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Mars probe flight capsule mechanical subsystems for trajectory and orbital entry
Since the time of contract award of the Orion Crew Exploration Vehicle in 2006, NASA has spearheaded the design, development, test and evaluation of the Orion aerodynamic decelerator system through a Government Furnished Equipment project in the Engineering Directorate of the Johnson Space Center. This paper will describe the Project structure and organization, the interfaces to the major stakeholders, the processes applied, and a few major budget, schedule and technical challenges overcome.
This study is a first look at the problem of building a lunar lander to support a small lunar surface base. One lander, which can land 25 metric tons, one way, or take a 6 metric ton crew capsule up and down is desired. A series of trade studies are used to narrow the choices and provide some general guidelines. Given a rough baseline, the systems are then reviewed. A conceptual design is then produced. The process was only carried through one iteration. Many more iterations are needed. Assumptions and groundrules are considered.
The development of a 50 W/10 W dual mode K-band downlink TWT is examined, and its performance is evaluated. The designs of the electron gun, RF circuit, and collector for the TWT, which is enclosed in a capsule, are described. It is observed that the high power mode (HPM) power output is at 50 GHz and the low power mode (LPM) output is at 12 GHz; the saturated gain is 52.5 dB for HPM and 3 dB for LPM; the AM-PM is 4.2 dB; the HPM dc power output is 104 W; and the LPM dc output is 42 W; and the efficiency is 45 percent for the HPM and 28.6 percent for the LPM.
The origins of the lifting-body idea are traced back to the mid-1950's, when the concept of a manned satellite reentering the Earth's atmosphere in the form of a wingless lifting body was first proposed. The advantages of low reentry deceleration loads, range capability, and horizontal landing of a lifting reentry vehicle (as compared with the high deceleration loads and parachute landing of a capsule) are presented. The evolution of the hypersonic HL-10 lifting body is reviewed from the theoretical design and development process to its selection as one of two low-speed flight vehicles for fabrication and piloted flight testing. The design, development, and flight testing of the low-speed, air-launched, rocket-powered HL-10 was part of an unprecedented NASA and contractor effort. NASA Langley Research Center conceived and developed the vehicle shape and conducted numerous theoretical, experimental, and wind-tunnel studies. NASA Flight Research Center (now NASA Dryden Flight Research Center) was responsible for final low-speed (Mach numbers less than 2.0) aerodynamic analysis, piloted simulation, control law development, and flight tests. The prime contractor, Northrop Corp., was responsible for hardware design, fabrication, and integration. Interesting and unusual events in the flight testing are presented with a review of significant problems encountered in the first flight and how they were solved. Impressions by the pilots who flew the HL-10 are included. The HL-10 completed a successful 37-flight program, achieved the highest Mach number and altitude of this class vehicle, and contributed to the technology base used to develop the space shuttle and future generations of lifting bodies.
