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Optimum methods for orbital resupply, maintenance, and repair of hybrid propellant rocket engine subsystem for orbiting space station attitude control
A computer program to simulate hybrid and electric advanced vehicle systems (HEAVY) is described. It is intended for use early in the design process: concept evaluation, alternative comparison, preliminary design, control and management strategy development, component sizing, and sensitivity studies. It allows the designer to quickly, conveniently, and economically predict the performance of a proposed drive train. The user defines the system to be simulated using a library of predefined component models that may be connected to represent a wide variety of propulsion systems. The development of three models are discussed as examples.
A computer program has been developed and is described herein for intraply hybrid composite design (INHYD). The program includes several composite micromechanics theories, intraply hybrid composite theories and a hygrothermomechanical theory. These theories provide INHYD with considerable flexibility and capability which the user can exercise through several available options. Key features and capabilities of INHYD are illustrated through selected samples.
A technology development program was undertaken to determine if the benefits of hybrid rocket propulsion could be realized for a Mars Ascent Vehicle (MAV) application. Specifically, the goal of this program was to increase the Technology Readiness Level (TRL) of a hybrid propulsion system such that it could be considered for a potential Mars Sample Return Campaign. Over the course of approximately five years, a new, wax-based fuel was developed, characterized and tested with Mixed Oxides of Nitrogen (from MON-3 to MON-25). Various ignition mechanisms were tested and solid hypergolic additives were evaluated for their potential to ignite the hybrid motor. Several hot-fire test campaigns were completed at both sub- and full-scale. The technology development program was born out of a JPL study documented by Shotwell and Karp that identified the Single Stage to Orbit (SSTO) hybrid propulsion system for a potential Mars Ascent Vehicle to be the lowest Gross Lift Off Mass option from the ten configurations evaluated. Benefits of the hybrid option included its predicted favorable low temperature storage and operation behavior, high performance and ability to restart (enabling the SSTO). The main disadvantage of the hybrid option was its low TRL,as it essentially started as a blank sheet design with a new fuel development. Near the end of the technology development program, a Preliminary Architecture Assessment (PAA) was completed to evaluate a single-stage hybrid propulsion system and a two-stage solid propulsion system for a potential MAV. The solid propulsion system was selected for further study in 2019, primarily because of its flight heritage. While the hybrid technology development program made many strides, there was still a list of challenges to overcome. This paper will discuss the substantial progress and remaining challenges from the technology development effort from 2015 through 2019. This includes fuel development and reformulation, sub- and full-scale testing at Space Propulsion Group, full scale testing at Parabilis, full scale testing at Whittinghill Aerospace, hypergolic additive testing at Purdue and Penn State and the evaluation of adding hypergolic additives to a full-scale grain. It also includes a discussion of the design that resulted from the Preliminary Architecture Assessment.
Results obtained in studying the origin and suppression of large-amplitude pressure oscillations in a 24 in. diameter hybrid motor using a liquid oxygen/hydroxylterminated polybutadiene/polycyclopentadiene propellant system are discussed. Tests conducted with liquid oxygen flow rates varying from 10 to 40 lbm/sec were designed to gauge the effectiveness of various vaporization chamber flow fields, injector designs, and levels of heat addition in suppressing high-frequency longitudinal mode oscillations. Longitudinal acoustic modes did not arise in any tests. However, initial testing revealed the presence of high-amplitude, sinusoidal, nonacoustic oscillations persisting throughout the burn durations. Analysis showed this to be analogous to chug mode instability in liquid rocket engines brought about by a coupling of motor combustion processes and the liquid oxygen feed system. Analytical models were developed and verified by test data to predict the amplitude and frequency of feed-system-coupled combustion pressure oscillations. Subsequent testing showed that increasing the feed system impedance eliminated the bulk mode instability. This paper documents the work completed to date in performance of the Hybrid Propulsion Technology for Launch Vehicle Boosters Program (NAS8-39942) sponsored by NASA's George C. Marshall Space Flight Center.
