture, based on a 24-hour on-orbit mission with a 7-day contingency. Safety analysis was also performed to identify major risks to crew survivability and assess the system's overall reliability. These procedures and analyses validate that the architecture's basic design and performance are reasonable to be used for risk trade studies. While the vehicle designs presented are not intended to represent a viable architecture, they will provide a valuable initial platform for developing and demonstrating innovative risk assessment capabilities.

Launch Vehicle↗

NASA NTRS2003

Multi-Disciplinary Analysis for Future Launch Systems Using NASA's Advanced Engineering Environment (AEE)

A new engineering environment constructed for the purposes of analyzing and designing Reusable Launch Vehicles (RLVs) is presented. The new environment has been developed to allow NASA to perform independent analysis and design of emerging RLV architectures and technologies. The new Advanced Engineering Environment (AEE) is both collaborative and distributed. It facilitates integration of the analyses by both vehicle performance disciplines and life-cycle disciplines. Current performance disciplines supported include: weights and sizing, aerodynamics, trajectories, propulsion, structural loads, and CAD-based geometries. Current life-cycle disciplines supported include: DDT&E cost, production costs, operations costs, flight rates, safety and reliability, and system economics. Involving six NASA centers (ARC, LaRC, MSFC, KSC, GRC and JSC), AEE has been tailored to serve as a web-accessed agency-wide source for all of NASA's future launch vehicle systems engineering functions. Thus, it is configured to facilitate (a) data management, (b) automated tool/process integration and execution, and (c) data visualization and presentation. The core components of the integrated framework are a customized PTC Windchill product data management server, a set of RLV analysis and design tools integrated using Phoenix Integration's Model Center, and an XML-based data capture and transfer protocol. The AEE system has seen production use during the Initial Architecture and Technology Review for the NASA 2nd Generation RLV program, and it continues to undergo development and enhancements in support of its current main customer, the NASA Next Generation Launch Technology (NGLT) program.

Monell, D.↗

NASA NTRS1966

Solar-Powered Electric Propulsion Systems: Engineering and Applications

Lightweight, multikilowatt solar power arrays in conjunction with electric propulsion offer potential improvements to space exploration, extending the usefulness of existing launch vehicles to higher-energy missions. Characteristics of solar-powered electric propulsion missions are outlined, and preliminary performance estimates are shown. Spacecraft system engineering is discussed with respect to parametric trade-offs in power and propulsion system design. Relationships between mission performance and propulsion system performance are illustrated. The present state of the art of electric propulsion systems is reviewed and related to the mission requirements identified earlier. The propulsion system design and test requirements for a mission spacecraft are identified and discussed. Although only ion engine systems are currently available, certain plasma propulsion systems offer some advantages in over-all system design. These are identified, and goals are set for plasma-thrustor systems to make them competitive with ion-engine systems for mission applications.

Stearns, J. W.↗

NASA NTRS2004

The Perfect Mate for Safe Fueling

Referred to as the "lifeline for any space launch vehicle" by NASA Space Launch Initiative Program Manager Warren Wiley, an umbilical is a large device that transports power, communications, instrument readings, and fluids such as propellants, pressurization gases, and coolants from one source to another. Numerous launch vehicles, planetary systems, and rovers require umbilical "mating". This process is a driving factor for dependable and affordable space access. With future-generation space vehicles in mind, NASA recently designed a smart, automated method for quickly and reliably mating and demating electrical and fluid umbilical connectors. The new umbilical concept is expected to replace NASA s traditional umbilical systems that release at vehicle lift-off (T-0). The idea is to increase safety by automatically performing hazardous tasks, thus reducing potential failure modes and the time and labor hours necessary to prepare for launch. The new system will also be used as a test bed for quick disconnect development and for advance control and leak detection. It incorporates concepts such as a secondary mate plate, robotic machine vision, and compliant motor motion control, and is destined to advance usage of automated umbilicals in a variety of aerospace and commercial applications.

Source record↗

NASA NTRS2013

Small Launch Vehicle Design Approaches: Clustered Cores Compared with Multi-Stage Inline Concepts

In an effort to better define small launch vehicle design options two approaches were investigated from the small launch vehicle trade space. The primary focus was to evaluate a clustered common core design against a purpose built inline vehicle. Both designs focused on liquid oxygen (LOX) and rocket propellant grade kerosene (RP-1) stages with the terminal stage later evaluated as a LOX/methane (CH4) stage. A series of performance optimization runs were done in order to minimize gross liftoff weight (GLOW) including alternative thrust levels, delivery altitude for payload, vehicle length to diameter ratio, alternative engine feed systems, re-evaluation of mass growth allowances, passive versus active guidance systems, and rail and tower launch methods. Additionally manufacturability, cost, and operations also play a large role in the benefits and detriments for each design. Presented here is the Advanced Concepts Office's Earth to Orbit Launch Team methodology and high level discussion of the performance trades and trends of both small launch vehicle solutions along with design philosophies that shaped both concepts. Without putting forth a decree stating one approach is better than the other; this discussion is meant to educate the community at large and let the reader determine which architecture is truly the most economical; since each path has such a unique set of limitations and potential payoffs.

