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NASA NTRS2007

Autonomous Airborne Refueling Demonstration: Phase I Flight-Test Results

The first phase of the Autonomous Airborne Refueling Demonstration (AARD) project was completed on August 30, 2006. The goal of this 15-month effort was to develop and flight-test a system to demonstrate an autonomous refueling engagement using the Navy style hose-and-drogue air-to-air refueling method. The prime contractor for this Defense Advanced Research Projects Agency (DARPA) sponsored program was Sierra Nevada Corporation (SNC), Sparks, Nevada. The responsible flight-test organization was the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center (DFRC), Edwards, California, which also provided the F/A-18 receiver airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois). The B-707-300 tanker airplane (The Boeing Company) was contracted through Omega Aerial Refueling Services, Inc., Alexandria, Virginia, and the optical tracking system was contracted through OCTEC Ltd., Bracknell, Berkshire, United Kingdom. Nine research flights were flown, testing the functionality and performance of the system in a stepwise manner, culminating in the plug attempts on the final flight. Relative position keeping was found to be very stable and accurate. The receiver aircraft was capable of following the tanker aircraft through turns while maintaining its relative position. During the last flight, six capture attempts were made, two of which were successful. The four misses demonstrated excellent characteristics, the receiver retreating from the drogue in a controlled, safe, and predictable manner that precluded contact between the drogue and the receiver aircraft. The position of the receiver aircraft when engaged and in position for refueling was found to be 5.5 to 8.5 ft low of the ideal position. The controller inputs to the F/A-18 were found to be extremely small.

Dibley, Ryan P.↗

NASA NTRS2007

Autonomous Airborne Refueling Demonstration, Phase I Flight-Test Results

The first phase of the Autonomous Airborne Refueling Demonstration (AARD) project was completed on August 30, 2006. The goal of this 15-month effort was to develop and flight-test a system to demonstrate an autonomous refueling engagement using the Navy style hose-and-drogue air-to-air refueling method. The prime contractor for this Defense Advanced Research Projects Agency (DARPA) sponsored program was Sierra Nevada Corporation (SNC), Sparks, Nevada. The responsible flight-test organization was the NASA Dryden Flight Research Center (DFRC), Edwards, California, which also provided the F/A-18 receiver airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois). The B-707-300 tanker airplane (The Boeing Company) was contracted through Omega Aerial Refueling Services, Inc., Alexandria, Virginia, and the optical tracking system was contracted through OCTEC Ltd., Bracknell, Berkshire, United Kingdom. Nine research flights were flown, testing the functionality and performance of the system in a stepwise manner, culminating in the plug attempts on the final flight. Relative position keeping was found to be very stable and accurate. The receiver aircraft was capable of following the tanker aircraft through turns while maintaining its relative position. During the last flight, six capture attempts were made, two of which were successful. The four misses demonstrated excellent characteristics, the receiver retreating from the drogue in a controlled, safe, and predictable manner that precluded contact between the drogue and the receiver aircraft. The position of the receiver aircraft when engaged and in position for refueling was found to be 5.5 to 8.5 ft low of the ideal position. The controller inputs to the F/A-18 were found to be extremely small

Dibley, Ryan P.↗

NASA NTRSDate not supplied

Validation of Transient Spacecraft Refueling Model with Gateway Breadboard Test Data

The ability to refuel spacecraft on-orbit is a key enabling technology for deep space human exploration. On-orbit refueling requires priming a pressurized liquid propellant from a source tank into fluid transfer lines at vacuum conditions, which could result in excessive surge pressures beyond the system’s qualified operating limits and potentially damage hardware. Therefore, it is imperative to employ numerical models during the development of flight hardware to parametrically characterize system performance over a wide range of operating conditions. Since priming transients are difficult to model accurately, it is important to validate those models with test data. As part of the Gateway bipropellant refueling system development, a simplified fluidic breadboard system was created using water as a simulant for fuel to support early program risk reduction of refueling operations. The objectives of breadboard testing were to gather performance data to characterize and demonstrate critical refueling operations and to validate numerical models that can be extended to predicting flight system performance. A description of the breadboard test system and the results of numerical model validation is presented. The model is shown to have very good agreement with test data.

Brian S Lusby↗

NASA NTRS1986

Tethered orbital refueling study

One of the major applications of the space station will be to act as a refueling depot for cryogenic-fueled space-based orbital transfer vehicles (OTV), Earth-storable fueled orbit maneuvering vehicles, and refurbishable satellite spacecraft using hydrazine. One alternative for fuel storage at the space station is a tethered orbital refueling facility (TORF), separated from the space station by a sufficient distance to induce a gravity gradient force that settles the stored fuels. The technical feasibility was examined with the primary focus on the refueling of LO2/LH2 orbital transfer vehicles. Also examined was the tethered facility on the space station. It was compared to a zero-gravity facility. A tethered refueling facility should be considered as a viable alternative to a zero-gravity facility if the zero-gravity fluid transfer technology, such as the propellant management device and no vent fill, proves to be difficult to develop with the required performance.

