Development of ultra-light composite-overwrapped propellant tanks for the Mars Exploration Rover cruise stage
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Mars Exploration Rover ultra-light composite-overw↗
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Ultralight propellant tank for Mars exploration rover cruise stage
The design of the ultralight propellant tanks and the PMD device, flight qualification testing of the tank and the PMD system, and damage control methods is discussed.
propellant tank composite tank PBO↗
Vibro-Acoustic Predictions of the MSL Cruise Stage and Correlation with Acoustic Measurements
No abstract available
Mars Science Laboratory (MSL)↗
Development of a Centrifugal Technique for the Microbial Bioburden Analysis of Freon (CFC-11)
NASA Procedural Requirement 8020.12C entitled "Planetary Protection Provisions for Robotic Extraterrestrial Missions" states that the source-specific encapsulated microbial density for encapsulated organisms (div(0)) in nonmetallic materials ranges from 1-30 spores/cubic cm. The standard laboratory procedure, NASA Standard Procedures for the Microbial Examination of Space Hardware, NHB 5340.1B, does not provide any direction into the methodologies to understand the bioburden within such a fluid as CFC-11 (Freon). This general specification value for the Freon would be applicable to the Freon charged within the Mars Science Laboratory fs (MSL fs) Heat Rejection System. Due to the large volume required to fill this system, MSL could not afford to conservatively allocate 55.8% of the total spore budget of the entire laboratory system (rover, descent stage, cruise stage, and aeroshell) of 5.00 X 10(exp 5) spores at launch. A novel filtration approach was developed to analyze the Freon employing a 50 kDa molecular weight cutoff (MCO) filter, followed by 0.22-micron pore-size filter to establish a calculated microbial bioburden.
Benardini, James N.↗
Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover
The addition of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to the Mars Science Laboratory (MSL) Rover requires an advanced thermal control system that is able to both recover and reject the waste heat from the MMRTG as needed in order to maintain the onboard electronics at benign temperatures despite the extreme and widely varying environmental conditions experienced both on the way to Mars and on the Martian surface. Based on the previously successful Mars landed mission thermal control schemes, a mechanically pumped fluid loop (MPFL) architecture was selected as the most robust and efficient means for meeting the MSL thermal requirements. The MSL heat recovery and rejection system (HRS) is comprised of two Freon (CFC-11) MPFLs that interact closely with one another to provide comprehensive thermal management throughout all mission phases. The first loop, called the Rover HRS (RHRS), consists of a set of pumps, thermal control valves, and heat exchangers (HXs) that enables the transport of heat from the MMRTG to the rover electronics during cold conditions or from the electronics straight to the environment for immediate heat rejection during warm conditions. The second loop, called the Cruise HRS (CHRS), is thermally coupled to the RHRS during the cruise to Mars, and provides a means for dissipating the waste heat more directly from the MMRTG as well as from both the cruise stage and rover avionics by promoting circulation to the cruise stage radiators. A multifunctional structure was developed that is capable of both collecting waste heat from the MMRTG and rejecting the waste heat to the surrounding environment. It consists of a pair of honeycomb core sandwich panels with HRS tubes bonded to both sides. Two similar HX assemblies were designed to surround the MMRTG on the aft end of the rover. Heat acquisition is accomplished on the interior (MMRTG facing) surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the fluid loops to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aluminum facesheets and aerogel as insulation inside a composite honeycomb core. Complex assemblies of hand-welded and uniquely bent aluminum tubes are bonded onto each side of the HX panels, and are specifically designed to be easily mated and demated to the rest of the RHRS in order to ease the integration effort.
Mastropietro, A. J.↗
Design and Preliminary Thermal Performance of the Mars Science Laboratory Rover Heat Exchangers
The challenging range of proposed landing sites for the Mars Science Laboratory Rover requires a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as -123 degrees Centigrade and as warm as 38 degrees Centigrade, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) and external radiators to maintain the temperature of sensitive electronics and science instruments within a -40 degrees Centigrade to 50 degrees Centigrade range. The MPFL also manages significant waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG). The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Two similar Heat Exchanger (HX) assemblies were designed to both acquire the heat from the MMRTG and radiate waste heat from the onboard electronics to the surrounding Martian environment. Heat acquisition is accomplished on the interior surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the MPFL to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aerogel as an insulator inside composite honeycomb sandwich panels. A complex assembly of hand welded and uniquely bent aluminum tubes are bonded onto the HX panels and were specifically designed to be easily mated and demated to the rest of the Rover Heat Recovery and Rejection System (RHRS) in order to ease the integration effort. During the cruise phase to Mars, the HX assemblies serve the additional function of transferring heat from the Rover MPFL to the separate Cruise Stage MPFL so that heat generated deep inside the Rover can be dissipated via the Cruise Stage radiators. Significant fabrication challenges had to be overcome in order to make the HX design a reality. The cruise phase thermal performance of the Rover HXs was verified in the cruise phase system level thermal vacuum test that was performed at JPL in January of 2009. The Rover HXs were modeled in I-DEAS TMG and predictions are compared to actual data from the test.
