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Spacecraft boost and abort guidance and control systems requirement study, boost dynamics and control analysis study. Exhibit A: Boost dynamics and control anlaysis

The simulation developments for use in dynamics and control analysis during boost from liftoff to orbit insertion are reported. Also included are wind response studies of the NR-GD 161B/B9T delta wing booster/delta wing orbiter configuration, the MSC 036B/280 inch solid rocket motor configuration, the MSC 040A/L0X-propane liquid injection TVC configuration, the MSC 040C/dual solid rocket motor configuration, and the MSC 049/solid rocket motor configuration. All of the latest math models (rigid and flexible body) developed for the MSC/GD Space Shuttle Functional Simulator, are included.

Williams, F. E.↗

Design development of the Apollo command and service module thrust vector attitude control systems

Development of the Apollo thrust vector control digital autopilot (TVC DAP) was summarized. This is the control system that provided pitch and yaw attitude control during velocity change maneuvers using the main rocket engine on the Apollo service module. A list of ten primary functional requirements for this control system are presented, each being subordinate to a more general requirement appearing earlier on the list. Development process functions were then identified and the essential information flow paths were explored. This provided some visibility into the particular NASA/contractor interface, as well as relationships between the many individual activities.

William H. Peters↗

Research in pilot scanning behavior

A NASA-developed oculometer, which measures pilot scanning behavior, is described in terms of design and operating parameters. Results are presented of tests conducted in a terminal configured vehicle (TVC) aft cockpit simulator, involving pilots making simulated instrument approaches. Attention is given to the amount of time the pilots spend scanning the SFD and EADI CRT displays, and to differences resulting from both the physical location of the CRTs (within a 30 x 30 x 30 cm space), and from their intrinsic characteristics.

Waller, M. C.↗

Solid rocket booster thrust vector control subsystem description

Major Solid Rocket Booster-Thrust Vector Control (SRB-TVC) subsystem components and subcomponents used in the Space Transportation System (STS) are identified. Simplified schematics, detailed schematics, figures, photographs, and data are included to acquaint the reader with the operation, performance, and physical layout as well as the materials and instrumentation used.

Redmon, J., Jr.↗

Thrust Vector Control using movable probes

A study was undertaken to determine if movable probes or struts positioned in the nozzle can be used to provide Thrust Vector Control of the Space Shuttle Solid Rocket Booster. The study employed CFD to determine estimates of the shock standoff distance from the probe. An empirical correlation was used to construct the shock shape and the pressure distribution generated by the probe. The TVC performance for a single and multiple number of probes was then used to determine requirements for a maximum thrust angle offset of 7.5 degrees. Consideration was given to what materials would be suitable for the probe and if active cooling is required. Based on the performance analysis and thermal requirements, a Probe Thrust Vector Control (PTVC) system was sized. Indications are that a PTVC system weight is in the 1500 1bm weight range, compared to the existing weight of 7500 1bm for the SRB nozzle gimble system.

Cavalleri, Robert↗

Electromechanical actuation for thrust vector control applications

The advanced launch system (ALS), is a launch vehicle that is designed to be cost-effective, highly reliable, and operationally efficient with a goal of reducing the cost per pound to orbit. An electromechanical actuation (EMA) system is being developed as an attractive alternative to the hydraulic systems. The controller will integrate 20 kHz resonant link power management and distribution (PMAD) technology and pulse population modulation (PPM) techniques to implement field-oriented vector control (FOVC) of a new advanced induction motor. The driver and the FOVC will be microprocessor controlled. For increased system reliability, a built-in test (BITE) capability will be included. This involves introducing testability into the design of a system such that testing is calibrated and exercised during the design, manufacturing, maintenance, and prelaunch activities. An actuator will be integrated with the motor controller for performance testing of the EMA thrust vector control (TVC) system. The EMA system and work proposed for the future are discussed.

Roth, Mary Ellen↗

Flywheel energy storage for electromechanical actuation systems

The authors describe a flywheel energy storage system designed specifically to provide load-leveling for a thrust vector control (TVC) system using electromechanical actuators (EMAs). One of the major advantages of an EMA system over a hydraulic system is the significant reduction in total energy consumed during the launch profile. Realization of this energy reduction will, however, require localized energy storage capable of delivering the peak power required by the EMAs. A combined flywheel-motor/generator unit which interfaces directly to the 20-kHz power bus represents an ideal candidate for this load leveling. The overall objective is the definition of a flywheel energy storage system for this application. The authors discuss progress on four technical objectives: (1) definition of the specifications for the flywheel-motor/generator system, including system-level trade-off analysis; (2) design of the flywheel rotor; (3) design of the motor/generator; and (4) determination of the configuration for the power management system.

