Lessons in Systems Engineering: The SSME Weight Growth History
This viewgraph presentation describes the Space Shuttle Main Engine (SSME) weight growth history and lessons learned from SSME weight imbalances.
Ryan, Richard↗
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Lessons in Systems Engineering - The SSME Weight Growth History
This viewgraph presentation describes the Space Shuttle Main Engine (SSME) weight growth history and lessons learned from SSME weight imbalances.
Ryan, Richard↗
Programs for Testing an SSME-Monitoring System
A suite of computer programs has been developed for special test equipment (STE) that is used in verification testing of the Health Management Computer Integrated Rack Assembly (HMCIRA), a ground-based system of analog and digital electronic hardware and software for "flight-like" testing for development of components of an advanced health-management system for the space shuttle main engine (SSME). The STE software enables the STE to simulate the analog input and the data flow of an SSME test firing from start to finish.
Lang, Andre↗
SSME Electrical Harness and Cable Development and Evolution
The Space Shuttle Main Engine (SSME) electrical harness and cable system consists of the various interconnecting devices necessary for operation of complex rocket engine functions. Thirty seven harnesses incorporate unique connectors, backshell adapters, conductors, insulation, shielding, and physical barriers for a long maintenance-free life while providing the means to satisfy performance requirements and to mitigate adverse environmental influences. The objective of this paper is to provide a description of the SSME electrical harness and cable designs as well as the development history and lessons learned.
Abrams, Russ↗
SSME Engine Controller Development and Evolution
The SSME engine controller is a redundant, micro-processor based control unit. The controller along with its embedded software provides closed loop control of the engine s thrust and mixture ratio during flight as well as configuring the engine state and operations during non-flight activities such as checkouts, and pre-start engine conditioning. It processes orbiter commands into engine actions and provides engine state and health information to the orbiter for immediate action, telemetry and recording. In addition the controller includes functions which continually monitor and manage engine health, and can activate a variety of fault mitigation actions to insure safe engine operation. The objective of this paper is to provide a description of the SSME engine controller as well as its developmental history and lessons learned
Abrams, Russ↗
Faces of the SSME (Group 11)
Members of the Space Shuttle Main Engine (SSME) team review some of their memories of working on the final shuttle launch and the importance of the SSME to the success of the Shuttle program.
Source record↗
Incipient failure detection (IFD) of SSME ball bearings
Because of the immense noise background during the operation of a large engine such as the SSME, the relatively low level unique ball bearing signatures were often buried by the overall machine signal. As a result, the most commonly used bearing failure detection technique, pattern recognition using power spectral density (PSD) constructed from the extracted bearing signals, is rendered useless. Data enhancement techniques were carried out by using a HP5451C Fourier Analyzer. The signal was preprocessed by a Digital Audio Crop. DAC-1024I noise cancelling filter in order to estimate the desired signal corrupted by the backgound noise. Reference levels of good bearings were established. Any deviation of bearing signals from these reference levels indicate the incipient bearing failures.
Source record↗
Evaluation of outer race tilt and lubrication on ball wear and SSME bearing life reductions
Several aspects of the SSME bearing operation were evaluated. The possibility of elastohydrodynamics (EHD) lubrication with a cryogenic fluid was analyzed. Films as thick as .61 microns were predicted with one theory which may be thick enough to provide hydrodynamic support. The film formation, however, is heavily dependent on good surface finish and a low bulk bearing temperature. Bearing dynamics to determine if the radial stiffness of a bearing which are dependent on bearing misalignment were analyzed. Four ball tests were conducted at several environmental conditions from an LN2 bath to 426 C in air. Surface coatings and ball materials are evaluated. Severe wear and high friction are measured for all ball materials except when the balls have surface lubricant coatings.
Kannel, J. W.↗
SSME main combustion chamber life prediction
Typically, low cycle fatigue life is a function of the cyclic strain range, the material properties, and the operating temperature. The reusable life is normally defined by the number of strain cycles that can be accrued before severe material degradation occurs. Reusable life is normally signified by the initiation or propagation of surface cracks. Hot-fire testing of channel wall combustors has shown significant mid-channel wall thinning or deformation during accrued cyclic testing. This phenomenon is termed cyclic-creep and appears to be significantly accelerated at elevated surface temperatures. This failure mode was analytically modelled. The cyclic life of the baseline SSME-MCC based on measured calorimeter heat transfer data, and the life sensitivity of local hot spots caused by injector effects were determined. Four life enhanced designs were assessed.
Cook, R. T.↗
The analysis and testing of blade platform friction dampers used in the high pressure fuel turbopump (HPFTP) of the Space Shuttle Main Engine (SSME)
Premature cracking of the first stage turbine blades in HPFTP of the SSME could be alleviated by redesign of the platform friction dampers that are used to reduce the vibration response of the blades. Analytical studies by the lumped mass method of friction damper effectiveness and spin pit tests of a straingaged bladed disk have been performed. Methodologies used in the program are described. Preliminary results show that the effectiveness of the blade platform dampers can be increased if the frequency and amplitude of the most damaging forcing functions can be defined.
Dominic, R. J.↗
SSME structural dynamic model development
A mathematical model of the Space Shuttle Main Engine (SSME) as a complete assembly, with detailed emphasis on LOX and High Fuel Turbopumps is developed. The advantages of both complete engine dynamics, and high fidelity modeling are incorporated. Development of this model, some results, and projected applications are discussed.