Fester, Dale A.↗

NASA NTRS2004

Calculated Drag of an Aerial Refueling Assembly Through Airplane Performance Analysis

This viewgraph document reviews NASA Dryden's work on Aerial refueling, with specific interest in calculating the drag of the refueling system. The aerodynamic drag of an aerial refueling assembly was calculated during the Automated Aerial Refueling project at the NASA Dryden Flight Research Center. An F/A-18A airplane was specially instrumented to obtain accurate fuel flow measurements and to determine engine thrust

Vachon, Jake↗

NASA NTRS2010

Risk Analysis of On-Orbit Spacecraft Refueling Concepts

On-orbit refueling of spacecraft has been proposed as an alternative to the exclusive use of Heavy-lift Launch Vehicles to enable human exploration beyond Low Earth Orbit (LEO). In these scenarios, beyond LEO spacecraft are launched dry (without propellant) or partially dry into orbit, using smaller or fewer element launch vehicles. Propellant is then launched into LEO on separate launch vehicles and transferred to the spacecraft. Refueling concepts are potentially attractive because they reduce the maximum individual payload that must be placed in Earth orbit. However, these types of approaches add significant complexity to mission operations and introduce more uncertainty and opportunities for failure to the mission. In order to evaluate these complex scenarios, the authors developed a Monte Carlo based discrete-event model that simulates the operational risks involved with such strategies, including launch processing delays, transportation system failures, and onorbit element lifetimes. This paper describes the methodology used to simulate the mission risks for refueling concepts, the strategies that were evaluated, and the results of the investigation. The results of the investigation show that scenarios that employ refueling concepts will likely have to include long launch and assembly timelines, as well as the use of spare tanker launch vehicles, in order to achieve high levels of mission success through Trans Lunar Injection.

Cirillo, William M.↗

NASA NTRSDate not supplied

Gateway bi-propellant refueling development testing and model validation activities

The Gateway is an upcoming long term lunar exploration program to be completed by NASA in partnership with ESA and other US and international partners. The system design of the Gateway contains both a high performance Xenon based Solar Electric Propulsion system, as well as a bi-propellant attitude control system. Both propulsion systems are designed for on-orbit refueling to enable long life performance of the Gateway. The ESPRIT-RM is a module which will expand the pressurized volume of Gateway, while also providing refueling capability for both the Xenon and Bipropellant propulsion systems, therefore extending the Gateway life on orbit. As part of the Gateway bi-propellant refueling system development, a simplified fluidic breadboard system was created to evaluate system performance and response using simulant fluids. The test plan includes verification activities with simulant (water, HFE-7100) to verify joined subsystem behavior in the critical operations, including propellant transfer demonstration between modules, transient tests and venting tests. Integrated testing occurred at TASUK in collaboration with NASA to support joint verification activities to de-risk the major functions of the ESPRIT BTS and the overall CONOPS of the refueling of the Gateway chemical propulsion system. Initially collected test data from the system testing is presented, as well as initial model validation, and correlated to collected high frequency test data and system response is shown. Initially collected data has shown the architected system performance is closing initial design assumptions, but much forward work remains to characterize and develop the system.

Christopher Daniel Radke↗

NASA NTRSDate not supplied

Joint Development Testing of the Integrated Gateway-Esprit Bipropellant Refuelling System

The Gateway is an upcoming long term lunar exploration program to be completed by NASA in partnership with ESA and other US and international partners. The system design of the Gateway contains both a high performance Xenon based Solar Electric Propulsion system, as well as a bi-propellant attitude control system. Both propulsion systems are designed for on-orbit refuelling to enable long life performance of the Gateway. The ESPRIT-RM is a module which will expand the pressurized volume of Gateway, while also providing refuelling capability for both the Xenon and Bipropellant propulsion systems, therefore extending the Gateway life on orbit. As part of the Gateway bi-propellant refuelling system development, a simplified fluidic breadboard system was created to evaluate system performance and response using simulant fluids. The test plan includes verification activities with simulant (water, HFE-7100) to verify joined subsystem behaviour in the critical operations, including propellant transfer demonstration between modules, transient tests and venting tests. Integrated testing will occur at TASUK in collaboration with NASA to support joint verification activities to de-risk the major functions of the ESPRIT Bipropellant Transfer Subsystem (BTS) and the overall CONOPS of the refuelling of the Gateway chemical propulsion system. Initially collected test data is presented and has shown the architected system performance is closing initial design assumptions, but much forward work is identified to continue to characterize and develop the system.