Topics discussed include: Detection of Chemical Precursors of Explosives; Detecting Methane From Leaking Pipelines and as Greenhouse Gas in the Atmosphere; Onboard Sensor Data Qualification in Human-Rated Launch Vehicles; Rugged, Portable, Real-Time Optical Gaseous Analyzer for Hydrogen Fluoride; A Probabilistic Mass Estimation Algorithm for a Novel 7-Channel Capacitive Sample Verification Sensor; Low-Power Architecture for an Optical Life Gas Analyzer; Online Cable Tester and Rerouter; A Three-Frequency Feed for Millimeter-Wave Radiometry; Capacitance Probe Resonator for Multichannel Electrometer; Inverted Three-Junction Tandem Thermophotovoltaic Modules; Fabrication of Single Crystal MgO Capsules; Inflatable Hangar for Assembly of Large Structures in Space; Mars Aqueous Processing System; Hybrid Filter Membrane; Design for the Structure and the Mechanics of Moballs; Pressure Dome for High-Pressure Electrolyzer; Cascading Tesla Oscillating Flow Diode for Stirling Engine Gas Bearings; Compact, Low-Force, Low-Noise Linear Actuator; Ultra-Compact Motor Controller; Extreme Ionizing-Radiation-Resistant Bacterium; Wideband Single-Crystal Transducer for Bone Characterization; Fluorescence-Activated Cell Sorting of Live Versus Dead Bacterial Cells and Spores; Nonhazardous Urine Pretreatment Method; Laser-Ranging Transponders for Science Investigations of the Moon and Mars; Ka-Band Waveguide Three-Way Serial Combiner for MMIC Amplifiers; Structural Health Monitoring with Fiber Bragg Grating and Piezo Arrays; Low-Gain Circularly Polarized Antenna with Torus-Shaped Pattern; Stereo and IMU- Assisted Visual Odometry for Small Robots; Global Swath and Gridded Data Tiling; GOES-R: Satellite Insight; Aquarius iPhone Application; Monitoring of International Space Station Telemetry Using Shewhart Control Charts; Theory of a Traveling Wave Feed for a Planar Slot Array Antenna; Time Manager Software for a Flight Processor; Simulation of Oxygen Disintegration and Mixing With Hydrogen or Helium at Supercritical Pressure; A Superfluid Pulse Tube Refrigerator Without Moving Parts for Sub-Kelvin Cooling; Sapphire Viewports for a Venus Probe; The Mobile Chamber; Electric Propulsion Induced Secondary Mass Spectroscopy; and Radiation-Tolerant DC-DC Converters.
The Altair lunar lander navigation system is driven by a set of requirements that not only specify a need to land within 100 m of a designated spot on the Moon, but also be capable of a safe return to an orbiting Orion capsule in the event of loss of Earth ground support. These requirements lead to the need for a robust and capable on-board navigation system that works in conjunction with an Earth ground navigation system that uses primarily ground-based radiometric tracking. The resulting system relies heavily on combining a multiplicity of data types including navigation state updates from the ground based navigation system, passive optical imaging from a gimbaled camera, a stable inertial measurement unit, and a capable radar altimeter and velocimeter. The focus of this paper is on navigation performance during the trans-lunar cruise, lunar orbit, and descent/landing mission phases with the goal of characterizing knowledge and delivery errors to key mission events, bound the statistical delta V costs for executing the mission, as well as the determine the landing dispersions due to navigation. This study examines the nominal performance that can be obtained using the current best estimate of the vehicle, sensor, and environment models. Performance of the system under a variety sensor outages and parametric trades is also examined.
The Orion Multi-Purpose Crew Vehicle will one day carry astronauts to the Moon and beyond, and Orion's heatshield is a critical component in ensuring their safe return to Earth. The Orion heatshield is the structural component responsible for absorbing the intense heating environment caused by re-entry to Earth's atmosphere. The heatshield is primarily composed of Avcoat, an ablative material that is consumed during the re-entry process. Ablation is primarily characterized by two processes: pyrolysis and recession. The decomposition of in-depth virgin material is known as pyrolysis. Recession occurs when the exposed surface of the heatshield reacts with the surrounding flow. The Orion heatshield design was changed from an individually filled Avcoat honeycomb to a molded block Avcoat design. The molded block Avcoat heatshield relies on an adhesive bond to keep it attached to the capsule. In some locations on the heatshield, the integrity of the adhesive bond cannot be verified. For these locations, a mechanical retention device was proposed. Avcoat ablation was modelled in CHAR and the in-depth virgin material temperatures were used in a Thermal Desktop model of the mechanical retention device. The retention device was analyzed and shown to cause a large increase in the maximum bondline temperature. In order to study the impact of individual ablation modelling parameters on the heatshield sizing process, a Monte Carlo simulation of the sizing process was proposed. The simulation will give the sensitivity of the ablation model to each of its input parameters. As part of the Monte Carlo simulation, statistical uncertainties on material properties were required for Avcoat. Several properties were difficult to acquire uncertainties for: the pyrolysis gas enthalpy, non-dimensional mass loss rate (B´c), and Arrhenius equation parameters. Variability in the elemental composition of Avcoat was used as the basis for determining the statistical uncertainty in pyrolysis gas enthalpy and B´c. A MATLAB program was developed to allow for faster, more accurate and automated computation of Arrhenius reaction parameters. These parameters are required for a material model to be used in the CHAR ablation analysis program. This MATLAB program, along with thermogravimetric analysis (TGA) data, was used to generate uncertainties on the Arrhenius parameters for Avcoat. In addition, the TGA fitting program was developed to provide Arrhenius parameters for the ablation model of the gap filler material, RTV silicone.