Waters, Eric D.↗

NASA NTRS2014

Use of DES Modeling for Determining Launch Availability for SLS

The National Aeronautics and Space Administration (NASA) is developing new capabilities for human and scientific exploration beyond Earth's orbit. This effort includes the Space Shuttle derived Space Launch System (SLS), the Orion Multi-Purpose Crew Vehicle (MPCV), and the Ground Systems Development and Operations (GSDO). There are several requirements and Technical Performance Measures (TPMs) that have been levied by the Exploration Systems Development (ESD) upon the SLS, Orion, and GSDO Programs including an integrated Launch Availability (LA) TPM. The LA TPM is used to drive into the SLS, Orion and GSDO designs a high confidence of successfully launching exploration missions that have narrow Earth departure windows. The LA TPM takes into consideration the reliability of the overall system (SLS, Orion and GSDO), natural environments, likelihood of a failure, and the time required to recover from an anomaly. A challenge with the LA TPM is the interrelationships between SLS, Orion, GSDO and the natural environments during launch countdown and launch delays that makes it impossible to develop an analytical solution for calculating the integrated launch probability. This paper provides an overview of how Discrete Event Simulation (DES) modeling was used to develop the LA TPM, how it was allocated down to the individual programs, and how the LA analysis is being used to inform and drive the SLS, Orion, and GSDO designs to ensure adequate launch availability for future human exploration.

Staton, Eric↗

NASA NTRS2014

Analyzing the Impacts of Natural Environments on Launch and Landing Availability for NASA's Exploration Systems Development Programs

The National Aeronautics and Space Administration (NASA) is developing new capabilities for human and scientific exploration beyond Earth orbit. Natural environments information is an important asset for NASA's development of the next generation space transportation system as part of the Exploration Systems Development (ESD) Programs, which includes the Space Launch System (SLS) and Multi-Purpose Crew Vehicle (MPCV) Programs. Natural terrestrial environment conditions - such as wind, lightning and sea states - can affect vehicle safety and performance during multiple mission phases ranging from pre-launch ground processing to landing and recovery operations, including all potential abort scenarios. Space vehicles are particularly sensitive to these environments during the launch/ascent and the entry/landing phases of mission operations. The Marshall Space Flight Center (MSFC) Natural Environments Branch provides engineering design support for NASA space vehicle projects and programs by providing design engineers and mission planners with natural environments definitions as well as performing custom analyses to help characterize the impacts the natural environment may have on vehicle performance. One such analysis involves assessing the impact of natural environments to operational availability. Climatological time series of operational surface weather observations are used to calculate probabilities of meeting/exceeding various sets of hypothetical vehicle-specific parametric constraint thresholds. Outputs are tabulated by month and hour of day to show both seasonal and diurnal variation. This paper will discuss how climate analyses are performed by the MSFC Natural Environments Branch to support the ESD Launch Availability (LA) Technical Performance Measure (TPM), the SLS Launch Availability due to Natural Environments TPM, and several MPCV (Orion) launch and landing availability analyses - including the 2014 Orion Exploration Flight Test 1 (EFT-1) mission.

Altino, Karen M.↗

NASA NTRS2014

Testing Orions Fairing Separation System

Traditional fairing systems are designed to fully encapsulate and protect their payload from the harsh ascent environment including acoustic vibrations, aerodynamic forces and heating. The Orion fairing separation system performs this function and more by also sharing approximately half of the vehicle structural load during ascent. This load-share condition through launch and during jettison allows for a substantial increase in mass to orbit. A series of component-level development tests were completed to evaluate and characterize each component within Orion's unique fairing separation system. Two full-scale separation tests were performed to verify system-level functionality and provide verification data. This paper summarizes the fairing spring, Pyramidal Separation Mechanism and forward seal system component-level development tests, system-level separation tests, and lessons learned.

Martinez, Henry↗

NASA NTRS2016

Paving the Path for Human Space Exploration: The Challenges and Opportunities

Lauri Hansen, Director of Engineering at NASA Johnson Space Center will discuss the challenges of human space exploration. The future of human exploration begins with our current earth reliant missions in low earth orbit. These missions utilize the International Space Station to learn how to safely execute deep space missions. In addition to serving as an exploration test bed and enabling world class research, the International Space Station enables NASA to build international and commercial partnerships. NASA's next steps will be to enable the commercialization of low earth orbit while concentrating on developing the spacecraft and infrastructure necessary for deep space exploration and long duration missions. The Orion multi-purpose crew vehicle and the Space Launch System rocket are critical building blocks in this next phase of exploration. There are many challenges in designing spacecraft to perform these missions including safety, complex vehicle design, and mass challenges. Orion development is proceeding well, and includes a significant partnership with the European Space Agency (ESA) to develop and build the Service Module portion of the spacecraft. Together, NASA and ESA will provide the capability to take humans further than we have ever been before - 70,000 km past the moon. This will be the next big step in expanding the frontiers of human exploration, eventually leading to human footprints on Mars.