Sebastian Hill↗

NASA NTRS2014

Refueling with In-Situ Produced Propellants

In-situ produced propellants have been identified in many architecture studies as key to implementing feasible chemical propulsion missions to destinations beyond lunar orbit. Some of the more noteworthy ones include: launching from Mars to return to Earth (either direct from the surface, or via an orbital rendezvous); using the Earth-Moon Lagrange point as a place to refuel Mars transfer stages with Lunar surface produced propellants; and using Mars Moon Phobos as a place to produce propellants for descent and ascent stages bound for the Mars surface. However successful implementation of these strategies require an ability to successfully transfer propellants from the in-situ production equipment into the propellant tankage of the rocket stage used to move to the desired location. In many circumstances the most desirable location for this transfer to occur is in the low-gravity environment of space. In support of low earth orbit propellant depot concepts, extensive studies have been conducted on transferring propellants in-space. Most of these propellant transfer techniques will be applicable to low gravity operations in other locations. Even ground-based transfer operations on the Moon, Mars, and especially Phobos could benefit from the propellant conserving techniques used for depot refueling. This paper will review the literature of in-situ propellants and refueling to: assess the performance benefits of the use in-situ propellants for mission concepts; review the parallels with propellant depot efforts; assess the progress of the techniques required; and provide recommendations for future research.

In-Situ Propellants↗

DOE OSTI2022

Liquid Hydrogen Heavy-Duty Vehicle Safety Review and Refueling Facility Design

Liquid hydrogen (LH 2 ) used as a fuel onboard a heavy-duty vehicle can result in increased storage capacity and faster refueling relative to compressed gas. However, there are concerns about hydrogen losses from boil-off, potential safety issues, gaps in codes and standards for cryogenic hydrogen fuel, and technical challenges with LH 2 systems for widespread transportation applications. A failure modes and effects analysis (FMEA), a safety codes and standards review, and a design review of the onboard liquid hydrogen system for a heavy-duty vehicle identified some of these potential safety issues and gaps in the codes and standards. The FMEA identified some medium and low risk failure points of the conceptual design, and the design review identified how carefully pressure relief needs to be considered for LH 2 systems. In addition, a conceptual design for a LH 2 refueling station was developed. Rough capital costs for the refueling station design were $\$1 million$ and the layout occupied approximately 13,000 ft 2 . These results can be used to inform future designs and analyses for LH 2 heavy-duty vehicles.

08 HYDROGEN↗

NASA NTRS1990

Constant propellant use rendezvous scenario across a launch window for refueling missions

Active rendezvous of an unmanned spacecraft with the Space Transportation System (STS) Shuttle for refueling missions is investigated. The operational constraints facing both the maneuvering spacecraft and the Shuttle during a rendezvous sequence are presented. For example, the user spacecraft must arrive in the generic Shuttle control box at a specified time after Shuttle launch. In addition, the spacecraft must be able to initiate the transfer sequence from any point in its orbit. The standard four-burn rendezvous sequence, consisting of two Hohmann transfers and an intermediate phasing orbit, is presented as a low-energy solution for rendezvous and retrieval missions. However, for refueling missions, the Shuttle must completely refuel the spacecraft and return to Earth with no excess fuel. This additional constraint is not satisfied by the standard four-burn sequence. Therefore, a variation of the four-burn rendezvous, the constant delta-V scenario, was developed to satisfy the added requirement.

Hametz, M. E.↗

NASA NTRS2004

The NASA Dryden AAR Project: A Flight Test Approach to an Aerial Refueling System

The integration of uninhabited aerial vehicles (UAVs) into controlled airspace has generated a new era of autonomous technologies and challenges. Autonomous aerial refueling would enable UAVs to travel further distances and loiter for extended periods over time-critical targets. The NASA Dryden Flight Research Center recently has completed a flight research project directed at developing a dynamic hose and drogue system model to support the development of an automated aerial refueling system. A systematic dynamic model of the hose and drogue system would include the effects of various influences on the system, such as flight condition, hose and drogue type, tanker type and weight, receiver type, and tanker and receiver maneuvering. Using two NASA F/A-18 aircraft and a conventional hose and drogue aerial refueling store from the Navy, NASA has obtained flight research data that document the response of the hose and drogue system to these effects. Preliminary results, salient trends, and important lessons are presented.