Heat Rejection System↗
Entry, Descent, and Landing Communications for the 2011 Mars Science Laboratory
The Mars Science Laboratory (MSL), established as the most advanced rover to land on the surface of Mars to date, launched on November 26th, 2011 and arrived to the Martian Gale Crater during the night of August 5th, 2012 (PDT). MSL will investigate whether the landing region was ever suitable to support carbon-based life, and examine rocks, soil, and the atmosphere with a sophisticated suite of tools. This paper addresses the flight system requirement by which the vehicle transmitted indications of the following events using both X-band tones and UHF telemetry to allow identification of probable root causes should a mission anomaly have occurred: Heat-Rejection System (HRS) venting, completion of the cruise stage separation, turn to entry attitude, atmospheric deceleration, bank angle reversal commanded, parachute deployment, heatshield separation, radar ground acquisition, powered descent initiation, rover separation from the descent stage, and rover release. During Entry, Descent, and Landing (EDL), the flight system transmitted a UHF telemetry stream adequate to determine the state of the spacecraft (including the presence of faults) at 8 kbps initiating from cruise stage separation through at least one minute after positive indication of rover release on the surface of Mars. The flight system also transmitted X-band semaphore tones from Entry to Landing plus one minute although since MSL was occulted, as predicted, by Mars as seen from the Earth, Direct-To-Earth (DTE) communications were interrupted at approximately is approx. 5 min after Entry ( approximately 130 prior to Landing). The primary data return paths were through the Deep Space Network (DSN) for DTE and the existing Mars network of orbiting assets for UHF, which included the Mars Reconnaissance Orbiter (MRO), Mars Odyssey (ODY), and Mars Express (MEX) elements. These orbiters recorded the telemetry data stream and returned it back to Earth via the DSN. The paper also discusses the total power received during EDL and the robustness of the telecom design strategy used to ensure EDL communications coverage.
relay operations↗
Mars Exploration Rover Entry, Descent, and Landing: A Thermal Perspective
Perhaps the most challenging mission phase for the Mars Exploration Rovers was the Entry, Descent, and Landing (EDL). During this phase, the entry vehicle attached to its cruise stage was transformed into a stowed tetrahedral Lander that was surrounded by inflated airbags through a series of complex events. There was only one opportunity to successfully execute an automated command sequence without any possible ground intervention. The success of EDL was reliant upon the system thermal design: 1) to thermally condition EDL hardware from cruise storage temperatures to operating temperature ranges; 2) to maintain the Rover electronics within operating temperature ranges without the benefit of the cruise single phase cooling loop, which had been evacuated in preparation for EDL; and 3) to maintain the cruise stage propulsion components for the critical turn to entry attitude. Since the EDL architecture was inherited from Mars Pathfinder (MPF), the initial EDL thermal design would be inherited from MPF. However, hardware and implementation differences from MPF ultimately changed the MPF inheritance approach for the EDL thermal design. With the lack of full inheritance, the verification and validation of the EDL thermal design took on increased significance. This paper will summarize the verification and validation approach for the EDL thermal design along with applicable system level thermal testing results as well as appropriate thermal analyses. In addition, the lessons learned during the system-level testing will be discussed. Finally, the in-flight EDL experiences of both MER-A and -B missions (Spirit and Opportunity, respectively) will be presented, demonstrated how lessons learned from Spirit were applied to Opportunity.
thermal↗
In-flight propulsion system characterization for both Mars Exploration Rover Spacecraft
Two Mars Exploration Rover spacecraft were dispensed to red planet in 2003, culminating in a phenomenally successful prime science mission. Twin cruise stage propulsion systems were developed in record time, largely through heritage with Mars Pathfinder. As expected, consumable usage was minimal during the short seven-month cruise for both spacecraft. Propellant usage models based on pressure and temperature agreed with throughput models with in a few percent. Trajectory correction maneuver performance was nominal, allowing the cancellation of near-Mars maneuvers. Spin thruster delivered impulse was 10-12% high vs. ground based models for the intial spin-down maneuvers, while turn performance was XX-XX% high/low vs. expectations. No clear indications for pressure transducer drift were noted during the brief MER missions.
maneuvers↗
Mars Pathfinder Cruise Stage/Entry Vehicle Separation Dynamics
Prior to atmospheric entry, Mars Pathfinder flight system will separate its entry vehicle from its cruise stage, and establish the entry conditions for a passive and unconventional entry, descent, and landing approach. This paper summarizes a separation dynamics analysis conducted to demonstrate that the cruise separation system design is viable and ensure that adequate design margins exist with the effects from parameter uncertainty included.