Hansen, Lauri↗

NASA NTRS2008

2007 Research and Engineering Annual Report

Selected research and technology activities at NASA Dryden Flight Research Center are summarized. These following activities exemplify the Center's varied and productive research efforts: Developing a Requirements Development Guide for an Automatic Ground Collision Avoidance System; Digital Terrain Data Compression and Rendering for Automatic Ground Collision Avoidance Systems; Nonlinear Flutter/Limit Cycle Oscillations Prediction Tool; Nonlinear System Identification Using Orthonormal Bases: Application to Aeroelastic/Aeroservoelastic Systems; Critical Aerodynamic Flow Feature Indicators: Towards Application with the Aerostructures Test Wing; Multidisciplinary Design, Analysis, and Optimization Tool Development Using a Genetic Algorithm; Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool; Extension of Ko Straight-Beam Displacement Theory to the Deformed Shape Predictions of Curved Structures; F-15B with Phoenix Missile and Pylon Assembly--Drag Force Estimation; Mass Property Testing of Phoenix Missile Hypersonic Testbed Hardware; ARMD Hypersonics Project Materials and Structures: Testing of Scramjet Thermal Protection System Concepts; High-Temperature Modal Survey of the Ruddervator Subcomponent Test Article; ARMD Hypersonics Project Materials and Structures: C/SiC Ruddervator Subcomponent Test and Analysis Task; Ground Vibration Testing and Model Correlation of the Phoenix Missile Hypersonic Testbed; Phoenix Missile Hypersonic Testbed: Performance Design and Analysis; Crew Exploration Vehicle Launch Abort System-Pad Abort-1 (PA-1) Flight Test; Testing the Orion (Crew Exploration Vehicle) Launch Abort System-Ascent Abort-1 (AA-1) Flight Test; SOFIA Flight-Test Flutter Prediction Methodology; SOFIA Closed-Door Aerodynamic Analyses; SOFIA Handling Qualities Evaluation for Closed-Door Operations; C-17 Support of IRAC Engine Model Development; Current Capabilities and Future Upgrade Plans of the C-17 Data Rack; Intelligent Data Mining Capabilities as Applied to Integrated Vehicle Health Management; STARS Flight Demonstration No. 2 IP Data Formatter; Space-Based Telemetry and Range Safety (STARS) Flight Demonstration No. 2 Range User Flight Test Results; Aerodynamic Effects of the Quiet Spike(tm) on an F-15B Aircraft; F-15 Intelligent Flight Controls-Increased Destabilization Failure; F-15 Integrated Resilient Aircraft Control (IRAC) Improved Adaptive Controller; Aeroelastic Analysis of the Ikhana/Fire Pod System; Ikhana: Western States Fire Missions Utilizing the Ames Research Center Fire Sensor; Ikhana: Fiber-Optic Wing Shape Sensors; Ikhana: ARTS III; SOFIA Closed-Door Flutter Envelope Flight Testing; F-15B Quiet Spike(TM) Aeroservoelastic Flight Test Data Analysis; and UAVSAR Platform Precision Autopilot Flight Results.

Stoliker, Patrick↗

NASA NTRS2016

Inviscid and Viscous CFD Analysis of Booster Separation for the Space Launch System Vehicle

This paper presents details of Computational Fluid Dynamic (CFD) simulations of the Space Launch System during solid-rocket booster separation using the Cart3D inviscid and Overflow viscous CFD codes. The discussion addresses the use of multiple data sources of computational aerodynamics, experimental aerodynamics, and trajectory simulations for this critical phase of flight. Comparisons are shown between Cart3D simulations and a wind tunnel test performed at NASA Langley Research Center's Unitary Plan Wind Tunnel, and further comparisons are shown between Cart3D and viscous Overflow solutions for the flight vehicle. The Space Launch System (SLS) is a new exploration-class launch vehicle currently in development that includes two Solid Rocket Boosters (SRBs) modified from Space Shuttle hardware. These SRBs must separate from the SLS core during a phase of flight where aerodynamic loads are nontrivial. The main challenges for creating a separation aerodynamic database are the large number of independent variables (including orientation of the core, relative position and orientation of the boosters, and rocket thrust levels) and the complex flow caused by exhaust plumes of the booster separation motors (BSMs), which are small rockets designed to push the boosters away from the core by firing partially in the direction opposite to the motion of the vehicle.

Viscous↗