The General Rotorcraft Aeromechanical Stability Program (GRASP), which is a hybrid between finite element programs and spacecraft-oriented multibody programs, is described in terms of its design and capabilities. Numerical results from GRASP are presented and compared with the results from an existing, special-purpose coupled rotor/body aeromechanical stability program and with experimental data of Dowell and Traybar (1975 and 1977) for large deflections of an end-loaded cantilevered beam. The agreement is excellent in both cases.
A systematic, computer-aided, self-documenting methodology for developing hybrid computer simulations of turbofan engines is presented. The methodology makes use of a host program that can run on a large digital computer and a machine-dependent target (hybrid) program. The host program performs all of the calculations and date manipulations needed to transform user-supplied engine design information to a form suitable for the hybrid computer. The host program also trims the self contained engine model to match specified design point information. A test case is described and comparisons between hybrid simulation and specified engine performance data are presented.
Establishment of a test facility and associated 11-in.-diameter motor for hybrid propulsion technology development at NASA's George C. Marshall Space Flight Center is discussed in this paper. Results of twenty 11-in.-diameter motor tests with a UTF-29901 (60 percent polycyclopentadiene, 40 percent hydroxyl-terminated polybutadiene)/gaseous oxygen propellant system are presented. Tests at this scale have developed fuel regression correlations for comparison with results of yet-to-be-completed, 24-in.-diameter motor tests; demonstrated combustion efficiency levels in the 95 percent range for both single- and multiple-port grain configurations; have shown smooth and stable throttling characteristics over flight-type throttle ranges; and have begun to establish criteria for stable combustion in hybrid motors. The testing of 24-in. motors has not as yet been initiated and is not addressed.
This paper offers a systematic, computer-aided, self-documenting methodology for developing hybrid computer simulations of turbofan engines. The methodology that is presented makes use of a host program that can run on a large digital computer and a machine-dependent target (hybrid) program. The host program performs all of the calculations and data manipulations that are needed to transform user-supplied engine design information to a form suitable for the hybrid computer. The host program also trims the self-contained engine model to match specified design point information. A test case is described and comparisons between hybrid simulation and specified engine performance data are presented.
A technology development program was undertaken to determine if the benefits of hybrid rocket propulsion could be realized for a Mars Ascent Vehicle (MAV) application. Specifically, the goal of this program was to increase the Technology Readiness Level (TRL) of a hybrid propulsion system such that it could be considered for a potential Mars Sample Return Campaign. Over the course of approximately five years, a new, wax-based fuel was developed, characterized and tested with Mixed Oxides of Nitrogen (from MON-3 to MON-25). Various ignition mechanisms were tested and solid hypergolic additives were evaluated for their potential to ignite the hybrid motor. Several hot-fire test campaigns were completed at both sub- and full-scale. The technology development program was born out of a JPL study documented by Shotwell and Karp that identified the Single Stage to Orbit (SSTO) hybrid propulsion system for a potential Mars Ascent Vehicle to be the lowest Gross Lift Off Mass option from the ten configurations evaluated. Benefits of the hybrid option included its predicted favorable low temperature storage and operation behavior, high performance and ability to restart (enabling the SSTO). The main disadvantage of the hybrid option was its low TRL, as it essentially started as a blank sheet design with a new fuel development. Near the end of the technology development program, a Preliminary Architecture Assessment (PAA) was completed to evaluate a single-stage hybrid propulsion system and a two-stage solid propulsion system for a potential MAV. The solid propulsion system was selected for further study in 2019, primarily because of its flight heritage. While the hybrid technology development program made many strides, there was still a list of challenges to overcome. This paper will discuss the substantial progress and remaining challenges from the technology development effort from 2015 through 2019. This includes fuel development and reformulation, sub- and full-scale testing at Space Propulsion Group, full scale testing at Parabilis, full scale testing at Whittinghill Aerospace, hypergolic additive testing at Purdue and Penn State and the evaluation of adding hypergolic additives to a fullscale grain. It also includes a discussion of the design that resulted from the Preliminary Architecture Assessment.