Hockney, Richard L.↗

Advanced electric motor technology flux mapping

Design of electric motors which fulfill the needs of Thrust Vector Control (TVC) actuators used in large rocket propelled launch vehicles is covered. To accomplish this end the methodology of design is laid out in some detail. In addition a point design of a motor to fulfill the requirements of a certain actuator specified by MSFC is accomplished and reported upon. In the course of this design great stress has been placed on ridding the actuator of internally generated heat. To conduct the heat out of the motor use is made of the unique properties of the in house MSFC designed driving electronics. This property is that as along as they are operated in a quasi-linear mode the electronics nullify the effects of armature inductance as far as the phase of the armature current versus the rotor position is concerned. Actually the additional inductance due to the extended end turns in this design is of benefit because in the shorted armature failure mode the armature current in the fault (caused by the rotor flux sweeping past the armature) is diminished at a given rotor speed when compared to a more conventional motor with lower inductance. The magnetic circuit is analyzed using electromagnetic finite element methods.

Doane, George B., III↗

Electrical Actuation Technology Bridging

This document contains the proceedings of the NASA Electrical Actuation Technology Bridging (ELA-TB) Workshop held in Huntsville, Alabama, September 29-October 1, 1992. The workshop was sponsored by the NASA Office of Space Systems Development and Marshall Space Flight Center (MSFC). The workshop addressed key technologies bridging the entire field of electrical actuation including systems methodology, control electronics, power source systems, reliability, maintainability, and vehicle health management with special emphasis on thrust vector control (TVC) applications on NASA launch vehicles. Speakers were drawn primarily from industry with participation from universities and government. In addition, prototype hardware demonstrations were held at the MSFC Propulsion Laboratory each afternoon. Splinter sessions held on the final day afforded the opportunity to discuss key issues and to provide overall recommendations. Presentations are included in this document.

Hammond, Monica↗

Trajectory optimization for the national aerospace plane

During the past six months the research objectives outlined in the last semi-annual report were accomplished. Specifically, these are: three-dimensional (3-D) fuel-optimal ascent trajectory of the aerospace plane and the effects of thrust vectoring control (TVC) on the fuel consumption and trajectory shaping were investigated; the maximum abort landing area (footprint) was studied; preliminary assessment of simultaneous design of the ascent trajectory and the vehicle configuration for the aerospace plane was also conducted. The work accomplished in the reporting period is summarized.

Lu, Ping↗

Design and application of electromechanical actuators for deep space missions

This progress report documents research and development efforts performed from August 16, 1993 through February 15, 1994 on NASA Grant NAG8-240, 'Design and Application of Electromechanical Actuators for Deep Space Missions.' Following the executive summary are four report sections: Motor Selection, Tests Stand Development, Health Monitoring and Fault Management, and Experiment Planning. Three specific motor types have been considered as prime movers for TVC EMA applications: the brushless dc motor, the permanent magnet synchronous motor, and the induction motor. The fundamental finding was that, in general, the primary performance issues were energy efficiency and thermal dissipation (rotor heating). In terms of all other issues, the three motor types were found to compare quite equally. Among the design changes made to the test stand since the last progress report is the addition of more mounting holes in the side beams. These additional holes allow the movable end beam to be attached in a greater number of positions than previously. With this change the movable end beam can move from full forward to full back in three inch increments. Specific mathematical details on the approach that have been employed for health monitoring and fault management (HMFM) have been reported previously. This approach is based on and adaptive Kalman filter strategy. In general, a bank of filters can be implemented for each primary fault type. Presently under consideration for the brushless dc machine are the following faults: armature winding open-circuits, armature winding short-circuits (phase-to-phase and phase-to-ground), bearing degradation, and rotor flux weakening. The mechanically oriented experiments include transient loading experiments, transverse loading experiment, friction experiment, motor performance experiment, and HMFM experiment.

Haskew, Tim A.↗

Design of a ZVS PWM inverter for a brushless DC motor in an EMA application

The Component Development Division of the Propulsion Laboratory at Marshall Space Flight Center (MSFC) is currently investigating the use of electromechanical actuators for use in space transportation applications such as Thrust Vector Control (TVC). These high power servomechanisms will require rugged, reliable, and compact power electronic modules capable of modulating several hundred amperes of current at up to 270 Vdc. This paper will discuss the design and implementation of a zero-voltage-switched PWM (Pulse Width Modulation) inverter which operates from a 270 Vdc source at currents up to 100 A.