High temperature materials and graphite and composite program review to include: Baseline for unirradiated material properties, ASTM test development, design and construction rules (ASME-based), new fuel matrix mechanical studies, Irradiation damage studies, vender irradiation capsules, graphite supply chain worries, and ceramic composite activities.
Double shell targets are a promising potential avenue to obtain robust neutron yield at current laser facilities. Similar to single shell designs, double shells require the symmetric implosion of an ablator in order to uniformly compress and heat a fuel volume, with the goal of achieving thermonuclear burn. Significant differences between double and single shells include the usage of an aluminum ablator as well as a reverse ramp laser pulse. In addition, double shells require a different convergence than single shells for fuel ignition. Numerical implosion studies at various energies with comparisons to experimental outcomes are required to gain confidence that simulations can capture the ablator shape from subscale to full scale. The current work builds on previous implosion experiments conducted at 1-MJ laser energy to confirm achieved ablator symmetry at 1.25 and 1.5 MJ. Average ablator P2 and P4 shapes measured in these experiments are within 5% of the simulated shape, which merits the platforms for further experimental studies.
Double shell targets are a promising potential avenue to obtain robust neutron yield at current laser facilities. Similar to single shell designs, double shells require the symmetric implosion of an ablator in order to uniformly compress and heat a fuel volume, with the goal of achieving thermonuclear burn. Significant differences between double and single shells include the usage of an aluminum ablator as well as a reverse ramp laser pulse. In addition, double shells require a different convergence than single shells for fuel ignition. Numerical implosion studies at various energies with comparisons to experimental outcomes are required to gain confidence that simulations can capture the ablator shape from subscale to full scale. The current work builds on previous implosion experiments conducted at 1-MJ laser energy to con firm achieved ablator symmetry at 1.25 and 1.5 MJ. Average ablator P2 and P4 shapes measured in these experiments are within 5% of the simulated shape, which merits the platforms for further experimental studies.
Landings in the Soyuz vehicle have generated more injuries than models have predicted, and the reason for this remains unknown. Presently, 3 new capsule-type spacecraft—the Orion, the SpaceX Dragon2, and the Boeing CST-100—are in various stages of development. To better understand the injury risk to Soyuz crewmembers, and to mitigate risk of future injuries onboard the new vehicles, we conducted a finite element (FE) modeling effort. At the outset of this study, previously developed FE models were available for the seats in the 3 new vehicles, whereas the Soyuz environment had not been modeled in an extensible manner. Thus, a model of the Soyuz seat was necessary to facilitate comparisons of all seat types.