A systematic, computer-aided, self-documenting methodology for developing hybrid computer simulations of turbofan engines is presented. The methodology that is pesented makes use of a host program that can run on a large digital computer and a machine-dependent target (hybrid) program. The host program performs all the calculations and data manipulations that are needed to transform user-supplied engine design information to a form suitable for the hybrid computer. The host program also trims the self-contained engine model to match specified design-point information. Part I contains a general discussion of the methodology, describes a test case, and presents comparisons between hybrid simulation and specified engine performance data. Part II, a companion document, contains documentation, in the form of computer printouts, for the test case.
This paper presents a detailed performance analysis of a multi-block overset grid compu- tational fluid dynamics app!ication on multiple state-of-the-art computer architectures. The application is implemented using a hybrid MPI+OpenMP programming paradigm that exploits both coarse and fine-grain parallelism; the former via MPI message passing and the latter via OpenMP directives. The hybrid model also extends the applicability of multi-block programs to large clusters of SNIP nodes by overcoming the restriction that the number of processors be less than the number of grid blocks. A key kernel of the application, namely the LU-SGS linear solver, had to be modified to enhance the performance of the hybrid approach on the target machines. Investigations were conducted on cacheless Cray SX6 vector processors, cache-based IBM Power3 and Power4 architectures, and single system image SGI Origin3000 platforms. Overall results for complex vortex dynamics simulations demonstrate that the SX6 achieves the highest performance and outperforms the RISC-based architectures; however, the best scaling performance was achieved on the Power3.
A parachute simulation environment (PSE) has been developed that aims to take advantage of legacy parachute simulation codes and modern object-oriented programming techniques. This hybrid simulation environment provides the parachute analyst with a natural and intuitive way to construct simulation tasks while preserving the pedigree and authority of established parachute simulations. NASA currently employs four simulation tools for developing and analyzing air-drop tests performed by the CEV Parachute Assembly System (CPAS) Project. These tools were developed at different times, in different languages, and with different capabilities in mind. As a result, each tool has a distinct interface and set of inputs and outputs. However, regardless of the simulation code that is most appropriate for the type of test, engineers typically perform similar tasks for each drop test such as prediction of loads, assessment of altitude, and sequencing of disreefs or cut-aways. An object-oriented approach to simulation configuration allows the analyst to choose models of real physical test articles (parachutes, vehicles, etc.) and sequence them to achieve the desired test conditions. Once configured, these objects are translated into traditional input lists and processed by the legacy simulation codes. This approach minimizes the number of sim inputs that the engineer must track while configuring an input file. An object oriented approach to simulation output allows a common set of post-processing functions to perform routine tasks such as plotting and timeline generation with minimal sensitivity to the simulation that generated the data. Flight test data may also be translated into the common output class to simplify test reconstruction and analysis.
The development of an analytical model of a small turboshaft engine designed for helicopter propulsion systems is described. The model equations were implemented on a hybrid computer system to provide a real time nonlinear simulation of the engine performance over a wide operating range. The real time hybrid simulation of the engine was used to evaluate a microprocessor based digital control module. This digital control module was developed as part of an advanced rotorcraft control program. After tests with the hybrid engine simulation the digital control module was used to control a real engine in an experimental program. A hybrid simulation of the engine's electrical hydromechanical control system was developed. This allowed to vary the fuel flow and torque load inputs to the hybrid engine simulation for simulating transient operation. A steady-state data and the experimental tests are compared. Analytical model equations, analog computer diagrams, and a digital computer flow chart are included.