Bell, J. Brett↗

SRM Internal Flow Tests and Computational Fluid Dynamic Analysis: RSRM Full Scale Motor Analyses - Volume 2

The purpose of the RSRM Nozzle Slag Ejection Precursor Test is to investigate the effect that slag ejection from the RSRM nozzle has on the chamber pressure and trust of the SRB's. In past firings of the Reusable Solid Rocket Motor (RSRM) both static test and flight motors have shown small pressure perturbations occurring primarily between 65 and 80 seconds. A joint NASA/Thiokol team investigation concluded that the cause of the pressure perturbations was the periodic ingestion and ejection of molten aluminum oxide slag from the cavity around the submerged nozzle nose which tends to trap and collect individual aluminum oxide droplets from the approach flow. The conclusions of the team were supported by numerous data and observations from special tests including high speed photographic films, real time radiography, plume calorimeters, accelerometers, strain gauges, nozzle TVC system force gauges, and motor pressure and thrust data. A simplistic slag ballistics model was formulated to relate a given pressure perturbation to a required slag quantity. Also, a cold flow model using air and water was developed to provide data on the relationship between the slag flow rate and the chamber pressure increase. Both the motor and the cold flow model exhibited low frequency oscillations in conjunction with periods of slag ejection. Motor and model frequencies were related to scaling parameters. The data indicate that there is a periodicity to the slag entrainment and ejection phenomena which is possibly related to organized oscillations from instabilities in the dividing streamline shear layer which impinges on the underneath surface of the nozzle.

Source record↗

Effects of Slag Ejection on Solid Rocket Motor Performance

In past firings of the Reusable Solid Rocket Motor (RSRM) both static test and flight motors have shown small pressure perturbations occurring primarily between 65 and 80 seconds. A joint NASA/Thiokol team investigation concluded that the cause of the pressure perturbations was the periodic ingestion and ejection of molten aluminum oxide slag from the cavity around the submerged nozzle nose which tends to trap and collect individual aluminum oxide droplets from the approach flow. The conclusions of the team were supported by numerous data and observations from special tests including high speed photographic films, real time radiography, plume calorimeters, accelerometers, strain gauges, nozzle TVC system force gauges, and motor pressure and thrust data. A simplistic slag ballistics model was formulated to relate a given pressure perturbation to a required slag quantity. Also, a cold flow model using air and water was developed to provide data on the relationship between the slag flow rate and the chamber pressure increase. Both the motor and the cold flow model exhibited low frequency oscillations in conjunction with periods of slag ejection. Motor and model frequencies were related to scaling parameters. The data indicate that there is a periodicity to the slag entrainment and ejection phenomena which is possibly related to organized oscillations from instabilities in the dividing streamline shear layer which impinges on the underneath surface of the nozzle.

Whitesides, R. Harold↗

X-33 Attitude Control Using the XRS-2200 Linear Aerospike Engine

The Vehicle Control Systems Team at Marshall Space Flight Center, Structures and Dynamics Laboratory, Guidance and Control Systems Division is designing, under a cooperative agreement with Lockheed Martin Skunkworks, the Ascent, Transition, and Entry flight attitude control systems for the X-33 experimental vehicle. Test flights, while suborbital, will achieve sufficient altitudes and Mach numbers to test Single Stage To Orbit, Reusable Launch Vehicle technologies. Ascent flight control phase, the focus of this paper, begins at liftoff and ends at linear aerospike main engine cutoff (MECO). The X-33 attitude control system design is confronted by a myriad of design challenges: a short design cycle, the X-33 incremental test philosophy, the concurrent design philosophy chosen for the X-33 program, and the fact that the attitude control system design is, as usual, closely linked to many other subsystems and must deal with constraints and requirements from these subsystems. Additionally, however, and of special interest, the use of the linear aerospike engine is a departure from the gimbaled engines traditionally used for thrust vector control (TVC) in launch vehicles and poses certain design challenges. This paper discusses the unique problem of designing the X-33 attitude control system with the linear aerospike engine, requirements development, modeling and analyses that verify the design.

Hall, Charles E.↗

Flight Control Role in RLV Configuration Development

A new optimization technique was used to aide in the selection of aerodynamic surfaces and Thrust Vectoring Control (TVC) based on maximizing control margin during ascent and entry portions of the trajectory. In order to meet the mass fraction requirement of RLV (Reusable Launch Vehicle), every substructure needed to be carefully designed to minimize the dry mass. The trajectory was designed to deliver the payload required for each mission subject to thermal and structural constraints. At each point on the trajectory the angle of attack and Mach number pair was used to calculate the control power required to trim and to stabilize the vehicle. The new optimization technique was based on finding the configuration that minimizes the control power peaks along the entire trajectory.

Youssef, Hussein↗

Status of Nozzle Aerodynamic Technology at MSFC

This viewgraph presentation provides information on the status of nozzle aerodynamic technology at MSFC (Marshall Space Flight Center). The objectives of this presentation were to provide insight into MSFC in-house nozzle aerodynamic technology, design, analysis, and testing. Under CDDF (Center Director's Discretionary Fund), 'Altitude Compensating Nozzle Technology', are the following tasks: Development of in-house ACN (Altitude Compensating Nozzle) aerodynamic design capability; Building in-house experience for all aspects of ACN via End-to-End Nozzle Test Program; Obtaining Experimental Data for Annular Aerospike: Thrust eta, TVC (thrust vector control) capability and surface pressures. To support selection/optimization of future Launch Vehicle propulsion we needed a parametric design and performance tool for ACN. We chose to start with the ACN Aerospike Nozzles.

Ruf, Joseph H.↗