Mars Sample Return was presented as the highest priority planetary science mission of the next decade [1]. Lemke et al. [2] present a Mars Sample Return mission concept in which the sample is returned directly from the surface of Mars to an Earth orbit. The sample is recovered in Earth Orbit instead of being transferred between spacecraft in Mars Orbit. This paper provides the details of this sample recovery in Earth orbit and presents as such a sub-element of the overall Mars sample return concept given in [2]. We start from the assumption that a Mars Ascent Vehicle (MAV), initially landed on Mars using a modified SpaceX Dragon capsule, has successfully delivered the sample, already contained within an Earth Return Vehicle (ERV), to a parking orbit around Mars. From the parking orbit, the ERV imparts sufficient Delta-V to inject itself into an earthbound trajectory and to be captured into an Earth orbit eventually. We take into account launch window and Delta-V considerations as well as the additional constraint of increased safety margins imposed by planetary protection regulations. We focus on how to overcome two distinct challenges of the sample return that are driven by the issues of planetary protection: (1) the design of an ERV trajectory meeting all the requirements including the need to avoid contamination of Earth's atmosphere; (2) the concept of operations for retrieving the Martian samples in Earth orbit in a safe way. We present an approach to retrieve the samples through a rendezvous between the ERV and a second SpaceX Dragon capsule. The ERV executes a trajectory that brings it from low Mars orbit (LMO) to a Moon-trailing Earth orbit at high inclination with respect to the Earth-Moon plane. After a first burn at Trans-Earth Injection (TEI), the trajectory uses a second burn at perigee during an Earth flyby maneuver to capture the ERV in Earth orbit. The ERV then uses a non-propulsive Moon flyby to come to a near-circular Moon-trailing orbit. To perform the Earth Orbit Rendezvous (EOR), a second Dragon capsule is then launched from Earth and a similar lunar flyby is performed to rendezvous with the ERV. The requirements for rendezvous, close proximity operations and capture of the sample canister are described. A concept of operations for sample retrieval is presented along with design specifications of the ERV, the required modifications to the Dragon capsule, as well as the hardware, software, sensors, actuators, and capture mechanisms used. In our concept, a container is mounted to the front hatch of Dragon, capable of accommodating the sample canister and sealing it from the rest of the capsule. The sample canister is captured using a robotic arm with a magnetic grappling mechanism. Dragon then performs a propulsive maneuver to return to Earth for a controlled re-entry while the ERV (sans sample container) is left in the Moon trailing orbit. Contingency cases and related mitigation strategies are also discussed, including the advantages and disadvantages of performing the ERV rendezvous with a crew.
As NASA prepares for exploration missions, it will be critical to understand and build upon known crew capabilities. Specifically, we need to know the functional capacities of crew at different stages of a mission and characterize these profiles so that the appropriate vehicle requirements and mission concepts of operations (ConOps) can be developed. One of the most complex phases of any missions is when there is a transition between gravity environments. For instance, both physiological adaptation to microgravity and subsequent re-entry into a gravity environment result in reduced functional capacity, even with rigorous adherence to inflight countermeasures. Quantification of the astronauts’ post-landing functional performance is necessary to design ConOps for exploration missions. Specifically, these two high-risk tasks may have to be performed soon after gravity transitions: •Unassisted capsule egress task after return to Earth •Planetary extravehicular activity (EVA) soon after landing on Mars or the Moon This study has been broken down into two phases. A pilot phase to assess the overall feasibility and demonstrate the capability to do these tasks shortly after landing and the full Egress Fitness study, which will be part of the CIPHER complement. This study uses a functional task approach to characterize performance of these high-risk tasks in long-duration ISS crewmembers before flight and shortly after return to Earth. Prior to any testing, each astronaut subject completes a suit fit check to ensure adequate sizing and mobility to be able to complete the EVA tasks. Pilot Egress Fitness pre-flight and post-flight testing includes an Earth based emergency egress out of a functional capsule mockup, and a short Mars gravity EVA simulation including suit donning, hatch egress, ladder descent, task board cable operations, baggage transfer over sand/rocky regolith, alignment with a rear entry port, and suit egress. Pre-flight testing can occur almost anytime pre-flight, but post-flight scheduling is much more critical with the capsule egress test occurring 1-4 hours after landing and the planetary EVA approximately 18-36 hours after landing. Data collected for both tasks includes task completion time, photo, and video. The EVA portion also includes collection of metabolic and heart rate. Pilot Egress Fitness study has completed baseline pre-flight testing on 3 astronaut subjects. Post-flight testing of the first two subjects will be completed in November 2021 and the final subject around March 2022. Results and lessons learned from this pilot study will inform the full Egress Fitness study, which will incorporate additional pre-flight sessions, longer EVA tasks, and post-flight testing on R+1, 4, and 7 to characterize the timeframe of recovery
