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Overview of the SLS Core Stage Thrust Vector Control System Design

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first 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 overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.

Thrust Vector Control↗

NASA NTRS1986

Functional and performance tests of two capillary pumped loop engineering models

This paper presents the results of the functional and performance tests for two capillary pumped loop (CPL) engineering models. Both CPL systems are aluminum/ammonia transport systems which contain eight parallel evaporators and six parallel condensers in a single loop. Tests conducted include the transport limit, heat load shearing between evaporators, liquid inventory/temperature control by the reservoir, pressure priming under heat load, diode function of condensers, and isolation of a single deprimed evaporator. Consistent performance results were obtained for both systems. Transport capabilities of up to 70 kw-m with individual evaporators managing up to 1.7 kw, with a corresponding input heat flux of 15w/sq cm, were demonstrated. These tests demonstrated the ability of a CPL system to operate over a wide range of conditions and thus established the viability of these systems for high power thermal management of large spacecraft, such as the NASA Space Station.

Ku, J.↗

NASA NTRS1978

Engineering aspects of geothermal development with emphasis on the Imperial Valley of California

This review was prepared in support of a geothermal planning activity of the County of Imperial. Engineering features of potential geothermal development are outlined. Acreage requirements for drilling and powerplants are estimated, as are the costs for wells, fluid transmission pipes, and generating stations. Rough scaling relationships are developed for cost factors as a function of reservoir temperature. Estimates are made for cooling water requirements, and possible sources of cooling water are discussed. Availability and suitability of agricultural wastewater for cooling are emphasized. The utility of geothermal resources for fresh water production in the Imperial Valley is considered.

Goldsmith, M.↗

NASA NTRS1982

Pore size engineering applied to starved electrochemical cells and batteries

To maximize performance in starved, multiplate cells, the cell design should rely on techniques which widen the volume tolerance characteristics. These involve engineering capillary pressure differences between the components of an electrochemical cell and using these forces to promote redistribution of electrolyte to the desired optimum values. This can be implemented in practice by prescribing pore size distributions for porous back-up plates, reservoirs, and electrodes. In addition, electrolyte volume management can be controlled by incorporating different pore size distributions into the separator. In a nickel/hydrogen cell, the separator must contain pores similar in size to the small pores of both the nickel and hydrogen electrodes in order to maintain an optimum conductive path for the electrolyte. The pore size distributions of all components should overlap in such a way as to prevent drying of the separator and/or flooding of the hydrogen electrode.

Abbey, K. M.↗

NASA NTRS2011

Thermal Management Tools for Propulsion System Trade Studies and Analysis

Energy-related subsystems in modern aircraft are more tightly coupled with less design margin. These subsystems include thermal management subsystems, vehicle electric power generation and distribution, aircraft engines, and flight control. Tighter coupling, lower design margins, and higher system complexity all make preliminary trade studies difficult. A suite of thermal management analysis tools has been developed to facilitate trade studies during preliminary design of air-vehicle propulsion systems. Simulink blocksets (from MathWorks) for developing quasi-steady-state and transient system models of aircraft thermal management systems and related energy systems have been developed. These blocksets extend the Simulink modeling environment in the thermal sciences and aircraft systems disciplines. The blocksets include blocks for modeling aircraft system heat loads, heat exchangers, pumps, reservoirs, fuel tanks, and other components at varying levels of model fidelity. The blocksets have been applied in a first-principles, physics-based modeling and simulation architecture for rapid prototyping of aircraft thermal management and related systems. They have been applied in representative modern aircraft thermal management system studies. The modeling and simulation architecture has also been used to conduct trade studies in a vehicle level model that incorporates coupling effects among the aircraft mission, engine cycle, fuel, and multi-phase heat-transfer materials.