Pathfinder↗
Mercury Lander: A Planetary Mission Concept Study for the 2023–2032 Decadal Survey
Mercury holds unique clues to the distribution of elements at the birth of the solar system and how planets form and evolve in close proximity to their host stars. The Mercury Lander mission concept returns in situ measurements to: understand Mercury’s unique mineralogy and geochemistry; characterize the massive core’s structure; measure the planet’s active and ancient magnetic fields at the surface; investigate the processes that alter the surface and produce the exosphere; and provide groundtruth for remote datasets. The mission concept achieves one Mercury year (~88 Earth days) of surface operations with an 11-instrument, high-heritage payload delivered to a landing site within Mercury’s widely distributed low-reflectance material, and addresses science goals encompassing geochemistry, geophysics, the Mercury space environment, and geology. The spacecraft launches on an expendable SpaceX Falcon Heavy in 2035. The four-stage flight system uses a solar-electric propulsion cruise stage to reach Mercury in2045. The orbital stage brings the spacecraft into a thermally safe orbit, then performs orbital maneuvers to prepare for descent. During the orbital phase, a narrow-angle camera acquires images for selecting a low-hazard landing zone within our region of interest. The descent stage begins the braking burn ~120 s before landing. The lander continues to touchdown, using continuous LIDAR operations to support hazard detection and safely deliver the payload to the surface. Landing is at dusk to meet thermal requirements, permitting ~30 hours of sunlight for initial observations. The radioisotope-powered lander continues operations through the Mercury night. Direct-to-Earth communication is possible for the initial three weeks of landed operations, drops out for six weeks, and resumes for the final month. Thermal conditions exceed lander operating temperatures shortly after sunrise, ending operations. A total of ~11 GB of data are returned to Earth. The Phase A–D mission cost estimate (50% unencumbered reserves, excluding launch vehicle) is $1.2 B(FY25$), comparing favorably with past New Frontiers missions and to the cost cap in the New Frontiers4 call(~$1.1B FY25$). This cost estimate shows that a Mercury Lander mission is feasible and compelling as a New Frontiers-class mission in the coming decade.
C M Ernst↗
Thermal Design and Flight Experience of the Mars Exploration Rover Spacecraft Computer-Controlled, Propulsion Line Heaters
The viewgraph presentation examines propulsion line heater design and problems in the Mars Rover. Topics include a Mars Exploration Rover (MER) project description and MER spacecraft configuration, mission overview, MER cruise stage hardware, thermal design drivers in the propulsion lines, propulsion line control set points prior to launch, MER A and B flight trajectories, MER A early and mid cruise flight experience, MER A and B mid cruise flight experience, MER B late cruise flight experience, and lessons learned
propulsion lines↗
Mission and Navigation Design for the 2009 Mars Science Laboratory Mission
NASA s Mars Science Laboratory mission will launch the next mobile science laboratory to Mars in the fall of 2009 with arrival at Mars occurring in the summer of 2010. A heat shield, parachute, and rocket-powered descent stage, including a sky crane, will be used to land the rover safely on the surface of Mars. The direction of the atmospheric entry vehicle lift vector will be controlled by a hypersonic entry guidance algorithm to compensate for entry trajectory errors and counteract atmospheric and aerodynamic dispersions. The key challenges for mission design are (1) develop a launch/arrival strategy that provides communications coverage during the Entry, Descent, and Landing phase either from an X-band direct-to-Earth link or from a Ultra High Frequency link to the Mars Reconnaissance Orbiter for landing latitudes between 30 deg North and 30 deg South, while satisfying mission constraints on Earth departure energy and Mars atmospheric entry speed, and (2) generate Earth-departure targets for the Atlas V-541 launch vehicle for the specified launch/arrival strategy. The launch/arrival strategy employs a 30-day baseline launch period and a 27-day extended launch period with varying arrival dates at Mars. The key challenges for navigation design are (1) deliver the spacecraft to the atmospheric entry interface point (Mars radius of 3522.2 km) with an inertial entry flight path angle error of +/- 0.20 deg (3 sigma), (2) provide knowledge of the entry state vector accurate to +/- 2.8 km (3 sigma) in position and +/- 2.0 m/s (3 sigma) in velocity for initializing the entry guidance algorithm, and (3) ensure a 99% probability of successful delivery at Mars with respect to available cruise stage propellant. Orbit determination is accomplished via ground processing of multiple complimentary radiometric data types: Doppler, range, and Delta-Differential One-way Ranging (a Very Long Baseline Interferometry measurement). The navigation strategy makes use of up to five interplanetary trajectory correction maneuvers to achieve entry targeting requirements. The requirements for cruise propellant usage and atmospheric entry targeting and knowledge are met with ample margins.
