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A goal of the Phase B study is to define the launch system interfaces for the reusable reentry satellite (RRS) program. The focus of the launch tradeoff study, documented in this report, is to determine which expendable launch vehicles (ELV's) are best suited for the RRS application by understanding the impact of all viable launch systems on RRS design and operation.
The overall Reusable Reentry Satellite (RRS) Phase B Study objective is to design a relatively inexpensive satellite to access space for extended periods of time, with eventual recovery of experiments on Earth. The expected principal use for such a system is research on the effects of variable gravity (0-1.5 g) and radiation on small animals, plants, lower life forms, tissue samples, and materials processes. The RRS will be capable of: (1) being launched by a variety of expendable launch vehicles; (2) operating in low earth orbit as a free flying unmanned laboratory; and (3) executing independent atmospheric reentry and soft landing. The RRS will be designed to be refurbished and reused up to three times a year for a period of 10 years. The information provided in this report describes the process involved in the evolution of the RRS overall configuration. This process considered reentry aerodynamics, aerothermodynamics, internal equipment layout, and vehicle mass properties. This report delineates the baseline design decisions that were used to initiate the RRS design effort. As a result, there will be deviations between this report and the RRS Final Report. In those instances, the RRS Final Report shall be considered to be the definitive reference.
This Interface Specification (IFS) identifies, defines, and controls the interface between the Reusable Reentry Satellite (RRS) Vehicle (RRV) Experiment Module (EM) and the Support Module (SM) equipment. Contained in this specification are the physical, functional, and environmental interface requirements for the SM and EM. This specification is tailored to the unique requirements of the EM associated with the Rodent Module. The addenda to this specification contain the requirements for alternate EM's.
The design and assessment work performed in defining the on-orbit Thermal Control Subsystem (TCS) requirements for the Reusable Reentry Satellite (RRS) is discussed. Specifically, it describes the hardware and design measures necessary for maintaining the Payload Module (PM) Environmental Control Life Support System (ECLSS) heat exchanger, the hydrazine propellant, and PM water supply within their required temperature limits.
The purpose of the Reusable Reentry Satellite (RRS) Propulsion System Trade Study described in this summary report was to investigate various propulsion options available for incorporation on the RRS and to select the option best suited for RRS application. The design requirements for the RRS propulsion system were driven by the total impulse requirements necessary to operate within the performance envelope specified in the RRS System Requirements Documents. These requirements were incorporated within the Design Reference Missions (DRM's) identified for use in this and other subsystem trade studies. This study investigated the following propulsion systems: solid rocket, monopropellant, bipropellant (monomethyl hydrazine and nitrogen tetroxide or MMH/NTO), dual-mode bipropellant (hydrazine and nitrogen tetroxide or N2H4/NTO), liquid oxygen and liquid hydrogen (LO2/LH2), and an advanced design propulsion system using SDI-developed components. A liquid monopropellant blowdown propulsion system was found to be best suited for meeting the RRS requirements and is recommended as the baseline system. This system was chosen because it is the simplest of all investigated, has the fewest components, and is the most cost effective. The monopropellant system meets all RRS performance requirements and has the capability to provide a very accurate deorbit burn which minimizes reentry dispersions. In addition, no new hardware qualification is required for a monopropellant system. Although the bipropellant systems offered some weight savings capability for missions requiring large deorbit velocities, the advantage of a lower mass system only applies if the total vehicle design can be reduced to allow a cheaper launch vehicle to be used. At the time of this trade study, the overall RRS weight budget and launch vehicle selection were not being driven by the propulsion system selection. Thus, the added cost and complexity of more advanced systems did not warrant application.
A hierarchical, decentralized diagnostic system is proposed for the Real-Time Diagnostic System component of the Intelligent Control System (ICS) for reusable rocket engines. The proposed diagnostic system has three layers of information processing: condition monitoring, fault mode detection, and expert system diagnostics. The condition monitoring layer is the first level of signal processing. Here, important features of the sensor data are extracted. These processed data are then used by the higher level fault mode detection layer to do preliminary diagnosis on potential faults at the component level. Because of the closely coupled nature of the rocket engine propulsion system components, it is expected that a given engine condition may trigger more than one fault mode detector. Expert knowledge is needed to resolve the conflicting reports from the various failure mode detectors. This is the function of the diagnostic expert layer. Here, the heuristic nature of this decision process makes it desirable to use an expert system approach. Implementation of the real-time diagnostic system described above requires a wide spectrum of information processing capability. Generally, in the condition monitoring layer, fast data processing is often needed for feature extraction and signal conditioning. This is usually followed by some detection logic to determine the selected faults on the component level. Three different techniques are used to attack different fault detection problems in the NASA LeRC ICS testbed simulation. The first technique employed is the neural network application for real-time sensor validation which includes failure detection, isolation, and accommodation. The second approach demonstrated is the model-based fault diagnosis system using on-line parameter identification. Besides these model based diagnostic schemes, there are still many failure modes which need to be diagnosed by the heuristic expert knowledge. The heuristic expert knowledge is implemented using a real-time expert system tool called G2 by Gensym Corp. Finally, the distributed diagnostic system requires another level of intelligence to oversee the fault mode reports generated by component fault detectors. The decision making at this level can best be done using a rule-based expert system. This level of expert knowledge is also implemented using G2.