The transition between gravity environments will involve one of the most complex, high-risk phases of any mission. For example, the reduced functional capacity caused by physiological deconditioning adaptations in microgravity coupled with the stressors of re-entry into partial gravity environments will increase risks to crew, even with rigorous adherence to inflight countermeasures. Quantification of the astronauts’ post-landing functional performance is necessary to design ConOps for exploration missions. Specifically, these two high-risk scenarios may be required to be performed soon after gravity transitions: • Nominal and/or emergency unassisted capsule egress task after return to Earth • Planetary extravehicular activity (EVA) soon after landing on Mars or the Moon This study is broken down into two phases. Phase 1: A feasibility study that will assess the overall feasibility and demonstrate the capability to do these tasks shortly after landing. Phase 2: the full Egress Fitness study, which is part of the CIPHER complement. This study uses a task-based approach to characterize functional performance of these high-risk scenarios in long-duration ISS crewmembers before flight and shortly after return to Earth. Prior to any testing, each astronaut subject completes a suit fit check to ensure adequate sizing and a mobility assessment to confirm completion of the EVA tasks. Pilot Egress Fitness pre-flight and post-flight testing includes an Earth-based emergency egress out of a functional capsule mockup and a short Mars gravity EVA simulation including suit donning, hatch egress, ladder descent, task board cable operations, baggage transfer over sand/rocky regolith, alignment with a rear entry port, and suit egress. Pre-flight testing will occur at any time point prior to flight. Post-flight assessment is much more critical with the capsule egress test that will occur 1–4 hours after landing and the planetary EVA approximately 18–36 hours after landing. The CIPHER study will incorporate additional pre-flight sessions, longer EVA tasks that include traverse and geology sampling, and post-flight sessions on R+1, 4, and 8 to characterize the timeframe of recovery. Data collected for both tasks include task completion time, photo, and video. The EVA portion also includes collection of metabolic and heart rate. Pilot Egress Fitness study has completed both baseline and post-flight testing on four astronaut subjects, with all four able to complete post-flight EVA testing and three able to complete postflight capsule egress testing. Preliminary results observe individual physiological variations, which were to be expected but also suggest the need to carefully track the timeline from undock to landing to testing. Furthermore, some task performance instructions and equipment may need to be adjusted to ensure results are primarily physiological. These and other lessons learned will be addressed with minor protocol changes in the full CIPHER Egress Fitness study.
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The Mars Exploration Rover mission will be the next opportunity for surface exploration of Mars in January 2004. Two rovers will be delivered to the surface of Mars using the same entry, descent, and landing scenario that was developed and successfully implemented by Mars Pathfinder. This investigation describes the trajectory analysis that was performed for the hypersonic portion of the MER entry. In this analysis, a six-degree-of-freedom trajectory simulation of the entry is performed to determine the entry characteristics of the capsules. In addition, a Monte Carlo analysis is also performed to statistically assess the robustness of the entry design to off-nominal conditions to assure that all entry requirements are satisfied. The results show that the attitude at peak heating and parachute deployment are well within entry limits. In addition, the parachute deployment dynamics pressure and Mach number are also well within the design requirements.
NASA's OSIRIS-REx spacecraft collected samples from carbonaceous near-Earth asteroid (101955) Bennu on October 20, 2020, and will deliver them to the Earth on September 24, 2023. The samples will be processed at the NASA Johnson Space Center (JSC), where most of the sample collection will be subsequently curated in a new cleanroom suite. The spacecraft collected loose regolith two ways: in a bulk sample chamber capable of holding up to 2 kg, and on industrial Velcro “contact pads” intended to collect small particles at the surface. Included in the JSC collection will be the bulk sample, the contact pads, contamination-monitoring witness plates, and supporting hardware. Planning for the curation of the samples and hardware started at the earliest phase of proposal development and continued in parallel with project development and execution. Because a major mission goal is characterization of organic compounds in the Bennu samples, extra effort was spent in the design stage to ensure a clean curation environment. Here, we describe the preparations to receive the sample, including the design, construction, outfitting, and monitoring of the cleanrooms at JSC; the planned recovery of the sample-containing capsule when it lands on Earth; and the approach to characterizing and cataloging the samples. These curation efforts will result in the distribution of pristine Bennu samples from JSC to the OSIRIS-REx science team, international partners, and the global scientific community for years to come.