From the first Saturn V rocket booster (S-II-T) testing in 1966 and the routine Space Shuttle Main Engine (SSME) testing beginning in 1975, to more recent test programs such as the X-33 Aerospike Engine, the Integrated Powerhead Development (IPD) program, and the Hybrid Sounding Rocket (HYSR), Stennis Space Center (SSC) continues to be a premier location for conducting large-scale testing. Central to each test program is the capability for sensor systems to deliver reliable measurements and high quality data, while also providing a means to monitor the test stand area to the highest degree of safety and sustainability. Sensor wiring is routed along piping and through cable trenches, making its way from the engine test area, through the test stand area and to the signal conditioning building before final transfer to the test control center. When sensor requirements lie outside the reach of the routine sensor cable routing, the use of wireless sensor networks becomes particularly attractive due to their versatility and ease of installation. As part of an on-going effort to enhance the testing capabilities of Stennis Space Center, the Test Technology and Development group has found numerous applications for its sensor-adaptable wireless sensor suite. While not intended for critical engine measurements or control loops, in-house hardware and software development of the sensor suite can provide improved testing capability for a range of applications including the safety monitoring of propellant storage barrels and as an experimental test-bed for embedded health monitoring paradigms.
From the first Saturn V rocket booster (S-II-T) testing in 1966 and the routine Space Shuttle Main Engine (SSME) testing beginning in 1975, to more recent test programs such as the X-33 Aerospike Engine, the Integrated Powerhead Development (IPD) program, and the Hybrid Sounding Rocket (HYSR), Stennis Space Center (SSC) continues to be a premier location for conducting large-scale propulsion testing. Central to each test program is the capability for sensor systems to deliver reliable measurements and high quality data, while also providing a means to monitor the test stand area to the highest degree of safety and sustainability. As part of an on-going effort to enhance the testing capabilities of Stennis Space Center, the Test Technology and Development group is developing and applying a number of wireless and intelligent sensor technologies in ways that are new to the test existing test environment.
Hybrid composite gears have been investigated as a weight saving technology for rotorcraft transmissions. These gears differ from conventional steel gears in that the structural material between the shaft interface and the gear rim is replaced with a lightweight carbon fiber composite. The work discussed here is an extension of previous coupon level hybrid gear tests to a full-scale bull gear. The NASA Glenn Research Center High-Speed Helical Gear Rig was modified for this program, allowing several hybrid gear web configurations to be tested while utilizing the same gear rim. Testing was performed on both a baseline (steel) web configuration and a hybrid (steel-composite) configuration. Vibration, orbit and temperature data were recorded and compared between configurations. Vibration levels did not differ greatly between the hybrid and steel configurations, nor did temperature differential between inlet and outlet. While orbit shape displayed differences between the hybrid and baseline configurations, the general overall amplitude was comparable. The hybrid configuration discussed here successfully ran at 3300 hp (2,460 kW), however, progressive growth of the orbit while running at this test condition discontinued the test. Further studies are planned to determine the cause of this behavior.
Hybrid composite gears have been investigated as a weight saving technology for rotorcraft transmissions. These gears differ from conventional steel gears in that the structural material between the shaft interface and the gear rim is replaced with a lightweight carbon fiber composite. The work discussed here is an extension of previous coupon level hybrid gear tests to a full-scale bull gear. The NASA Glenn Research Center High-Speed Helical Gear Rig was modified for this program allowing several hybrid gear web configurations to be tested while utilizing the same gear rim. Testing was performed on both a baseline (steel) web configuration and a hybrid (steel-composite)configuration. Vibration, orbit and temperature data were recorded and compared between configurations. Vibration levels did not differ greatly between the hybrid and steel configurations, nor did temperature differential between inlet and outlet. While orbit shape displayed differences between the hybrid and baseline configurations, the general overall amplitude was comparable. The hybrid configuration discussed here successfully ran at 3300 hp(2,460 kW), however, progressive growth of the orbit while running at this test condition discontinued the test. Researchers continue to search for the cause of this orbit shift.