The topics addressed are: (1) thermal protection system technology needs; and (2) long-term, reusable thermal protection materials, such as recently developed materials (CMC's, metallics, ceramics, etc.), which require ground and flight testing, basic materials whose properties are properties verified/quantified, and load-carrying hot structured and controlled surfaced materials.
One of the promising launch concepts that could replace the current space shuttle launch system is a two-stage, winged, vertical-takeoff, fully reusable launch vehicle. During the boost phase of ascent, the booster provides propellant for the orbiter engines through a cross-feed system. When the vehicle reaches a Mach number of 3, the booster propellants are depleted and the booster is staged and glides unpowered to a horizontal landing at a launch site runway. Two major design issues for this class of vehicle are the staging maneuver and the booster glideback. For the staging maneuver analysis, a technique was developed that provides for a successful separation of the booster from the orbiter over a wide range of staging angles of attack. A longitudinal flight control system was developed for control of the booster during the staging maneuver. For the booster glide back analysis, a guidance algorithm was developed that successfully guides the booster from the completion of the staging maneuver to a launch site runway while encountering many off-nominal atmospheric, aerodynamic, and staging conditions.
The establishment of a lunar base is technologically and financially challenging. Given the necessary resources and political support, it can be done. In addition to the geopolitical obstacles, however, there are logistical problems involved in establishing such bases that can only be overcome with the acquisition of a significant transportation and communications network in the Earth-Moon spatial region. Considering the significant number of payloads that will be required in this process, the mass-specific cost of launching these payloads, and the added risk and cost of human presence in space, it is clearly desirable to automate major parts of such an operation. One very costly and time-consuming factor in this picture is the delivery of payloads to the Moon. Foreseeable payloads would include atmospheric modules, inflatable habitat kits, energy and oxygen plant elements, ground vehicles, laboratory modules, crew supplies, etc. The duration of high-risk human presence on the Moon could be greatly reduced if all such payloads were delivered to the prospective base site in advance of crew arrival. In this view, the idea of a 'Self-Unloading Reusable Lunar Lander' (SURLL) arises naturally. The general scenario depicts the lander being brought to low lunar orbit (LLO) from Earth atop a generic Orbital Transfer Vehicle (OTV). From LLO, the lander shuttles payloads down to the lunar surface, where, by means of some resident, detachable unloading device, it deploys the payloads and returns to orbit. The general goal is for the system to perform with maximum payload capability, automation, and reliability, while also minimizing environmental hazards, servicing needs, and mission costs. Our response to this demand is UM-HAUL, or the UnManned Heavy pAyload Unloader and Lander. The complete study includes a system description, along with a preliminary cost analysis and a design status assessment.
A two-day conference on the structural integrity and durability of reusable space propulsion systems was held on 14 to 15 May 1991 at the NASA Lewis Research Center. Presentations were made by industry, university, and government researchers organized into four sessions: (1) aerothermodynamic loads; (2) instrumentation; (3) fatigue, fracture, and constitutive modeling; and (4) structural dynamics. The principle objectives were to disseminate research results and future plans in each of four areas. This publication contains extended abstracts and the visual material presented during the conference. Particular emphasis is placed on the Space Shuttle Main Engine (SSME) and the SSME turbopump.
Automated test and checkout computer tools that have been developed for commercial and military aircraft are presently shown to be applicable to reusable launch vehicle and spacecraft propulsion systems, for the sake of reductions in maintenance personnel and calendar time. Attention is given to the potential uses of the Programmable Engine Tester and the Integrated Functional Test System in the context of SSME problems. It is found that while direct application of existing automated checkout systems would be difficult, future spacecraft propulsion technology can be designed for integral operation with such systems.
A cyclical Mars exploration scenario is described which combines the use of libration points in the earth-moon and sun-Mars systems with a pair of reusable nuclear electric propulsion (NEP) transfer vehicles. In this approach, the NEP transfer vehicles are stationed at the cislunar and cismartian libration points, and involves short cislunar point escape and capture spirals. It eliminates any spiral requirements at Mars by utilizing the cismartian point as a transportation node. Chemical/aerobrake vehicles are used to transport humans between earth and the cislunar point as well as between Mars and the cismartian point.