Mission design↗
Mars Pathfinder mission operations concepts
The Mars Pathfinder Project plans a December 1996 launch of a single spacecraft. After jettisoning a cruise stage, an entry body containing a lander and microrover will directly enter the Mars atmosphere and parachute to a hard landing near the sub-solar latitude of 15 degrees North in July 1997. Primary surface operations last for 30 days. Cost estimates for Pathfinder ground systems development and operations are not only lower in absolute dollars, but also are a lower percentage of total project costs than in past planetary missions. Operations teams will be smaller and fewer than typical flight projects. Operations scenarios have been developed early in the project and are being used to guide operations implementation and flight system design. Recovery of key engineering data from entry, descent, and landing is a top mission priority. These data will be recorded for playback after landing. Real-time tracking of a modified carrier signal through this phase can provide important insight into the spacecraft performance during entry, descent, and landing in the event recorded data is never recovered. Surface scenarios are dominated by microrover activity and lander imaging during 7 hours of the Mars day from 0700 to 1400 local solar time. Efficient uplink and downlink processes have been designed to command the lander and microrover each Mars day.
Sturms, Francis M., Jr.↗
The Mars Pathfinder Mission and Science Results
Mars Pathfinder, the first low-cost, quick Discovery class mission to be completed, successfully landed on the surface of Mars on July 4, 1997, deployed and navigated a small rover, and collected data from 3 science instruments and 10 technology experiments. The mission operated on Mars for 3 months and returned 2.3 Gbits of new data, including over 16,500 lander and 550 rover images, 16 chemical analyses of rocks and soil, and 8.5 million individual temperature, pressure and wind measurements. The rover traversed 100 m clockwise around the lander, exploring about 200 square meters of the surface. The mission captured the imagination of the public, and garnered front page headlines during the first week. A total of about 566 million internet "hits" were registered during the first month of the mission, with 47 million "hits" on July 8th alone, making the Pathfinder landing by far the largest internet event in history at the time. Pathfinder was the first mission to deploy a rover on Mars. It carried a chemical analysis instrument, to characterize the rocks and soils in a landing area over hundreds of square meters on Mars, which provided a calibration point or "ground truth" for orbital remote sensing observations. The combination of spectral imaging of the landing area by the lander camera, chemical analyses aboard the rover, and close-up imaging of colors, textures and fabrics with the rover cameras offered the potential of identifying rocks (petrology and mineralogy). With this payload, a landing site in Ares Vallis was selected because it appeared acceptably safe and offered the prospect of analyzing a variety of rock types expected to be deposited by catastrophic floods, which enabled addressing first-order scientific questions such as differentiation of the crust, the development of weathering products, and the nature of the early Martian environment and its subsequent evolution. The 3 instruments and rover allowed seven areas of scientific investigation: the geology and geomorphology of the surface, mineralogy and geochemistry of rocks and soils, physical properties of surface materials, magnetic properties of airborne dust, atmospheric science including aerosols, and rotational and orbital dynamics of Mars. Scientists were assembled into 7 Science Operations Groups that were responsible for requesting measurements by the 3 instruments, rover and engineering subsystems for carrying out their scientific investigations and for analyzing the data and reporting on their findings. The spacecraft was launched on December 4, 1996 and had a 7 month cruise to Mars, with four trajectory correction maneuvers. The vehicle entered the atmosphere directly following cruise stage separation. Parachute deployment, heatshield and lander separation, radar ground acquisition, airbag inflation and rocket ignition all occurred before landing at 2:58 AM true local solar time (9:56:55 AM PDT). The lander bounced at least 15 times up to 12 in high without airbag rupture, demonstrating the robustness of this landing system. Reconstruction of the final landing sequence indicates that the parachute/backshel1/1ander was tilted due to a northwest directed wind and wind shear, which resulted in the lander bouncing about I km to the northwest and initially downhill about 20 m from where the solid rockets fired. Two anomalously bright spots located in the lander scene are likely the heatshield, which continued in a ballistic trajectory about 2 km downrange (west southwest), and the backshell/parachute, which stayed nearer to where the rockets fired. Unconnected disturbed soil patches in the scene indicate that the final few bounces of the lander were from the east-southeast and were followed by a gentle roll to the west before coming to rest on the base petal. The location of the lander away from where the solid rockets fired and considerations of the exhaust products used to inflate the airbags and their fate, indicate that the Pathfinder landing system is one of the cleanest designed leaving the local area essentially contaminant free. The radio signal from the low-=gain antenna was received at 11:34 AM PDT indicating a successful landing.