McCarthy, Kevin↗

NASA NTRS1972

Pressure ramp programmer; IMBLMS Phase B4 Additional Tasks: Task 3.0 pressure ramp programmer

A pressure ramp programmer model was designed, fabricated and tested. This model, in conjunction with an automatic blood pressure monitor, automatically controls the pressure in the blood pressure monitor arterial cuff. The cuff pressurization cycle is designed to maximize accuracy and repeatability of blood pressure measurements. The key feature of this automatic cycle is rapid blood pressure cuff bleed down from an initial setting until systolic (diastolic) pressure is encountered followed by a short repressurization and slow bleed, long enough to permit accurate systolic (diastolic) pressure determination. The system includes a pressure reservoir which bleeds the cuff through a precision needle valve; a solenoid valve which permits rapid pressurization from the reservoir; and a pressure sensor which provides information for bleed rate and set point controls. Korotkoff sound signals from a microphone in the blood pressure cuff (not part of the system) provide decision information to the digital control system. The system completed a series of engineering tests using simulated Korotkoff sound inputs. The system performed successfully in all cases and was stable over an extended period of time.

Fogal, G. L.↗

NASA NTRS1931

Pressure Fluctuations in a Common-Rail Fuel Injection System

This report presents the results of an investigation to determine experimentally the instantaneous pressures at the discharge orifice of a common-rail fuel injection system in which the timing valve and cut-off valve were at some distance from the automatic fuel injection valve, and also to determine the methods by which the pressure fluctuations could be controlled. The results show that pressure wave phenomena occur between the high-pressure reservoir and the discharge orifice, but that these pressure waves can be controlled so as to be advantageous to the injection of the fuel. The results also give data applicable to the design of such an injection system for a high-speed compression-ignition engine.

Rothrock, A M↗

NASA NTRS1995

Numerical thermal analyses of heat exchangers for the stirling engine application

The Regenerator, Cooler and Heater for the NASA Space Power Research Engine (SPRE) have been analyzed in detail for laminar, incompressible and oscillatory flow conditions. Each component has been analyzed independently and in detail with the regenerator being modeled as two-parallel-plates channel with a solid wall. The ends of the channel are exposed to two reservoir maintained at different temperature thus providing an axial temperature gradient along the channel. The cooler and heater components have been modeled as circular pipes with isothermal walls. Two different types of thermal boundary conditions have been investigated for the cooler and heater, namely, symmetric and asymmetric temperature inflow. In symmetric temperature inflow the flow enters the channel with the same temperature in throughout the velocity cycle whereas, in asymmetric temperature inflow the flow enters with a different temperature in each half cycle. The study was conducted over a wide range of Maximum Reynolds number (RE(max) varying from 75 to 60000, Valensi number (Va) from 2.5 to 800, and relative amplitude of fluid displacement (A(sub r) from 0.357 to 1.34. A two dimensional Finite volume method based on the SIMPLE algorithm was used to solve the governing partial differential equations. Post processing programs were developed to effectively describe the heat transfer mechanism under oscillatory flows. The computer code was validated by comparing with existing analytical solutions for oscillating flows. The thermal field have been studied with the help of temperature contour and three dimensional plots. The instantaneous friction factor, wall heat flux and heat transfer coefficient have been examined. It has been concluded that in general, the frictional factor and heat transfer coefficient are higher under oscillatory flow conditions when the Valensi number is high. Also, the thermal efficiency decreases for lower A(r) values. Further, the usual steady state definition for the heat transfer coefficient does not seem to be valid.

Kannapareddy, Mohan Raj↗

NASA NTRS1978

Engineering model 8-cm thruster subsystem

An Engineering Model (EM) 8 cm Ion Thruster Propulsion Subsystem was developed for operation at a thrust level 5 mN (1.1 mlb) at a specific impulse 1 sub sp = 2667 sec with a total system input power P sub in = 165 W. The system dry mass is 15 kg with a mercury-propellant-reservoir capacity of 8.75 kg permitting uninterrupted operation for about 12,500 hr. The subsystem can be started from a dormant condition in a time less than or equal to 15 min. The thruster has a design lifetime of 20,000 hr with 10,000 startup cycles. A gimbal unit is included to provide a thrust vector deflection capability of + or - 10 degrees in any direction from the zero position. The EM subsystem development program included thruster optimization, power-supply circuit optimization and flight packaging, subsystem integration, and subsystem acceptance testing including a cyclic test of the total propulsion package.