Five kinetic models are compared for their ability to predict recombination coefficients for oxygen and nitrogen atoms over high-temperature reusable surface insulation (HRSI). Four of the models are derived using Rideal-Eley or Langmuir-Hinshelwood catalytic mechanisms to describe the reaction sequence. The fifth model is an empirical expression that offers certain features unattainable through mechanistic description. The results showed that a four-parameter model, with temperature as the only variable, works best with data currently available. The model describes recombination coefficients for oxygen and nitrogen atoms for temperatures from 300 to 1800 K. Kinetic models, with atom concentrations, demonstrate the influence of atom concentration on recombination coefficients. These models can be used for the prediction of heating rates due to catalytic recombination during re-entry or aerobraking maneuvers. The work further demonstrates a requirement for more recombination experiments in the temperature ranges of 300-1000 K, and 1500-1850 K, with deliberate concentration variation to verify model requirements.
The description, analysis, and experimental results of a method for identifying possible defects on High Temperature Reusable Surface Insulation (HRSI) of the Orbiter Thermal Protection System (TPS) is presented. Currently, a visual postflight inspection of Orbiter TPS is conducted to detect and classify defects as part of the Orbiter maintenance flow. The objective of the method is to automate the detection of defects by identifying anomalies between preflight and postflight images of TPS components. The initial version is intended to detect and label gross (greater than 0.1 inches in the smallest dimension) anomalies on HRSI components for subsequent classification by a human inspector. The approach is a modified Golden Template technique where the preflight image of a tile serves as the template against which the postflight image of the tile is compared. Candidate anomalies are selected as a result of the comparison and processed to identify true anomalies. The processing methods are developed and discussed, and the results of testing on actual and simulated tile images are presented. Solutions to the problems of brightness and spatial normalization, timely execution, and minimization of false positives are also discussed.
A concept is shown for a fully reusable, earth to orbit launch vehicle with horizontal takeoff and landing, employing an air-turborocket for low speed and a rocket for high speed acceleration, both using LH2 fuel. The turborocket employs a modified liquid air cycle to supply the oxidizer. The rocket uses 90 percent pure LOX that is collected from the atmosphere, separated, and stored during operation of the turborocket from about Mach 2 to Mach 5 or 6. The takeoff weight and the thrust required at takeoff are markedly reduced by collecting the rocket oxidizer in-flight. The paper shows an approach and the corresponding technology needs for using ALES propulsion in a SSTO vehicle. Reducing the trajectory altitude at the end of collection reduces the wing area and increases payload. The use of state-of-the-art materials, such as graphite polyimide, is critical to meet the structure weight objective for SSTO. Configurations that utilize 'waverider' aerodynamics show great promise to reduce the vehicle weight.
Martin Marietta and Aerojet are co-investigating the feasibility and viability of reusable launch vehicle designs. We are assessing two vehicle concepts, each delivering 8000 lb to a geosynchronous transfer orbit (GTO). Both accomplish this task as a two-state system. The major difference between the two concepts is staging. The first concept, the two-stage-to-orbit (TSTO) system, stages at about 16 kft/sec, allowing immediate return of the first stage to the launch site using its airbreathing propulsion system for a powered cruise flight. The second concept, the single-stage-to-orit (SSTO) system, accomplishes stage separation in a stable low earth orbit (LEO).
A health monitoring expert system software architecture has been developed to support condition-based health monitoring of rocket engines. Its first application is in the diagnosis decisions relating to the health of the high pressure oxidizer turbopump (HPOTP) of Space Shuttle Main Engine (SSME). The post test diagnostic system runs off-line, using as input the data recorded from hundreds of sensors, each running typically at rates of 25, 50, or .1 Hz. The system is invoked after a test has been completed, and produces an analysis and an organized graphical presentation of the data with important effects highlighted. The overall expert system architecture has been developed and documented so that expert modules analyzing other line replaceable units may easily be added. The architecture emphasizes modularity, reusability, and open system interfaces so that it may be used to analyze other engines as well.
An intelligent control system for reusable rocket engines under development at NASA Lewis Research Center requires a graphical user interface to allow observation of the closed-loop system in operation. The simulation testbed consists of a real-time engine simulation computer, a controls computer, and several auxiliary computers for diagnostics and coordination. The system is set up so that the simulation computer could be replaced by the real engine and the change would be transparent to the control system. Because of the hard real-time requirement of the control computer, putting a graphical user interface on it was not an option. Thus, a separate computer used strictly for the graphical user interface was warranted. An object-oriented LISP-based graphical user interface has been developed on a Texas Instruments Explorer 2+ to indicate the condition of the engine to the observer through plots, animation, interactive graphics, and text.