Golombek, M. P.↗
Inflatable Re-Entry Vehicle Experiment (IRVE) Design Overview
Inflatable aeroshells offer several advantages over traditional rigid aeroshells for atmospheric entry. Inflatables offer increased payload volume fraction of the launch vehicle shroud and the possibility to deliver more payload mass to the surface for equivalent trajectory constraints. An inflatable s diameter is not constrained by the launch vehicle shroud. The resultant larger drag area can provide deceleration equivalent to a rigid system at higher atmospheric altitudes, thus offering access to higher landing sites. When stowed for launch and cruise, inflatable aeroshells allow access to the payload after the vehicle is integrated for launch and offer direct access to vehicle structure for structural attachment with the launch vehicle. They also offer an opportunity to eliminate system duplication between the cruise stage and entry vehicle. There are however several potential technical challenges for inflatable aeroshells. First and foremost is the fact that they are flexible structures. That flexibility could lead to unpredictable drag performance or an aerostructural dynamic instability. In addition, durability of large inflatable structures may limit their application. They are susceptible to puncture, a potentially catastrophic insult, from many possible sources. Finally, aerothermal heating during planetary entry poses a significant challenge to a thin membrane. NASA Langley Research Center and NASA's Wallops Flight Facility are jointly developing inflatable aeroshell technology for use on future NASA missions. The technology will be demonstrated in the Inflatable Re-entry Vehicle Experiment (IRVE). This paper will detail the development of the initial IRVE inflatable system to be launched on a Terrier/Orion sounding rocket in the fourth quarter of CY2005. The experiment will demonstrate achievable packaging efficiency of the inflatable aeroshell for launch, inflation, leak performance of the inflatable system throughout the flight regime, structural integrity when exposed to a relevant dynamic pressure and aerodynamic stability of the inflatable system. Structural integrity and structural response of the inflatable will be verified with photogrammetric measurements of the back side of the aeroshell in flight. Aerodynamic stability as well as drag performance will be verified with on board inertial measurements and radar tracking from multiple ground radar stations. The experiment will yield valuable information about zero-g vacuum deployment dynamics of the flexible inflatable structure with both inertial and photographic measurements. In addition to demonstrating inflatable technology, IRVE will validate structural, aerothermal, and trajectory modeling techniques for the inflatable. Structural response determined from photogrammetrics will validate structural models, skin temperature measurements and additional in-depth temperature measurements will validate material thermal performance models, and on board inertial measurements along with radar tracking from multiple ground radar stations will validate trajectory simulation models.
Hughes, Stephen J.↗
Mars Exploration Rover: thermal design is a system engineering activity
The Mars Exploration Rovers (MER), were launched in June and July of 2003, repsectively and successfully landed on Mars in early and late January of 2004, repectively. The flight system architecture implemented many successful features of the Mars Pathfinder (MPF) system: A cruise stage that transported an entry vehicle that housed the Lander, which in turn, used airbags to cushion the Rover during the landing event.
lessons learned↗
Aerocapture Inflatable Decelerator (AID)
Forward Attached Inflatable Decelerators, more commonly known as inflatable aeroshells, provide an effective, cost efficient means of decelerating spacecrafts by using atmospheric drag for aerocapture or planetary entry instead of conventional liquid propulsion deceleration systems. Entry into planetary atmospheres results in significant heating and aerodynamic pressures which stress aeroshell systems to their useful limits. Incorporation of lightweight inflatable decelerator surfaces with increased surface-area footprints provides the opportunity to reduce heat flux and induced temperatures, while increasing the payload mass fraction. Furthermore, inflatable aeroshell decelerators provide the needed deceleration at considerably higher altitudes and Mach numbers when compared with conventional rigid aeroshell entry systems. Inflatable aeroshells also provide for stowage in a compact space, with subsequent deployment of a large-area, lightweight heatshield to survive entry heating. Use of a deployable heatshield decelerator not only enables an increase in the spacecraft payload mass fraction and but may also eliminate the need for a spacecraft backshell and cruise stage. This document is the viewgraph slides for the paper's presentation.
Reza, Sajjad↗