Herron, B. G.↗

NASA NTRS1976

Atmospheric cloud physics laboratory project study

Engineering studies were performed for the Zero-G Cloud Physics Experiment liquid cooling and air pressure control systems. A total of four concepts for the liquid cooling system was evaluated, two of which were found to closely approach the systems requirements. Thermal insulation requirements, system hardware, and control sensor locations were established. The reservoir sizes and initial temperatures were defined as well as system power requirements. In the study of the pressure control system, fluid analyses by the Atmospheric Cloud Physics Laboratory were performed to determine flow characteristics of various orifice sizes, vacuum pump adequacy, and control systems performance. System parameters predicted in these analyses as a function of time include the following for various orifice sizes: (1) chamber and vacuum pump mass flow rates, (2) the number of valve openings or closures, (3) the maximum cloud chamber pressure deviation from the allowable, and (4) cloud chamber and accumulator pressure.

Schultz, W. E.↗

NASA NTRS1978

Engineering Model 8-cm Thruster System

Development of an Engineering Model 8-cm Mercury Ion Thruster System for Satellite Control has been successfully completed. This system operates at a specific impulse in excess of 2600 sec, produces a thrust of 5 mN with a total input power of 165 W; it has a dry mass of 16.6 kg and a mercury-propellant-reservoir capacity of 8.75 kg. This paper summarizes the development work, the system characteristics and performance, and the testing undertaken to verify the design.

Herron, B. G.↗

NASA NTRS1958

X-15 hydraulic-system development

Despite the exacting requirements and conditions of the X-15 including much higher temperature, high horsepower, and extreme vibration and duty cycles, the hydraulic flight control systems compare favorably, weightwise, with preceding models. Although some items, such as the pumps, are heavier, the total system, excluding actuators, weighs approximately 195 pounds as compared with 196 pounds for the F-107A airplane. Use of the new piggy-back pump, with its low flow during most of the operating time, also permitted a reduction in fluid capacity of the hydraulic reservoirs and the total systems, even though the volume of some of the actuators is quite large. This effected a considerable saving in fluid weight. Complete ground-support equipment is available and this equipment, as well as the airplane systems, contains means for complete 5- to 15- micron filtration under controlled temperature conditions. By use of advanced engineering techniques and extensive laboratory testing, it has been possible to provide a sound, lightweight hydraulic system for this advanced, high-performance airplane. (author)

Culleton, R J↗

NASA NTRS1986

Satellite data in aquatic area research - Some ideas for future studies

Attempts to apply aquatic remote sensing to the preparation of parametric map-like presentations, quantitative evaluations and time-related investigations in various water areas in Finland are presented. The potential use of Landsat MSS data in aquatic area studies, including limology, aquatic botany, geomorphology and engineering is evaluated using computer-aided digital remote sensing techniques. MSS data may provide information about depth, Secchi disc values, humus content in water, and productivity. Aquatic vegetation classification using MSS is possible only where vegetation units are large enough in respect to the 0.5 hectares ground resolution. Multitemporal satellite imagery has been used to evaluate alterations in the littoral areas of some Finnish water reservoirs between successive periods of high water. It is concluded that although MSS data can be of use in aquatic studies, it should be used in connection with field data and/or TM and SPOT data.

Raitala, Jouko T.↗

NASA NTRS1989

CELSS Breadboard Project at the Kennedy Space Center

The CELSS Breadboard Project is described, noting that it was initiated to study aspects of a CELSS for long-term space missions. Topics for extensive investigation included air and water regeneration, engineering control, and food production. The many options available for growing food crops in commercial plant growth chambers were investigated and the best of this information was translated to the Biomass Production Chamber (BPC). The chamber contains 20 sq m of crop growing area under 96 400 W HPS lamps; sixteen 0.25 sq m plant growth trays used on each of four growing shelves for a total of 64 trays; and one 256-L nutrient solution reservoir with the appropriate continuous-flow, thin-film plumbing for each shelf. A heating, ventilating, and air-conditioning system maintains atmospheric conditions and serves to distribute oxygen and carbon dioxide and maintain pressure at 12 mm of water. The control and monitoring subsystem, which uses a programmable logic controller, manages the BPC subsystems.