Foley, M. J.↗
Rotordynamic Analysis of the SSME Turbopumps Using Reduced Models
Alternative methods for the rotor-dynamic and sensitivity analysis of large rotor systems are examined. The methods are assessed for their ability to utilize accurate models of reduced size along with effective procedures for describing the dynamic behavior of the systems. Frequency response-based techniques are developed for determining the steady state response to imbalance of the space shuttle main engine (SSME) turbopumps and the related eigenvalue problem. The rotor and housing are represented by reduced receptances associated with their coupling points. The housing may be described by all of its normal modes within a frequency range of interest. The effects of truncated higher and lower modes are accounted for in an approximate manner. A procedure is described for determining the sensitivity of the coupling forces to changes in the coupling elements and rotor speed of the turbopump systems. In addition, an eigenvalue sensitivity analysis technique is adopted for application to the systems. Computer programs were developed for the numerical implementation of the impedance and eigenvalue sensitivity formulated in this study.
Noah, S. T.↗
Vibration, acoustic, and shock design and test criteria for components on the Solid Rocket Boosters (SRB), Lightweight External Tank (LWT), and Space Shuttle Main Engines (SSME)
The vibration, acoustics, and shock design and test criteria for components and subassemblies on the space shuttle solid rocket booster (SRB), lightweight tank (LWT), and main engines (SSME) are presented. Specifications for transportation, handling, and acceptance testing are also provided.
Source record↗
SSME lifetime prediction and verification, integrating environments, structures, materials: The challenge
The planned missions for the space shuttle dictated a unique and technology-extending rocket engine. The high specific impulse requirements in conjunction with a 55-mission lifetime, plus volume and weight constraints, produced unique structural design, manufacturing, and verification requirements. Operations from Earth to orbit produce severe dynamic environments, which couple with the extreme pressure and thermal environments associated with the high performance, creating large low cycle loads and high alternating stresses above endurance limit which result in high sensitivity to alternating stresses. Combining all of these effects resulted in the requirements for exotic materials, which are more susceptible to manufacturing problems, and the use of an all-welded structure. The challenge of integrating environments, dynamics, structures, and materials into a verified SSME structure is discussed. The verification program and developmental flight results are included. The first six shuttle flights had engine performance as predicted with no failures. The engine system has met the basic design challenges.
Ryan, R. S.↗
SSME thrust chamber simulation using Navier-Stokes equations
The capability of the PHOENICS fluid dynamics code in predicting two-dimensional, compressible, and reacting flow in the combustion chamber and nozzle of the space shuttle main engine (SSME) was evaluated. A non-orthogonal body fitted coordinate system was used to represent the nozzle geometry. The Navier-Stokes equations were solved for the entire nozzle with a turbulence model. The wall boundary conditions were calculated based on the wall functions which account for pressure gradients. Results of the demonstration test case reveal all expected features of the transonic nozzle flows. Of particular interest are the locations of normal and barrel shocks, and regions of highest temperature gradients. Calculated performance (global) parameters such as thrust chamber flow rate, thrust, and specific impulse are also in good agreement with available data.
Przekwas, A. J.↗
Using a data base management system for modelling SSME test history data
The usefulness of a data base management system (DBMS) for modelling historical test data for the complete series of static test firings for the Space Shuttle Main Engine (SSME) was assessed. From an analysis of user data base query requirements, it became clear that a relational DMBS which included a relationally complete query language would permit a model satisfying the query requirements. Representative models and sample queries are discussed. A list of environment-particular evaluation criteria for the desired DBMS was constructed; these criteria include requirements in the areas of user-interface complexity, program independence, flexibility, modifiability, and output capability. The evaluation process included the construction of several prototype data bases for user assessement. The systems studied, representing the three major DBMS conceptual models, were: MIRADS, a hierarchical system; DMS-1100, a CODASYL-based network system; ORACLE, a relational system; and DATATRIEVE, a relational-type system.
Abernethy, K.↗
Evaluation of PHOENICS as a design analysis tool for SSME
The use of the computational fluid dynamics computer code PHOENICS was proposed as a design analysis tool for improving the Space Shuttle Main Engines (SSME). The PHOENICS is a general purpose computer code for the simulation of fluid-flow, heat-transfer and combustion processes arising in engineering, scientific research and environment. It analyzes one or two-phase flows, in one, two, or three dimensions. The application of PHOENICS to evaluate the performance of high-pressure gaseous-hydrogen filters is examined. The usefulness of the code and the ability of the code to handle successively more complex features of the device are demonstrated.
Ventrice, M. B.↗
Vibration characteristics of the HPOTP (High Pressure Oxygen Turbopump) of the SSME (Space Shuttle Main Engine)
A review is presented of various rotordynamic problems which have been encountered and eliminated in developing the current flight engines, and continuing subsynchronous problems which are being encountered in developing a 109% power level engine. The basic model for the High Pressure Oxygen Turbopump (HPOTP) of the SSME including the structural dynamic model for the rotor and housing and component models for the liquid and gas seals, turbine-clearance excitation forces, and impeller-diffuser forces are discussed. Results from a linear model are used to examine the synchronous response and stability characteristics of the HPOTP, examining bearing load and stability problems associated with the second critical speed. Various seal modifications are examined and shown to have favorable consequences with respect to bearing reactions and stability.
Childs, D. W.↗