Hansen, Jennifer L.↗

NASA NTRS2005

The NASA Dryden Flight Test Approach to an Aerial Refueling System

Hansen, Jennifer L.↗

NASA NTRS2007

Automated Aerial Refueling Hitches a Ride on AFF

The recent introduction of uninhabited aerial vehicles [UAVs (basically, remotely piloted or autonomous aircraft)] has spawned new developments in autonomous operation and posed new challenges. Automated aerial refueling (AAR) is a capability that will enable UAVs to travel greater distances and loiter longer over targets. NASA Dryden Flight Research Center, in cooperation with the Defense Advanced Research Projects Agency (DARPA), the Naval Air Systems Command (NAVAIR), the Naval Air Force Pacific Fleet, and the Air Force Research Laboratory, rapidly conceived and accomplished an AAR flight research project focused on collecting a unique, high-quality database on the dynamics of the hose and drogue of an aerial refueling system. This flight-derived database would be used to validate mathematical models of the dynamics in support of design and analysis of AAR systems for future UAVs. The project involved the use of two Dryden F/A-18 airplanes and an S-3 hose-drogue refueling store on loan from the Navy. In this year-long project, which was started on October 1, 2002, 583 research maneuvers were completed during 23 flights.

Jennifer L Hansen↗

NASA NTRS2011

Aerial Refueling Process Rescheduling Under Job Related Disruptions

The Aerial Refueling Scheduling Problem (ARSP) can be defined as determining the refueling completion times for each fighter aircraft (job) on the multiple tankers (machines) to minimize the total weighted tardiness. ARSP assumes that the jobs have different release times and due dates. The ARSP is dynamic environment and unexpected events may occur. In this paper, rescheduling in the aerial refueling process with a time set of jobs will be studied to deal with job related disruptions such as the arrival of new jobs, the departure of an existing job, high deviations in the release times and changes in job priorities. In order to keep the stability and to avoid excessive computation, partial schedule repair algorithm is developed and its preliminary results are presented.

Kaplan, Sezgin↗

NASA NTRS2011

Thermal Design Considerations of the Robotic Refueling Mission (RRM)

The Robotic Refueling Mission (RRM) is a flight demonstration of the tasks required to perform robotic refueling of orbiting spacecraft. RRM will be mounted to an ExPress Adapter Plate (ExPA) for launch and installed onto the International Space Station (ISS) Express Logistics Carrier 4 (ELC4). RRM operations will be conducted using the Special Purpose Dexterous Manipulator (SPDM) robotic arm on the ISS with the ORU/Tool Changeout Mechanism (OTCM) for grasping tools and completing the refueling demonstration tasks. This paper presents the thermal considerations and design of the RRM including the tools required for the tasks.

Gregory, Teri H.↗

NASA NTRSDate not supplied

Parametric Cost Analysis of Refueling Options in Cislunar Space

Over the next several years NASA intends to develop and maintain a sustained human presence in cislunar space and on the surface of the Moon. The sustained lunar presence will then serve as a steppingstone for human missions to Mars. To propel the spacecraft taking humans and cargo to and from the lunar surface and to and from Mars will require on the order of hundreds of tons of propellant. Single-use refueling elements (expendable tankers) may be more cost-effective for smaller campaigns, but as the propellant demand grows, so does the potential for a cost benefit from reusable tankers. The cost of two different architectures for delivering propellant to cislunar space was estimated and compared. The first architecture relies on expendable tankers for propellant delivery while the second architecture reuses every element, including launch vehicle stages. The study determined that if the cost of reusing refueling tankers is consistent with the current state of the art, the expendable refueling architecture is more cost effective. However, refinements of the methods used to estimate launch and tanker reuse costs are needed to provide more precise estimates of the breakeven point.

Daniel J Tiffin↗

NASA NTRS2020

Optimal Low Thrust Orbit Transfers for Space Telescope Refueling at SEL2

The James Webb Space Telescope (JWST), a ten billion-dollar infrared telescope with a 6.5m primary mirror to be launched in 2021, is designed to operate in a Halo orbit around the second Sun-Earth Lagrange point (SEL2) for five to ten years. At that point fuel for station keeping and attitude maneuvers will run out. Refueling missions to JWST, as well as to similar space telescope missions proposed for SEL2, could greatly enhance the “science-per-dollar” value and promote a more sustainable use of space assets. In this paper, we present a novel approach to designing fuel optimal trajectories that will allow the refueling spacecraft to arrive at the SEL2 Halo orbit with maximum final mass (i.e. fuel payload). The low thrust optimal control problem is formulated using an indirect optimization method, leading to a two-point boundary value problem with a bang-bang control structure. We make use of a hyperbolic tangent smoothing technique for performing continuation on the thrust magnitude to reduce the sharpness of the control switches in early iterations and, thus, promote convergence. The problem is posed and solved in the circular restricted three-body problem. In this dynamical system, invariant manifolds exist that can be utilized to reduce fuel consumption. The here presented methodology to this challenging and important problem in astrodynamics demonstrates a significant potential for low-cost refueling mission design.

Woollands, Robyn↗