Prince, R. P.↗

NASA NTRS1991

Detonation duct gas generator demonstration program

The feasibility of the generation of detonation waves moving periodically across high speed channel flow is experimentally demonstrated. Such waves are essential to the concept of compressing requirements and increasing the engine pressure compressor with the objective of reducing conventional compressor requirements and increasing the engine thermodynamic efficiency through isochoric energy addition. By generating transient transverse waves, rather than standing waves, shock wave losses are reduced by an order of magnitude. The ultimate objective is to use such detonation ducts downstream of a low pressure gas turbine compressor to produce a high overall pressure ratio thermodynamic cycle. A 4 foot long, 1 inch x 12 inch cross-section, detonation duct was operated in a blow-down mode using compressed air reservoirs. Liquid or vapor propane was injected through injectors or solenoid valves located in the plenum or the duct itself. Detonation waves were generated when the mixture was ignited by a row of spark plugs in the duct wall. Problems with fuel injection and mixing limited the air speeds to about Mach 0.5, frequencies to below 10 Hz, and measured pressure ratios of about 5 to 6. The feasibility of the gas dynamic compression was demonstrated and the critical problem areas were identified.

Wortman, Andrew↗

NASA NTRS2008

Variable Conductance Heat Pipes for Radioisotope Stirling Systems

In a Stirling radioisotope system, heat must continually be removed from the GPHS modules, to maintain the GPHS modules and surrounding insulation at acceptable temperatures. Normally, the Stirling convertor provides this cooling. If the Stirling engine stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS, but also ending the mission. An alkali-metal Variable Conductance Heat Pipe (VCHP) was designed to allow multiple stops and restarts of the Stirling engine. A VCHP turns on with a delta T of 30 C, which is high enough to not risk standard ASRG operation but low enough to save most heater head life. This VCHP has a low mass, and low thermal losses for normal operation. In addition to the design, a proof-of-concept NaK VCHP was fabricated and tested. While NaK is normally not used in heat pipes, it has an advantage in that it is liquid at the reservoir operating temperature, while Na or K alone would freeze. The VCHP had two condensers, one simulating the heater head, and the other simulating the radiator. The experiments successfully demonstrated operation with the simulated heater head condenser off and on, while allowing the reservoir temperature to vary over 40 to 120 C, the maximum range expected. In agreement with previous NaK heat pipe tests, the evaporator delta T was roughly 70 C, due to distillation of the NaK in the evaporator.

Anderson, William G.↗

NASA NTRS1979

Primary Electric Propulsion Technology Study

An investigation of the 30-cm engineering-model-thruster technology with emphasis placed on the development of models for understanding and predicting the operational characteristics and wear-out mechanisms of the thruster as a function of operating or design parameters is presented. The task studies include: (1) the wear mechanisms and wear rates that determine the useful lifetime of the thruster discharge chamber; (2) cathode lifetime as determined by the depletion of barium from the barium-aluminate-impregnated-porous-tungsten insert that serves as a barium reservoir; (3) accelerator-grid-system technology; (4) a verification of the high-voltage propellant-flow-electrical-isolator design developed under NASA contract NAS3-20395 for operation at 10-kV applied voltage and 10-A equivalent propellant flow with mercury and argon propellants. A model was formulated for predicting performance.

Poeschel, R. L.↗

NASA NTRS1975

The cesium bombardment engine north-south stationkeeping experiment on ATS-6

Two one millipound-thrust cesium bombardment ion thrusters have been developed and integrated on the ATS-F spacecraft for the purpose of demonstrating compatible north-south stationkeeping of a synchronous communication satellite. Preliminary operation of the two thrusters on ATS-6 was completely successful on the first run of each. In addition to verifying operation, the principal accomplishments were the demonstration of a total absence of interference with the communications systems, verification of the predicted spacecraft operating potential, demonstration of compatibility with the star tracker, and demonstration of spacecraft attitude by thrust vectoring. Subsequent attempts to operate the thrusters have not been successful. Analysis indicates that the problem is associated with operation of the propellant reservoirs in zero-g.

Worlock, R. M.↗